DAQ-2024-008128

Prepared for
Westinghouse Electric Co. LLC
Prepared by
Ramboll US Consulting, Inc.
Salt Lake City, Utah
San Francisco, California
Project Number
1940104937
Date
March 2024
RACT ANALYSIS FOR OZONE
NONATTAINMENT
WESTINGHOUSE ELECTRIC CO. LLC
OGDEN, UTAH
i
CONTENTS
1.INTRODUCTION ................................................................................................................................. 1
2.FACILITY AND EMISSIONS INFORMATION ........................................................................................ 2
2.1 Facility Description ..................................................................................................... 2
2.1.1 Separations Process ............................................................................................. 2
2.1.2 Pure Chlorination Process ..................................................................................... 2
2.1.3 Reduction Process ................................................................................................ 3
2.1.4 Zircaloy Fabrication Process .................................................................................. 3
2.2 Facility Emissions ....................................................................................................... 4
3.RACT METHODOLOGY ....................................................................................................................... 6
3.1 Step 1 – Identify All Available Control Technologies ........................................................ 6
3.2 Step 2 – Eliminate Technically Infeasible Options ........................................................... 6
3.3 Step 3 – Rank Remaining Control Technologies by Control Effectiveness ........................... 6
3.4 Step 4 – Evaluate Most Effective Controls and Document Results ..................................... 6
3.5 Step 5 – Select RACT .................................................................................................. 7
4.RACT ANALYSIS FOR CHLORINATION CONTROL STACK .................................................................... 8
4.1 Step 1 – Identify All Available Control Technologies ........................................................ 8
4.2 Step 2 – Eliminate Technically Infeasible Options ........................................................... 9
4.3 Steps 3-5 – Select RACT ............................................................................................. 9
4.4 Monitoring, Recordkeeping, and Reporting ..................................................................... 9
5.RACT ANALYSIS FOR SMALL COMBUSTION DEVICES ........................................................................ 9
5.1 RACT Analysis for NOX Emissions ................................................................................10
5.1.1 Step 1 – Identify All Available Control Technologies ................................................10
5.1.2 Step 2 – Eliminate Technically Infeasible Options ....................................................11
5.1.3 Steps 3-5 – Select RACT ......................................................................................12
5.1.4 Monitoring, Recordkeeping, and Reporting .............................................................12
5.2 RACT Analysis for VOC Emissions ................................................................................12
5.2.1 Steps 1-5 – Select RACT ......................................................................................12
5.2.2 Monitoring, Recordkeeping, and Reporting .............................................................12
6.RACT ANALYSIS FOR PROCESS VOC FROM SEPARATIONS SYSTEM VENTS ..................................... 13
6.1 Step 1 – Identify All Available Control Technologies .......................................................13
6.2 Step 2-5 – Select RACT ..............................................................................................14
6.3 Monitoring, Recordkeeping, and Reporting ....................................................................14
7.RACT ANALYSIS FOR VOC FROM PAINT/SPRAY BOOTH .................................................................. 15
7.1 Step 1 – Identify All Available Control Technologies .......................................................15
7.2 Step 2 – Eliminate Technically Infeasible Options ..........................................................15
7.3 Steps 3-5 – Select RACT ............................................................................................16
7.4 Monitoring, Recordkeeping, and Reporting ....................................................................16
8.RACT ANALYSIS FOR STORAGE TANKS ............................................................................................ 17
8.1 Step 1 – Identify All Available Control Technologies .......................................................17
8.2 Steps 2-5 – Select RACT ............................................................................................17
8.3 Monitoring, Recordkeeping, and Reporting ....................................................................17
9.RACT ANALYSIS FOR PICKLING OPERATIONS .................................................................................. 18
9.1 Step 1 – Identify All Available Control Technologies .......................................................18
9.2 Step 2 – Eliminate Technically Infeasible Options ..........................................................18
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9.3 Steps 3-5 – Select RACT ............................................................................................19
9.4 Monitoring, Recordkeeping, and Reporting ....................................................................19
10.RACT ANALYSIS FOR BOILERS .......................................................................................................... 20
10.1 RACT Analysis for NOX Emissions ................................................................................20
10.1.1 Step 1 – Identify All Available Control Technologies ................................................20
10.1.2 Step 2 – Eliminate Technically Infeasible Options ....................................................21
10.1.3 Step 3 – Rank Remaining Control Technologies by Control Effectiveness ....................21
10.1.4 Step 4 – Evaluate Most Effective Controls and Document Results ..............................22
10.1.5 Step 5 – Select RACT ..........................................................................................22
10.1.6 Monitoring, Recordkeeping, and Reporting .............................................................22
10.2 RACT Analysis for VOC Emissions ................................................................................22
10.2.1 Steps 1-5 – Select RACT ......................................................................................22
10.2.2 Monitoring, Recordkeeping, and Reporting .............................................................22
11.RACT ANALYSIS FOR NATURAL GAS EMERGENCY GENERATORS .................................................... 23
11.1 RACT Analysis for NOX Emissions ................................................................................23
11.1.1 Step 1 – Identify All Available Control Technologies ................................................23
11.1.2 Step 2 – Eliminate Technically Infeasible Options ....................................................23
11.1.3 Steps 3-5 – Select RACT ......................................................................................23
11.1.4 Monitoring, Recordkeeping, and Reporting .............................................................24
11.2 RACT Analysis for VOC Emissions ................................................................................24
11.2.1 Step 1 – Identify All Available Control Technologies ................................................24
11.2.2 Step 2 – Eliminate Technically Infeasible Options ....................................................24
11.2.3 Step 3-5 – Select RACT .......................................................................................24
11.2.4 Monitoring, Recordkeeping, and Reporting .............................................................25
12.RACT ANALYSIS FOR DIESEL EMERGENCY GENERATORS ................................................................ 26
12.1 RACT Analysis for NOX Emissions ................................................................................26
12.1.1 Step 1 – Identify All Available Control Technologies ................................................26
12.1.2 Step 2 – Eliminate Technically Infeasible Options ....................................................26
12.1.3 Steps 3-5 – Select RACT ......................................................................................26
12.1.4 Monitoring, Recordkeeping, and Reporting Requirements .........................................27
12.2 RACT Analysis for VOC Emissions ................................................................................27
12.2.1 Step 1 – Identify All Available Control Technologies ................................................27
12.2.2 Step 2 – Eliminate Technically Infeasible Options ....................................................27
12.2.3 Steps 3-5 – Select RACT ......................................................................................27
12.2.4 Monitoring, Recordkeeping, and Reporting .............................................................28
13.RACT ANALYSIS FOR FUGITIVE MIBK............................................................................................... 29
13.1 Steps 1-5 – Select RACT ............................................................................................29
13.2 Monitoring, Recordkeeping, and Reporting ....................................................................29
14.SUMMARY OF PROPOSED RACT ..................................................................................................... 30
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TABLES
Table 1: Western Zirconium RACT Analysis Equipment .................................................................. 4
Table 2: Economic Feasibility Thresholds ..................................................................................... 7
Table 3: Western Zirconium Proposed RACT for NOX ....................................................................30
Table 4: Western Zirconium Proposed RACT for VOC ...................................................................31
APPENDICES
Appendix A: Summary of RBLC Search Results
Appendix B: RACT Cost Calculations
Appendix C: Vendor Quotes
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ACRONYMS/ABBREVIATIONS
˚F – Degrees Fahrenheit
BAAQMD – Bay Area Air Quality Management District
BACT – Best Available Control Technology
CAA – Clean Air Act
CO – Carbon Monoxide
DOC – Diesel Oxidation Catalyst
EPA – Environmental Protection Agency
FGR – Flue Gas Recirculation
gal - Gallon
GCP – Good Combustion Practices
GMP – Good Management Practices
HAP – Hazardous Air Pollutant
Hf – Hafnium
HNO3 – Nitric Acid
hr – Hour
kW – Kilowatt
LAER - Lowest Achievable Emission Rate
lb - Pound
LNB – Low-NOX Burner
MIBK – Methyl Isobutyl Ketone
MMBtu – Million British Thermal Units
NAAQS – National Ambient Air Quality Standards
NESHAP – National Emission Standards for Hazardous Air Pollutants
NOX – Oxides of Nitrogen
NSPS – New Source Performance Standards
NWF – Northern Wasatch Front
O&M – Operations and Maintenance
ppm – Parts per Million
ppmv – Parts per Million by Volume
PTE – Potential to Emit
RACT – Reasonably Available Control Technology
RBLC – RACT/BACT/LAER Clearinghouse
RTO – Regenerative Thermal Oxidizer
SCFM - Standard Cubic Feet per Minute
SCR – Selective Catalytic Reduction
SNCR – Selective Non-Catalytic Reduction
SIP – State Implementation Plan
TBACT – Best Available Control Technology for Toxics
TO – Thermal Oxidizer
tpy – Tons per Year
UDAQ – Utah Division of Air Quality
ULNB – Ultra Low-NOX Burner
VOC – Volatile Organic Compounds
yr - year
Zr – Zirconium
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1.INTRODUCTION
On August 3, 2018, the Environmental Protection Agency (EPA) designated the Northern Wasatch
Front (NWF) as marginal nonattainment for the 2015 8-hour ozone National Ambient Air Quality
Standards (NAAQS). The NWF failed to achieve attainment of the standard by August 3, 2021, and
was reclassified to moderate status on November 7, 2022. As a moderate nonattainment area, the
NWF is required to attain the 0.070 parts per million by volume (ppmv) federal 8-hour ozone standard
by August 3, 2024. However, recent monitoring indicates that it will not attain the standard and will
be reclassified as serious nonattainment status in February 2025. The serious nonattainment
classification will establish new thresholds for major stationary sources. Specifically, as oxides of
nitrogen (NOX) and volatile organic compounds (VOCs) are precursors to ozone, the reclassification
from moderate to serious will establish major source potential to emit (PTE) thresholds of 50 tons per
year (tpy) of NOX or VOCs.
Section 110 of the Clean Air Act (CAA) mandates states to develop State Implementation Plans (SIPs)
to outline strategies to achieve and maintain NAAQS. Under the Ozone Implementation Rule in 83
Federal Register 62998, SIPs must include Reasonably Available Control Technology (RACT) for all
major stationary sources located in nonattainment areas classified as moderate or higher. In
accordance with the Ozone Implementation Rule, the Utah Division of Air Quality (UDAQ) is requiring
all major sources and pending major sources to submit RACT analyses for the control of NOX and VOC
emissions by January 2, 2024.
On May 31, 2023, UDAQ notified Westinghouse Electric Co. LLC (Western Zirconium, WZ) that
because the Ogden Zirconium Hafnium Production Plant (the “Facility”) has a PTE of over 50 tpy of
NOX, the Facility will become a major source once the non-attainment area is reclassified. Therefore,
WZ is required to submit a RACT analysis for all emission units that emit NOX and/or VOCs by January
2, 2024.1
The RACT proposals submitted to UDAQ must include the following:
•A list of each NOX and VOCs emission unit at the facility. All emission units that emit or have the
potential to emit NOX and/or VOCs must be evaluated.
•A physical description of each emission unit and its operating characteristics.
•Estimates of the potential and actual NOX and VOC emissions from each affected source and
associated supporting documentation.
•The proposed alternative NOX RACT requirement(s) or NOX RACT emissions limitations.
•The proposed alternative VOC RACT requirement(s) or VOC RACT emissions limitations.
•Supporting documentation for the technical and economic considerations for each affected
emission unit.
•A schedule for completing implementation of the RACT requirement or RACT emissions limitation
by May of 2026.
•Proposed testing, monitoring, recordkeeping, and reporting procedures to demonstrate compliance
with the proposed RACT requirement(s) and/or limitations.
•Additional information requested by UDAQ necessary for the evaluation of the RACT analyses.
1 The Facility was provided an extension of this deadline to March 15, 2024, approved by UDAQ via email on
February 7, 2024 (after previous extension requests had been approved prior to the January 2nd and subsequent
submission deadlines).
2
2.FACILITY AND EMISSIONS INFORMATION
2.1 Facility Description
WZ manufactures nuclear grade zirconium (Zr) and hafnium (Hf) products using raw feed materials at
its plant located at 10000 W 900 S in Ogden, UT. WZ operates under the Title V Operating Permit
#5700006005 issued on September 5, 2023. The production process begins with the separations
process where zirconium oxychloride crystals are converted into either zirconium oxide or hafnium
oxide and the two compounds are separated. The two oxides then go through the chlorination process,
in which they are converted into zirconium chloride or hafnium chloride. The next chemical process is
where the zirconium chloride or hafnium chloride react in a furnace with magnesium to produce pure
zirconium or hafnium. The metals are then fabricated into the final alloys using furnaces. The final
alloys are then shaped using extrusion and mills to form the final product. An overview of each
process is described in detail below:
2.1.1 Separations Process
The separations process begins with mixing zirconium oxychloride crystals with deionized water in
feed storage tanks. The dissolved zirconium oxide crystals are then sent to feed mix tanks where they
are mixed with zirconyl chloride solution.
The feed mix tanks feed into the first of three hafnium extraction columns where hafnium is removed
from the zirconyl chloride solution. The bottom of the final hafnium extraction column feeds to the top
of the thio removal columns, and ammonium thiocyanate is removed from the zirconium chloride
solution by contacting it with acid to produce zirconium raffinate. The zirconium raffinate enters a
steam stripper and the zirconium material is then sent to a zirconium precipitation kettle. In the
precipitation kettle, the zirconium material is mixed with ammonium hydroxide and ammonium sulfate
from the hafnium filter press. This material is then mixed with ammonium hydroxide before going to a
filter and then a slurry tank. The mixture goes to a filter press with the ammonium hydroxide leaving
the process to be neutralized and the zirconium oxide product being sent to a calciner. Gases from the
calciner are sent through a quench scrubber, then through a caustic scrubber, followed by electrostatic
precipitators before being emitted from the process stack.
The hafnium rich material, from the top of the first hafnium extraction columns, is sent to the two
zirconium stripper columns, where traces of zirconium are removed from the hafnium-bearing solvent.
In the second zirconium stripper column, acid enters near the top of the column. The bottoms feed
back to the first zirconium stripper column and the tops go to the two hafnium scrubbing columns.
The hafnium scrubbing columns remove hafnium from the solvent and thio from the hafnium sulfuric
acid solution. The hafnium raffinate goes through a steam stripper and thio is recycled back to the
process. The hafnium is then sent to a hafnium precipitation tank where it is mixed with ammonium
hydroxide reacting to form hafnium oxide. The oxide is then sent to a hafnium filter press, followed by
a calciner producing hafnium oxides. Gases from the hafnium oxide calciner go through the caustic
scrubber and electrostatic precipitators before being emitted through the process stack.
The solvent and thio are both recovered for reuse in the process. Gases from the columns and
precipitation tanks are combusted in the thermal oxidizer (TO) unit that uses natural gas emissions
from the TO are discharged through a stack.
2.1.2 Pure Chlorination Process
The zirconium oxide powder is sent to pure chlorination where zirconium and hafnium are run through
this process separately. Note that only zirconium is listed here, but hafnium follows an identical
process. The purpose of pure chlorination is to convert the zirconium oxide (or hafnium oxide) to

3

zirconium tetrachloride (ZrCl4) (or hafnium tetrachloride HfCl4), for processing into zirconium (or
hafnium) metal. ZrCl4 is obtained by reacting petroleum coke, zirconium oxide, and chlorine to form a
gas product that is then condensed resulting in pure zirconium tetrachloride solid product. The first
step of this process is to mix specific ratios of zirconium oxide and petroleum coke into a feed vat. The
vat enters the top of a feed hopper where it enters the chlorinator, a mixing unit where the solids are
reacted with a mixture of chlorine and nitrogen. Reactive material leaves the chlorinator and goes to
primary and secondary condensers. The condensate, ZrCl4, is placed in cans and sent to retort loading
in reductions.
Vapors from the secondary condenser are sent to a jet fume scrubber. The bottoms, made up of
hydrochloric acid and zirconium oxychloride, are sent to an elementary neutralization tank to be
reacted with CaO to form CaCl2 before being sent to the evaporation pond. Vapors from the jet fume
scrubber are sent to a pure caustic scrubber where they are mixed with NaOH. Effluent from the pure
caustic scrubber is sent to the salt evaporation pond while any remaining vapors are sent to the
venturi scrubber. The venturi scrubber sends liquids to a venturi scrubber recycle tank while vapors
are sent out the stack.
2.1.3 Reduction Process
The purpose of the reduction phase is to react the ZrCl4 with magnesium to create a sponge of pure
zirconium. The ZrCl4 from the Pure Chlorination Process is placed in a reduction retort, a large cylinder
with a hollow center that extends over halfway up the retort. Magnesium is loaded into a crucible and
then a retort assembly is created by welding a lid over the Reduction Retort and the crucible to the
bottom. This assembly is placed in a pre-evacuation furnace to remove any vapor from the furnace
before being placed in the reduction furnace. The resulting product is a zirconium regulus that is
covered by magnesium chloride.
The magnesium chloride is removed from the crucible and the zirconium regulus is sent to a
distillation vessel to remove any unreacted magnesium or magnesium chloride from the zirconium
regulus. The remaining zirconium reduces to a dense sponge like constituency, called a sponge
regulus, which is sent to a break-up press and then a grading press. The zirconium pieces are sent to
a primary sponge crusher and then a secondary sponge crusher after which they undergo size
screening. Material that is appropriately sized goes to a hopper, a picking conveyor where discolored
or burned pieces are removed, and then sent to a splitter. The crushed zirconium sponge is placed in
barrels for the zircaloy fabrication process.
2.1.4 Zircaloy Fabrication Process
Zircaloy Fabrication is where the pure zirconium sponge is combined with alloying elements, which is
an electron beam welded into a melting electrode. The electrodes are melted and cast into ingots in
vacuum arc furnaces. The ingots are forged into logs or slabs for further processing to final product.
Forged slabs are hot rolled to plate product, annealed, conditioned, ultrasonically inspected, and
pickled. Further gauge reductions are obtained by cold rolling to sheet and strip products. Coiled strip
product is continuously annealed in an inert atmosphere furnace. Bar products are manufactured by
successive swaging reductions followed by salt bath or vacuum anneals. Wire is produced by drawing
swaged products to successively smaller gauges, interspersed with vacuum anneals. Tube shells are
produced by extruding beta-quenched billets, vacuum annealing, conditioning and pickling. Extruded
tube shells are further reduced to Trex by pilgering, vacuum annealing, conditioning and pickling. All
tube shells are ultrasonically inspected for internal and surface defects and dimensions.
Logs are cut into billets (smaller diameter logs), placed in an induction heater and then a beta-quench
tank. The processed billets are then sent to an extrusion press. Some material is re-extruded and

4

then goes to swaging and drawing where it is swaged into bar products or to draw machinery to be
thinned into wire products. The other material from the extrusion press is sent to a vacuum annealing
furnace, to a pilger mill, back to the annealing furnace and then to condition and pickle. At that point
this material is made into either extrude tube shell or Trex.
Material exiting the forge as slabs are sent to a furnace and then a quench tank. Slabs are sent to a
roller heath furnace and from there to the hot mill. Material exiting the hot mill is either air annealed
and considered to be hot rolled plate product, or it is sent to the cold mill. Materials exiting the cold
mill undergo one of three additional processes. The first process has the materials sent to a vacuum
annealing furnace and then processed through the cold mill again. The second process has material
exiting the cold mill after the vacuum annealing furnace as cold rolled sheet and strip product. The
third process has material exiting the cold mill sent to an inert atmosphere continuous anneal and are
then considered Cold Rolled Coil Product.
2.2 Facility Emissions
The plant is currently a Title V major source with hazardous air pollutant (HAP) emissions exceeding
the major source threshold of 25 tpy at the Facility. HAP and VOC emissions are primarily composed of
chlorine, ethyl benzene, formaldehyde, hexane, hydrochloric acid, hydrofluoric acid, methyl isobutyl
ketone (MIBK), and xylenes.
Table 1 presents all emission units at the Facility that emit NOX and/or VOC and that are included in
this RACT analysis.2,3
Table 1: Western Zirconium RACT Analysis Equipment
Equipment PTE NOX
(TPY)
Actual NOX
(TPY)
PTE VOC
(TPY)
Actual VOC
(TPY)
Chlorination Control Stack N/A N/A 2.2 0.62
Separations Zr Oxide Kiln 2.1 0.51 0.12 0.028
Separations Hf Oxide Kiln 2.6 0.79 0.14 0.043
Separations System Vents 7.6 5.0 0.49 0.32
MIBK Storage Tank N/A N/A 0.081 0.024
Reduction Process Furnaces 0.71 0.30 0.039 0.017
Reduction Process Ovens 0.36 0.15 0.020 0.0083
Pre-Evacuation Furnaces 4.7 1.7 0.26 0.11
Lances 0.053 0.022 0.0029 0.0012
Pickling Operations 13.3 8.1 N/A N/A
Hot Mill Vent 0.11 0.048 0.0062 0.0026
Paint/Spray Booth 0.52 0.22 2.97 0.06
Boilers 14.4 6.0 0.79 0.33
Natural Gas Emergency Generators 1.4 0.34 Not Quantified 0.075
Diesel Emergency Generators 6.7 1.1 Not Quantified 0.31
Diesel Storage N/A N/A 0.0013 3.0E-04
Gasoline Storage N/A N/A 0.28 0.18
Propane Vaporizer 0.018 4.3E-04 0.0010 4.0E-05
Fugitive MIBK N/A N/A Not Quantified 0.039

2 NOX and VOC PTE taken from Westinghouse’s 2023 internal emissions calculations workbook.
3 NOX and VOC actuals taken from Westinghouse’s SLEIS 2022 emissions report.

5

All correspondence regarding this submission should be addressed to:
John Wester
10000 West 900 South
Ogden, UT 84404-9799
[phone]
[e-mail]

6

3. RACT METHODOLOGY
As required under CAA 182(b)(2), areas in moderate nonattainment for the 2015 8-hour ozone NAAQS
must implement RACT for existing major sources of VOCs and NOX. When implementing RACT for a
specific facility, the EPA states, “RACT for a particular source is determined on a case-by-case basis
considering the technological and economic circumstances of the individual source.”4
Below are the five steps included in the following RACT analysis.
3.1 Step 1 – Identify All Available Control Technologies
Identify available control technologies for each emission unit. Methods for identifying potential
technologies include researching the RACT/BACT/LAER Clearinghouse (RBLC) database, surveying
regulatory agencies, reviewing regulatory standards, conferring with experienced control technology
experts, conferring with equipment vendors, and reviewing available literature including submitted
UDAQ RACT reports related to previous SIP designations.
3.2 Step 2 – Eliminate Technically Infeasible Options
Control technologies identified in the previous step are then considered for their technological
feasibility. Determining if a control technology is technically feasible includes evaluation based on
physical, chemical, and engineering principles in addition to demonstration in the field.5 Only the
control equipment that has been demonstrated in practice for sources per the resources noted in Step
1 are considered in the RACT analysis. Along with the RBLC database, WZ reviewed the following
RACT and best available control technology (BACT) guideline documents to identify control
technologies demonstrated in practice:
• Texas Commission on Environmental Quality Air Pollution Control Guidance Document
• Bay Area Air Quality Management District (BAAQMD) BACT/Best Available Control Technology for
Toxics (TBACT) Workbook
After reviewing all control technologies, technically infeasible options will be eliminated from further
steps. A summary of the RBLC search results is provided in Appendix A.
3.3 Step 3 – Rank Remaining Control Technologies by Control Effectiveness
Any control technologies not eliminated in Step 2 are ranked by overall control effectiveness.6 Ranking
based on control effectiveness is not required when all technologies have the same control efficiency
or if there is only one option.
3.4 Step 4 – Evaluate Most Effective Controls and Document Results
The most effective option is then evaluated based on energy, environmental, and economic impacts. If
a technically feasible control option is eliminated, the next most effective option is evaluated. This
process will continue until the control technology cannot be eliminated by environmental, energy, or
economic impacts.7 UDAQ has published cost thresholds for different levels of emissions reductions for

4 Federal Register (1979). Vol. 44. No. 181. Proposed Rules – State Implementation Plan; General Preamble for
Proposed Rulemaking on Approval of Plan Revisions for Nonattainment Areas – Supplement (on Control Techniques
Guidelines).
5 U.S. EPA (1990). New Source Review Workshop Manual (Draft): Prevention of Significant Deterioration and
Nonattainment Area Permitting. https://www.epa.gov/sites/default/files/2015-07/documents/1990wman.pdf
6 Ibid.
7 Ibid.
7
the purpose of RACT analyses, which are provided in Table 4.8 The high end of these threshold
ranges were used in the RACT analysis to determine economic feasibility (i.e., a reduction of 2.50 tpy
would have a cost effectiveness threshold of $10,000/ton removed). Cost effectiveness calculations
are included in Appendix B.
Table 2: Economic Feasibility Thresholds
Note: This table is presented in 2023 dollars and is intended to assist in RACT
determinations, however additional discretion is applicable to all final RACT
determinations.
3.5 Step 5 – Select RACT
The emission rate resulting from the most effective control technology from Step 4 is proposed as
RACT for the pollutant and emission unit.9
8 UDAQ (2023). DAQ-061-23 Memorandum, Propose for Final Adoption: Amendment to Section R307-110-12;
Incorporation of Utah State Implementation Plan, Section IX.D.11:2015 Ozone NAAQS Northern Wasatch Front
Nonattainment Area.
9 U.S. EPA (1990). New Source Review Workshop Manual. https://www.epa.gov/sites/default/files/2015-
07/documents/1990wman.pdf
Annualized Cost
($/ton removed) Total Tons Reduced (TPY)
$0 - $5,000 Any
$5,000 - $10,000 Reduction ≥ 2.00
$10,000 - $15,000 Reduction ≥ 5.00
$15,000 - $20,000 Reduction ≥ 10.00
$20,000 - $25,000 Reduction ≥ 15.00
$25,000 - $30,000 Reduction ≥ 20.00
$30,000 - $35,000 Reduction ≥ 25.00
$35,000 - $40,000 Reduction ≥ 30.00
$40,000+ Case-by-Case

8

4. RACT ANALYSIS FOR CHLORINATION CONTROL STACK
The chlorination control stack system includes two (2) heated chlorinators for the Zr process and one
(1) heated chlorinator for the Hf process. Existing system controls consist of a Venturi scrubber,
caustic scrubber, and jet fume scrubber for removal of chlorine and chlorates from the emission unit
discharge. The chlorination control stack has a maximum outlet flow of 18,000 standard cubic feet per
minute (SCFM). The chlorination control stack system generates emissions of VOCs.
4.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database, EPA fact
sheets, and UDAQ rules. The identified control technologies for the chlorination system for VOC
reduction are:
• TO,
• Scrubber/Absorber,
• Carbon Adsorption System, and
• Good Management Practices (GMP).
Thermal Oxidizer
TOs are widely used for VOC control. They operate by combusting VOCs at high temperatures,
typically above 1400 °F, converting them into carbon dioxide and water vapor. Thermal oxidizers can
be further categorized into direct-fired, regenerative, catalytic, or recuperative types, each with
specific applications and advantages.10 TOs can achieve a VOC destruction efficiency of 99 percent.11
Scrubber/Absorber
A scrubber removes pollutants from industrial exhaust streams by passing the exhaust stream through
a tower packed with a material that reacts with the pollutant to neutralize it. In the case of VOCs, the
removal of pollutants in the gaseous stream is achieved by absorption. The scrubbing liquid, usually
water, is used to absorb the pollutant. Wet scrubbers used for this type of pollutant control are often
referred to as absorbers. Most absorbers have removal efficiencies in excess of 90 percent, depending
on pollutant absorbed. Wet scrubbers can also be used to remove particulate matter. The same
principal of absorption applies to caustic scrubbers used to remove acidic gases and acidic pollutants.
In a caustic scrubber, the exhaust stream passes through a tower packed with a material that reacts
with the acid gas to neutralize it. Lower efficiencies are achieved for exhausts with relatively insoluble
compounds at low concentrations.
Carbon Adsorption System
Carbon adsorption generally involves the adsorption of organic compounds on activated carbon.
Adsorption is most effective at lower temperatures and is affected by ambient humidity. Periodic
replacement of the activated carbon is required as buildup of compounds on the filter media will occur.
For VOC concentrations between 500 and 2,000 ppmv, the control efficiency of carbon adsorption can
be 95-99 percent.12

10 EPA (2017). Air Pollution Control Cost Manual, Section 3.2, Chapter 2 – Incinerators and Oxidizers.
https://www.epa.gov/sites/default/files/2017-12/documents/oxidizersincinerators_chapter2_7theditionfinal.pdf
11 Ibid.
12 EPA (2018). Carbon Adsorbers, Chapter 1. https://www.epa.gov/sites/default/files/2018-
10/documents/final_carbonadsorberschapter_7thedition.pdf
9
Good Management Practices
GMP are a collection of best practices for various types of equipment. At a minimum, GMP consist of
proper maintenance and operation, including routine testing and recordkeeping.
4.2 Step 2 – Eliminate Technically Infeasible Options
Thermal Oxidizer
TO is considered technically infeasible for the chlorination control stack as the concentration,
temperature, and heating value of the gas is too low to combust without a significant amount of
auxiliary gas (usually natural gas). Furthermore, while reducing VOC, emissions of NOX and carbon
monoxide (CO) would be created from VOC oxidation and combustion of the auxiliary gas, which
creates adverse environmental impacts that outweigh the benefits from VOC destruction.
Scrubber/Absorber
A wet scrubber is considered technically infeasible for the chlorination control stack as the
concentration of VOC is too low for it to be effective and is not demonstrated in practice for this
quantity of VOC emissions.
Carbon Adsorption System
Carbon adsorption is considered technically infeasible for the chlorination control stack as the
concentration of VOC is too low for adsorption to be effective.
Good Management Practices
GMP is considered technically feasible for the chlorination control stack.
4.3 Steps 3-5 – Select RACT
Based on the information provided in the previous section, GMP is the only remaining control
technology and is thus proposed as RACT for the chlorination control stack for VOC emissions.
4.4 Monitoring, Recordkeeping, and Reporting
WZ will follow procedures outlined in the Operations and Maintenance (O&M) manual to ensure proper
operation of the unit to minimize VOC emissions. Deviations will be reported in the semi-annual and
annual compliance certification in accordance with the Title V permit.
WZ currently conducts performance tests every two years to demonstrate compliance with the
particulate matter limit. In addition, the pressure drop across the Venturi scrubber is monitored and
recorded every 15 minutes. These monitoring activities will also demonstrate proper functioning of the
emission unit.
5.RACT ANALYSIS FOR SMALL COMBUSTION DEVICES
WZ operates several natural gas combustion devices with heat input capacities less than 10 million
British thermal units per hour (MMBtu/hr). As the RACT analysis is the same for all of these
combustion devices, this section applies to all of them. These sources generate emissions of NOX and
VOCs.
The small combustion devices are:
•Separations Zr Oxide Kiln – WZ has one (1) Zr oxide kiln with a firing capacity of 5 MMBtu/hr.
•Separations Hf Oxide Kiln – WZ has one (1) Hf oxide kiln with a firing capacity of 3 MMBtu/hr.
•Separations System Vents – Emissions from the separation system columns and precipitation
tanks are vented to a 2.0 MMBtu/hr TO which reduces VOC emissions through combustion with
10
supplemental natural gas. It is positioned after a pre-scrubber and assists in controlling primarily
MIBK emissions. Therefore, a RACT analysis is presented for these combustion emissions.
•Reduction Process Furnaces and Ovens – The reduction process includes ten (10) furnaces
with ratings of 1.1 MMBtu/hr each or 11 MMBtu/hr total, and one (1) 2.5 MMBtu/hr burnout oven.
•Pre-Evacuation Furnaces – WZ has ten (10) pre-evacuation furnaces fired with natural gas,
each with a rating of 1.1 MMBtu/hr.
•Lances – WZ has crucible and retort natural gas-fired lances rated at 0.124 MMBtu/hr. Only one
lance runs at a time.
•Hot Mill Vent – The hot mills operate at a firing capacity of 0.265 MMBtu/hr and emissions are
directed to the hot mill vent.
•Propane Vaporizer – The emergency propane vaporizer system consists of four (4) vaporizer
burners each rated 0.15 MMBtu/hr and two (2) mixer burners with a rating of 0.47 MMBtu/hr
each.
•Paint Spray Booth – The drive-through paint spray booth consists of one (1) natural gas-fired
burner with a rating of 1.2 MMBtu/hr.
5.1 RACT Analysis for NOX Emissions
5.1.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database, EPA fact
sheets, and UDAQ rules. The identified control technologies for NOX reduction are:
•Selective Catalytic Reduction (SCR),
•Selective Non-catalytic Reduction (SNCR),
•Ultra-low NOX Burners (ULNB),
•Low-NOX Burners (LNB),
•Flue Gas Recirculation (FGR), and
•Good Combustion Practices (GCP).
Selective Catalytic Reduction
SCR is a method of NOX control that uses a catalyst and reagent to reduce NOX emissions. SCR is
typically implemented on stationary source combustion units which require a high level of NOX
reduction.13 Urea is generally used as the reduction reagent. NOX removal efficiencies for SCR are
high, at 90 percent.14
Selective Non-Catalytic Reduction
SNCR is similar to SCR but does not involve catalytic reduction, thus decreasing the NOX
reduction efficiency. Instead, reduction is achieved through very high temperatures (1,400 -
2,000 ˚F). ˚.
13 EPA (2017). Air Pollution Control Cost Manual, Section 4 – Chapter
2.https://www.epa.gov/sites/default/files/2017-
12/documents/scrcostmanualchapter7thedition_2016revisions2017.pdf
14 EPA. Air Pollution Control Technology Fact Sheet – SCR. https://www3.epa.gov/ttncatc1/dir1/fscr.pdf
11
Ultra-low NOX Burner
An ULNB is a type of LNB that can reduce NOX emissions to very low levels, usually below 30
ppmv, corrected to 3 percent oxygen.15 ULNB technology has been shown to achieve NOX
emissions of 9 ppmv.16
Low NOX Burner
NOX formation can be reduced through the restriction of oxygen, flame temperature, or residence
time, which is the principle of LNB technology. Staged fuel and air burners are both intended to reduce
the formation of thermal NOX. When LNB technology is implemented, emissions of NOX can be reduced
by 50 percent compared to standard burners.17
Flue Gas Recirculation
FGR is a NOX control technology wherein the exhaust gas is routed into the inlet with the addition of a
forced hot gas fan.18 FGR is most effective for natural gas and low-nitrogen fuels because it lowers the
available oxygen which reduces the formation of NOX. The NOX reduction efficiency of FGR is 30-60
percent.19
Good Combustion Practices
GCP includes combustion zone control of temperature and excess air, increased thermal efficiency,
and staged combustion, if possible. GCP generally involves proper maintenance and operations of
combustion equipment. For natural gas-fired combustion units, use of pipeline natural gas is
considered GCP.
5.1.2 Step 2 – Eliminate Technically Infeasible Options
Selective Catalytic Reduction
SCR is considered technically infeasible as this technology is not demonstrated in practice for natural
gas-fired equipment with firing rates less than 10 MMBtu/hr.
Selective Non-Catalytic Reduction
SNCR is considered technically infeasible as this technology is not demonstrated in practice for natural
gas-fired equipment with firing rates less than 10 MMBtu/hr.
Ultra-low NOX Burner
ULNB technology is considered technically infeasible as this technology is not demonstrated in practice
for natural gas-fired equipment with firing rates less than 10 MMBtu/hr.
Low NOX Burner
LNB technology is considered technically infeasible as this technology is not demonstrated in practice
for natural gas-fired equipment with firing rates less than 10 MMBtu/hr.
15 Oak Ridge National Laboratory (2002). Guide to Low-Emission Boiler and Combustion Equipment
Selection. https://www.energy.gov/eere/amo/articles/guide-low-emission-boiler-and-combustion-equipment-
selection
16 Power Flame.
Nova Low NOx Burners. https://www.powerflame.com/index.php?option=com_content&view=article&id=110&Ite
mid=57
17 AP‐42 Table 1.4‐1 – Emission Factors for Nitrogen Oxides and Carbon Monoxide from Natural Gas
Combustion. https://www3.epa.gov/ttnchie1/ap42/ch01/final/c01s04.pdf
18 Power Engineering (2003). NOx Control on a Budget: Induced Flue Gas Recirculation. https://www.power-
eng.com/news/nosubx-sub-control-on-a-budget-induced-flue-gas-recirculation/#gref
19 Pollution Online (2000). NOx Emission Reduction Strategies. https://www.pollutiononline.com/doc/nox-emission-
reduction-strategies-0001
12
Flue Gas Recirculation
FGR is considered technically infeasible as this technology is not demonstrated in practice for natural
gas-fired equipment with firing rates less than 10 MMBtu/hr.
Good Combustion Practices
GCP is considered technically feasible for the small combustion devices.
5.1.3 Steps 3-5 – Select RACT
Based on the information provided in the previous section, the firing of natural gas with GCP is the
only remaining control technology and is thus proposed as NOX RACT for the small combustion
devices.
5.1.4 Monitoring, Recordkeeping, and Reporting
WZ will follow O&M procedures, recordkeeping, and reporting requirements per their O&M manual and
Title V conditions. Deviations will be reported in the semi-annual and annual compliance certification
in accordance with the Title V permit.
5.2 RACT Analysis for VOC Emissions
Each of the small combustion devices presented in Section 5 generates VOC emissions due to
combustion of natural gas. In addition, the separations system vents and paint spray booth emit
process VOCs which are addressed in Sections 6 and 7, respectively. RACT for VOC emissions from
combustion of natural gas for the small combustion devices is presented in the following subsections.
5.2.1 Steps 1-5 – Select RACT
WZ only identified one control method for VOC emissions from small combustion equipment, the firing
of pipeline natural gas with GCP. Add-on VOC controls are not demonstrated in practice for natural
gas-fired combustion equipment with firing rates less than 10 MMBtu/hr. RACT/BACT for VOCs
generated by natural gas combustion equipment is frequently listed in the RBLC as “proper
operation,” “none,” or “no control,” and there are often notes indicating that no control technology
was technically feasible.
GCP for VOC control also involves appropriate fuel residence times, proper fuel-air mixing, and
temperature control. Based on the analysis above, the use of GCP is proposed as VOC RACT for the
small combustion devices.
5.2.2 Monitoring, Recordkeeping, and Reporting
WZ will follow O&M procedures, recordkeeping, and reporting requirements per their O&M manual and
Title V conditions. Deviations will be reported in the semi-annual and annual compliance certification
in accordance with the Title V permit.
13
6.RACT ANALYSIS FOR PROCESS VOC FROM
SEPARATIONS SYSTEM VENTS
The Facility’s separations system vents emit process VOCs in addition to the combustion VOC
emissions addressed in Section 5. The separations system includes columns and precipitation tanks
that emit VOCs, primarily MIBK. HAP and VOC emissions from the separations system vents are
controlled by a pre-scrubber followed by a TO.
6.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies from the existing controls installed on the emission
sources. The identified control technologies for VOC reduction are:
•TO,
•Scrubber/Absorber,
•Activated Carbon Bed, and
•GMP.
Thermal Oxidizer
TOs are widely used for VOC control. They operate by combusting VOCs at high temperatures,
typically above 1400 °F, converting them into carbon dioxide and water vapor. Thermal oxidizers can
be further categorized into direct-fired, regenerative, catalytic, or recuperative types, each with
specific applications and advantages.20 TOs can achieve a VOC destruction efficiency of 99 percent.21
Scrubber/Absorber
A scrubber removes pollutants from industrial exhaust streams by passing the exhaust stream through
a tower packed with a material that reacts with the pollutant to neutralize it. In the case of VOCs, the
removal of pollutants in the gaseous stream is done by absorption. The scrubbing liquid, usually
water, is used to absorb the pollutant. Wet scrubbers used for this type of pollutant control are often
referred to as absorbers. Most absorbers have removal efficiencies in excess of 90 percent, depending
on pollutant absorbed. Wet scrubbers can also be used to remove particulate matter. The same
principal of absorption applies to caustic scrubbers used to remove acidic gases and acidic pollutants.
In a caustic scrubber, the exhaust stream passes through a tower packed with a material that reacts
with the acid gas to neutralize it. Lower efficiencies are achieved for exhausts with relatively insoluble
compounds at low concentrations.
Carbon Adsorption System
Carbon adsorption generally involves the adsorption of inorganic or organic compounds on activated
carbon. Adsorption is most effective at lower temperatures and is affected by ambient humidity.
Periodic replacement of the activated carbon is required as buildup of compounds on the filter media
will occur. For VOC concentrations between 500 and 2,000 ppmv, the control efficiency of carbon
adsorption can be 95-99 percent.22
20 EPA (2017). Air Pollution Control Cost Manual, Section 3.2, Chapter 2 – Incinerators and Oxidizers.
https://www.epa.gov/sites/default/files/2017-12/documents/oxidizersincinerators_chapter2_7theditionfinal.pdf
21 Ibid.
22 EPA (2018). Carbon Adsorbers, Chapter 1. https://www.epa.gov/sites/default/files/2018-
10/documents/final_carbonadsorberschapter_7thedition.pdf
14
Good Management Practices
GMP are a collection of best practices for various types of equipment. GMP would consist of proper
maintenance and operation, including routine monitoring and recordkeeping.
6.2 Step 2-5 – Select RACT
VOC emissions from the separations system are already controlled by a pre-scrubber followed by a
TO. The TO is the most effective control for VOC reduction; thus, the TO and pre-scrubber are
proposed as RACT for VOC from the separations system.
6.3 Monitoring, Recordkeeping, and Reporting
WZ’s Title V permit includes monitoring, recordkeeping, and reporting requirements for the proper
operation of the TO system. In accordance with the Title V permit, the operating temperature in the
combustion chamber of the TO is monitored continuously to ensure sufficient destruction of VOC. The
temperature is recorded weekly and if the temperature less than the specified limit, the temperature
is recorded every minute for one hour to verify compliance. WZ records deviations from the stated
requirements and reports deviations in the semi-annual and annual compliance certification in
accordance with the Title V permit.
15
7.RACT ANALYSIS FOR VOC FROM PAINT/SPRAY BOOTH
The drive-through paint spray booth consists of one (1) natural gas-fired burner with a rating of 1.2
MMBtu/hr. In addition to the combustion source, the paint spray booth emits VOCs from the spraying
of paints in the booth. RACT for NOX and VOC emissions from the paint spray booth heater are
addressed in Section 5.
7.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database, EPA fact
sheets, and UDAQ rules. The identified control technologies for the paint spray booth for VOC
reduction are:
•TO,
•Carbon Adsorption System, and
•GMP.
Thermal Oxidizer
TOs are widely used for VOC control. They operate by combusting VOCs at high temperatures,
typically above 1400 °F, converting them into carbon dioxide and water vapor. Thermal oxidizers can
be further categorized into direct-fired, regenerative, catalytic, or recuperative types, each with
specific applications and advantages.23 TOs can achieve a VOC destruction efficiency of 99 percent.24
Carbon Adsorption System
Carbon adsorption generally involves the adsorption of organic compounds on activated carbon.
Adsorption is most effective at lower temperatures and is affected by ambient humidity. Periodic
replacement of the activated carbon is required as buildup of compounds on the filter media will occur.
For VOC concentrations between 500 and 2,000 ppmv, the control efficiency of carbon adsorption can
be 95-99 percent.25
Good Management Practices
GMP for the paint spray booth VOC emissions include safe storage/containment of VOC-containing
materials, quick identification and cleanup of spills, and proper maintenance and operation of the unit.
Additionally, GMP include minimizing the volume of coatings used in a process through training of staff
on proper application methods. VOC emissions can be further reduced by employing low-VOC content
coatings and solvents, where possible.
7.2 Step 2 – Eliminate Technically Infeasible Options
Thermal Oxidizer
TO is considered a technically infeasible control for a paint spray booth of this size as it is not
demonstrated in practice. Per Texas and BAAQMD guidelines Regenerative Thermal Oxidizers (RTOs)
are required for paint spray booths with more than 60 tpy of VOC and 50 lb/day of VOC, respectively.
23 EPA (2017). Air Pollution Control Cost Manual, Section 3.2, Chapter 2 – Incinerators and Oxidizers.
https://www.epa.gov/sites/default/files/2017-12/documents/oxidizersincinerators_chapter2_7theditionfinal.pdf
24 Ibid.
25 EPA (2018). Carbon Adsorbers, Chapter 1. https://www.epa.gov/sites/default/files/2018-
10/documents/final_carbonadsorberschapter_7thedition.pdf
16
Carbon Adsorption System
Carbon adsorption is considered a technically infeasible control for a paint spray booth of this size as it
is not demonstrated in practice. Per Texas BACT and BAAQMD BACT/TBACT guidelines add-on controls
are required for paint spray booths with more than 60 tpy of VOC and 50 lb/day of VOC, respectively.
Good Management Practices
GMP are considered technically feasible for the paint/spray booth.
7.3 Steps 3-5 – Select RACT
Based on the information provided in the previous section, GMP are the only remaining control
technology option and are thus proposed as RACT for the paint spray booth VOC emissions. WZ
minimizes VOC emissions by complying with the Title V permit Condition II.B.13 which limits VOC
emissions to no more than 2.94 tpy, opacity to 10 percent, and fiberglass resin consumption of no
more than 60 gal/yr.
7.4 Monitoring, Recordkeeping, and Reporting
WZ will follow procedures outlined in the O&M manual and Title V permit to ensure proper operation of
the unit to minimize VOC emissions as follows:
•Record the amount of paint consumed and calculate VOC emissions on a rolling 12-month period.
•Conduct a visual inspection of the paint booth using Method 9 once per quarter.
•Record the consumption of fiberglass resin and calculate the rolling 12-month total.
WZ will record deviations from the stated requirements and reports deviations in the semi-annual and
annual compliance certification in accordance with the Title V permit.
17
8.RACT ANALYSIS FOR STORAGE TANKS
The RACT analysis is the same for VOC emissions from all storage tanks. Therefore, the following
subsections apply to all storage tanks at the facility as follows:
•MIBK Storage Tank – The MIBK storage tank has a capacity of 8,813 gallons and is controlled by
a vertical fixed roof.
•Diesel Storage Tanks – WZ has two (2) diesel storage tanks with a combined capacity of 4,750
gallons.
•Gasoline Storage Tank – WZ has one (1) gasoline storage tank with a capacity of 2,000 gallons.
8.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database and EPA New
Source Performance Standards (NSPS). The identified control technologies for VOC reduction are:
•Closed System with Control Device (vapor recovery system),
•Floating Roof Tank, and
•GMP.
8.2 Steps 2-5 – Select RACT
Closed systems with control devices and floating roof tanks are prescribed methods for reducing VOC
emissions in EPA’s NSPS 40 CFR 60 Subpart Kb, Standards of Performance for Volatile Organic Liquid
Storage Vessels (Including Petroleum Liquid Storage Vessels) for Which Construction, Reconstruction,
or Modification Commenced After July 23, 1984. However, WZ’s tanks are not subject to this subpart
because the tanks do not meet the capacity and vapor pressure applicability thresholds: storage
vessels with a capacity greater than or equal to 75 cubic meters (m3) (19,813 gal) storing a volatile
organic liquid with a maximum true vapor pressure greater than 15.0 kilopascals (kPa); and each
storage vessel with a capacity greater than or equal to 151 m3 (39,890 gal) storing a volatile organic
liquid with a maximum true vapor pressure greater than 3.5 kPa. Retrofitting these tanks with floating
roofs and/or installing a closed system and control device would be cost prohibitive as the combined
VOC PTE from these tanks is 0.29 tpy. Furthermore, a search of similar tanks on RBLC did not identify
any tanks with these control technologies, therefore, these technologies are not demonstrated in
practice for the above-mentioned storage tanks.
In our search for similar tanks, WZ identified a single control method for VOC emissions from storage
tanks: GMP. From a search of the RBLC, it was found that pollution prevention techniques (GMP) were
selected as BACT for many similar source types. GMP includes submerged filling, a light-colored tank,
quarterly inspections, and correcting any observed leakage from the tank, pump, and/or lines.
Based on the analysis above, the use of GMP is the proposed VOC RACT for the above-mentioned
storage tanks.
8.3 Monitoring, Recordkeeping, and Reporting
WZ will follow procedures outlined in the O&M manual to ensure proper operation of the unit to
minimize VOC emissions. Deviations will be reported in the semi-annual and annual compliance
certification in accordance with the Title V permit.
18
9.RACT ANALYSIS FOR PICKLING OPERATIONS
The WZ pickling processes consist of two operations: round pickling and flat pickling. NOX emissions
are produced from the spontaneous vaporizing of a nitric acid (HNO3) solution used in pickling. The
pickling tanks are open and emit into the enclosed area where the vats sit. The air in these enclosed
areas is pulled from the rooms and controlled by a scrubber before being emitted to the atmosphere.
The pickling operations do not emit VOCs.
9.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database, EPA fact
sheets, and UDAQ rules. The identified control technologies for the pickling processes for NOX
reduction are:
•SCR,
•SNCR, and
•GMP.
Selective Catalytic Reduction
SCR is a method of NOX control that utilizes a catalyst and reagent to reduce NOX emissions. SCR is
typically implemented on stationary source combustion units which require a high level of NOX
reduction.26 Urea is generally used as the reduction reagent. NOX removal efficiencies for SCR are
high, at 90 percent.27
Selective Non-Catalytic Reduction
SNCR is similar to SCR but does not involve catalytic reduction, thus decreasing the NOX reduction
efficiency. Instead, reduction is achieved through very high temperatures (1,400 - 2,000 ˚F).
Good Management Practices
GMP are a collection of best practices for various types of equipment. GMP would consist of proper
maintenance and operation, including routine testing and recordkeeping.
9.2 Step 2 – Eliminate Technically Infeasible Options
Selective Catalytic Reduction
SCR is considered technically infeasible as the temperature of the gas is too low for effective control.
Selective Non-Catalytic Reduction
SNCR is considered technically infeasible as the temperature of the gas is too low for effective control
and the emissions will not be a low-oxygen environment.
Good Management Practices
GMP for the pickling process would include proper maintenance and operation of the pickling tanks,
vacuum systems/vents, and scrubber. Leaks and/or cracks should be addressed immediately.
26 EPA (2017). Air Pollution Control Cost Manual, Section 4 – Chapter
2.https://www.epa.gov/sites/default/files/2017-
12/documents/scrcostmanualchapter7thedition_2016revisions2017.pdf
27 EPA. Air Pollution Control Technology Fact Sheet – SCR. https://www3.epa.gov/ttncatc1/dir1/fscr.pdf
19
9.3 Steps 3-5 – Select RACT
Based on the information provided in the previous section, GMP is the only remaining control
technology for NOX emissions from the pickling process and is thus proposed as RACT.
9.4 Monitoring, Recordkeeping, and Reporting
WZ will follow procedures outlined in the O&M manual to ensure proper operation of the unit to
minimize emissions. WZ currently conducts performance tests every two years to demonstrate
compliance with the HNO3 limit. This test will also demonstrate proper functioning of the emission unit
and control systems. Deviations will be reported in the semi-annual and annual compliance
certification in accordance with the Title V permit.
20
10.RACT ANALYSIS FOR BOILERS
WZ has two (2) natural gas-fired boilers, each with a rating of 16.75 MMBtu/hr, originally installed in
1979.
10.1 RACT Analysis for NOX Emissions
10.1.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database, EPA fact
sheets, and UDAQ rules. The identified control technologies for the boilers for NOX reduction are:
•SCR,
•SNCR,
•ULNB,
•LNB,
•FGR, and
•GCP.
Selective Catalytic Reduction
SCR is a method of NOX control that utilizes a catalyst and reagent to reduce NOX emissions. SCR is
typically implemented on stationary source combustion units which require a high level of NOX
reduction.28 Urea is generally used as the reduction reagent. NOX removal efficiencies for SCR are
high, at 90 percent.29
Selective Non-Catalytic Reduction
SNCR is similar to SCR but does not involve catalytic reduction, thus decreasing the NOX reduction
efficiency. Instead, reduction is achieved through very high temperatures (1,400 - 2,000 ˚F).
Ultra-low NOX Burner
An ULNB is a type of LNB that can reduce NOX emissions to very low levels, usually below 30 ppmv,
corrected to 3 percent oxygen.30 ULNB technology has been shown to achieve NOX emissions of 9
ppmv.31
Low NOX Burner
NOX formation can be reduced through the restriction of oxygen, flame temperature, or residence
time, which is the principle of LNB technology. Staged fuel and staged air burners are both intended to
reduce the formation of thermal NOX. When LNB technology is implemented, emissions of NOX can be
reduced by 50 percent compared to standard burners.32
28 EPA (2017). Air Pollution Control Cost Manual, Section 4 – Chapter
2.https://www.epa.gov/sites/default/files/2017-
12/documents/scrcostmanualchapter7thedition_2016revisions2017.pdf
29 EPA. Air Pollution Control Technology Fact Sheet – SCR. https://www3.epa.gov/ttncatc1/dir1/fscr.pdf
30 Oak Ridge National Laboratory (2002). Guide to Low-Emission Boiler and Combustion Equipment
Selection. https://www.energy.gov/eere/amo/articles/guide-low-emission-boiler-and-combustion-equipment-
selection
31 Power Flame.
Nova Low NOx Burners. https://www.powerflame.com/index.php?option=com_content&view=article&id=110&Itemi
d=57
32 AP‐42 Table 1.4‐1 – Emission Factors for Nitrogen Oxides and Carbon Monoxide from Natural Gas
Combustion. https://www3.epa.gov/ttnchie1/ap42/ch01/final/c01s04.pdf
21
FGR is a NOX control technology wherein the exhaust gas is routed into the inlet with the addition of
a forced hot gas fan.33 FGR is most effective for natural gas and low-nitrogen fuels because it lowers the
available oxygen which reduces the formation of NOX. The NOX capture efficiency of FGR is 30-60
percent.34
Good Combustion Practices
GCP includes combustion zone control of temperature and excess air, increased thermal efficiency,
and staged combustion, if possible. Good combustion practices generally involve proper maintenance
and operations of combustion equipment. For natural gas-fired combustion units, use of pipeline
natural gas is considered GCP.
10.1.2 Step 2 – Eliminate Technically Infeasible Options
Selective Catalytic Reduction
SCR is considered technically infeasible as it is not demonstrated in practice for boilers of this size.
Selective Non-Catalytic Reduction
SNCR is considered technically infeasible as it is not demonstrated in practice for boilers of this size
and because SNCR is typically installed on solid fuel-burning boilers.
Ultra-low NOX Burner
ULNB technology is considered technically feasible for the boilers.
Low NOX Burner
LNB technology is considered technically feasible for the boilers.
Flue Gas Recirculation
FGR is not technically feasible for the boilers due to the potential loss of efficiency from the
reconfiguration and number of tubes and nozzles. In order to maintain the same steam input, the
Facility would need to burn more fuel. Thus, there would not be a reduction in emissions.
Good Combustion Practices
GCP is considered technically feasible for the boilers.
10.1.3 Step 3 – Rank Remaining Control Technologies by Control Effectiveness
Based on the information provided in the previous section, feasible technologies for control of NOX
from the boilers are the following, with the most effective control first and least effective control last:
1.ULNB (83 percent),
2.LNB (60 percent), and
3.GCP.
No control efficiency was estimated for GCP. Control efficiencies for ULNB and LNB were calculated by
a vendor, Cleaver Brooks Ghost Solutions (presented in Appendix C).
33 Power Engineering (2003). NOX Control on a Budget: Induced Flue Gas Recirculation. https://www.power-
eng.com/news/nosubx-sub-control-on-a-budget-induced-flue-gas-recirculation/#gref
34 Pollution Online (2000). NOX Emission Reduction Strategies. https://www.pollutiononline.com/doc/nox-emission-
reduction-strategies-0001
Flue Gas Recirculation

22

10.1.4 Step 4 – Evaluate Most Effective Controls and Document Results
The most effective control is ULNB. The cost of retrofitting the boilers was determined based on a
vendor quote obtained from Cleaver Brooks Ghost Solutions. The cost effectiveness calculated for
ULNBs was $24,797/ton of NOX. This is not considered cost effective as it is above the UDAQ cost
effectiveness threshold of $15,000/ton of NOX for a NOX reduction of over 5 tpy. The next most
effective control is LNB. The cost of retrofitting the boilers with LNBs for the boilers was determined
based on a vendor quote obtained from Cleaver Brooks Ghost Solutions. The cost effectiveness
calculated for LNBs was $32,123/ton of NOX. This is not considered cost effective as it is above the
UDAQ cost effectiveness threshold of $10,000/ton of NOX for a NOX reduction of over 2 tpy. Thus, the
only remaining control option is GCP. Detailed cost effectiveness calculations are included in Appendix
B and vendor quotes are provided in Appendix C.
10.1.5 Step 5 – Select RACT
Based on the analysis in the previous section, the use of pipeline natural gas with GCP is proposed as
NOX RACT for the boilers.
10.1.6 Monitoring, Recordkeeping, and Reporting
WZ will follow O&M procedures and reporting requirements per their O&M manual and Title V
conditions. Deviations will be reported in the semi-annual and annual compliance certification in
accordance with the Title V permit.
10.2 RACT Analysis for VOC Emissions
10.2.1 Steps 1-5 – Select RACT
WZ only identified one control method for VOC emissions from the boilers, the firing of pipeline natural
gas with GCP. Add-on VOC controls are not demonstrated in practice for natural gas-fired combustion
equipment of this size. RACT/BACT for VOCs on natural gas combustion equipment is frequently listed
in the RBLC as “proper operation,” “none,” or “no control,” and there are often notes indicating that no
control technology was technically feasible.
GCP for VOC control involves appropriate fuel residence times, proper fuel-air mixing, and
temperature control. Based on the analysis above, the use of pipeline natural gas with GCP is
proposed as VOC RACT for the boiler.
10.2.2 Monitoring, Recordkeeping, and Reporting
WZ will follow procedures outlined in the O&M manual to ensure proper operation of the unit to
minimize emissions. Deviations will be reported in the semi-annual and annual compliance certification
in accordance with the Title V permit.

23

11. RACT ANALYSIS FOR NATURAL GAS EMERGENCY
GENERATORS
WZ has four (4) natural gas-fueled emergency generators with ratings from 50 kilowatt (kW) to 300
kW.
11.1 RACT Analysis for NOX Emissions
11.1.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database, EPA fact
sheets, and UDAQ rules. The identified control technologies for the natural gas-fueled emergency
generators for NOX reduction are:
• SCR, and
• NSPS Certified Engines/Combustion Process Modifications.
Selective Catalytic Reduction
SCR is a method of NOX control which utilizes a catalyst and reagent to reduce NOX emissions. SCR is
typically implemented on stationary source combustion units which require a high level of NOX
reduction.35 Urea is generally used as the reduction reagent. NOX removal efficiencies for SCR are high
at 90 percent.36
NSPS Certified Engines/Combustion Process Modifications
Combustion process modifications are incorporated in the engine design. Typical design features
include electronic fuel/air ratio and timing controllers, pre-chamber ignition, intercoolers, and
optimized fuel mix. Currently available new engines, i.e., NSPS certified engines, include these
features as standard equipment and rely on them to comply with EPA Engine NSPS emission
standards.
11.1.2 Step 2 – Eliminate Technically Infeasible Options
Selective Catalytic Reduction
SCR is considered technically infeasible for installation on the natural gas-fueled emergency
generators as the operating temperatures required for performance of the SCR catalyst cannot be
achieved during maintenance/testing.
NSPS Certified Engines/Combustion Process Modifications
Operation of an NSPS-compliant engine is considered technically feasible for the natural gas
emergency generators.
11.1.3 Steps 3-5 – Select RACT
Operation of an NSPS certified engine that incorporates combustion process modifications is the only
remaining control technology. Thus, operation of a NSPS certified engine is proposed as NOX RACT for
the natural gas-fueled emergency generators.

35 EPA (2017). Air Pollution Control Cost Manual, Section 4 – Chapter 2.
https://www.epa.gov/sites/default/files/2017-
12/documents/scrcostmanualchapter7thedition_2016revisions2017.pdf
36 EPA. Air Pollution Control Technology Fact Sheet – SCR. https://www3.epa.gov/ttncatc1/dir1/fscr.pdf

24

11.1.4 Monitoring, Recordkeeping, and Reporting
WZ maintains records regarding the certification of the engine to NSPS standards. In order to maintain
the engine certification, WZ must operate and maintain the engine according to the manufacturer's
instructions and keep records of maintenance conducted. WZ will follow procedures outlined in the
O&M manual to ensure proper operation of the generator and the air-to-fuel ratio controller to
minimize emissions. WZ will only combust pipeline natural gas as a primary fuel and propane as a
backup fuel and keep records of any period that a fuel other than natural gas or propane is used.
Deviations will be reported in the semi-annual and annual compliance certification in accordance with
the Title V permit.
11.2 RACT Analysis for VOC Emissions
11.2.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database, EPA fact
sheets, and UDAQ rules. The identified control technologies for the natural gas-fueled emergency
generators for VOC reduction are:
• Oxidation Catalyst, and
• NSPS Certified Engines/Combustion Process Modifications.
Catalytic Oxidation
An oxidation catalyst employs a module containing an oxidation catalyst that is located in the exhaust
path of the engine. In the catalyst module, VOCs diffuse through the surfaces of a ceramic honeycomb
structure coated with noble metal catalyst particles. Oxidation reactions on the catalyst surface forms
carbon dioxide and water. Typical vendor indications are that 90 percent reduction in VOC emissions
may be achieved.
NSPS Certified Engines/Combustion Process Modifications
Combustion process modifications are incorporated in the engine design. Typical design features
include electronic fuel/air ratio and timing controllers, pre-chamber ignition, intercoolers, and
optimized fuel mix. Currently available new engines, i.e., NSPS certified engines, include these
features as standard equipment and rely on them to comply with EPA Engine NSPS emission
standards.
11.2.2 Step 2 – Eliminate Technically Infeasible Options
Oxidation Catalyst
Operation of an oxidation catalyst is considered technically feasible for the natural gas emergency
generators.
NSPS Certified Engines/Combustion Process Modifications
Operation of an NSPS-compliant engine is considered technically feasible for the natural gas
emergency generators.
11.2.3 Step 3-5 – Select RACT
Use of an oxidation catalyst is the most effective control. However, given the low number of routine
operating hours per year and the small size of the engines, the cost for catalytic oxidation for VOC
control will be prohibitive.

25

Operation of an NSPS certified engine that incorporates combustion process modifications is the only
remaining control technology. Thus, operation of a NSPS certified engine is proposed as VOC RACT for
the natural gas-fueled emergency generators.
11.2.4 Monitoring, Recordkeeping, and Reporting
WZ will follow the monitoring, recordkeeping, and recording requirements described in Section 11.1.4.
26
12.RACT ANALYSIS FOR DIESEL EMERGENCY
GENERATORS
WZ has four (4) diesel-fueled emergency generators each with a rating of 557 kW.
12.1 RACT Analysis for NOX Emissions
12.1.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database, EPA fact
sheets, and UDAQ rules. The identified control technologies for the diesel-fueled emergency
generators for NOX reduction are:
•SCR, and
•NSPS Certified Engines/Combustion Process Modifications.
Selective Catalytic Reduction
SCR is a method of NOX control which utilizes a catalyst and reagent to reduce NOX emissions. SCR is
typically implemented on stationary source combustion units which require a high level of NOX
reduction.37 Urea is generally used as the reduction reagent. NOX removal efficiencies for SCR are high
at 90 percent.38
NSPS Certified Engines/Combustion Process Modifications
NSPS certified engines rely on combustion to comply with EPA Engine NSPS or NESHAP emission
standards. Combustion process modifications are incorporated in the engine design. Typical design
features include turbochargers, aftercoolers, positive crankcase ventilation, and high-pressure fuel
injection. Currently available new engines, i.e., NSPS certified engines, include these features as
standard equipment and rely on them to comply with EPA Engine NSPS emission standards.
12.1.2 Step 2 – Eliminate Technically Infeasible Options
Selective Catalytic Reduction
SCR is considered technically infeasible for installation on the diesel-fueled emergency generators as
normal operating temperatures cannot be achieved during maintenance/testing.
NSPS Certified Engines/Combustion Process Modifications
The diesel-fueled emergency generators already comply with NSPS Subpart IIII, thus this control is
considered technically feasible.
12.1.3 Steps 3-5 – Select RACT
Operation of an NSPS certified engine that incorporates combustion process modifications is the only
remaining control technology. Thus, operation of a NSPS certified engine is proposed as NOX RACT for
the diesel-fueled emergency generators.
37 EPA (2017). Air Pollution Control Cost Manual, Section 4 – Chapter 2.
https://www.epa.gov/sites/default/files/2017-
12/documents/scrcostmanualchapter7thedition_2016revisions2017.pdf
38 EPA. Air Pollution Control Technology Fact Sheet – SCR. https://www3.epa.gov/ttncatc1/dir1/fscr.pdf

27

12.1.4 Monitoring, Recordkeeping, and Reporting Requirements
WZ maintains records regarding the certification of the engine to NSPS standards. In order to maintain
the engine certification, WZ must operate and maintain the certified engine according to the
manufacturer's instructions and only change those emission-related settings that are permitted by the
manufacturer. WZ will follow procedures outlined in the O&M manual to ensure proper operation of the
generator to minimize emissions. WZ will only combust diesel with sulfur content no greater than 15
ppm and minimum cetane index of 40. WZ has a non-resettable hour meter on each engine and keep
records of emergency and non-emergency operation. Deviations will be reported in the semi-annual
and annual compliance certification in accordance with the Title V permit.
12.2 RACT Analysis for VOC Emissions
12.2.1 Step 1 – Identify All Available Control Technologies
WZ identified applicable control technologies using sources including the RBLC database, EPA fact
sheets, and UDAQ rules. The identified control technologies for the diesel-fueled emergency
generators for VOC reduction are:
• Diesel Oxidation Catalyst (DOC), and
• NSPS Certified Engines/Combustion Process Modifications.
Diesel Oxidation Catalyst
DOC is a method of emissions control for diesel combustion equipment. DOCs are catalytic converters
designed specifically for diesel engines and are used to reduce VOC emissions, among other
pollutants.
NSPS Certified Engines/Combustion Process Modifications
NSPS certified engines rely on combustion settings to comply with EPA Engine NSPS or NESHAP
emission standards. Combustion process modifications are incorporated in the engine design. Typical
design features include turbochargers, aftercoolers, positive crankcase ventilation, and high-pressure
fuel injection. NSPS certified engines, include these features as standard equipment and rely on them
to comply with EPA Engine NSPS emission standards.
12.2.2 Step 2 – Eliminate Technically Infeasible Options
Diesel Oxidation Catalyst
DOC is considered technically feasible for installation on the diesel-fueled emergency generators.
DOCs were costed by using a cost rate calculated from a vendor quote from Miratech (presented in
Appendix C). The cost effectiveness calculated for was $17,312/ton of VOC. This is considered cost
ineffective as it is above the UDAQ cost effectiveness threshold of $5,000/ton of VOC for a VOC
reduction of under 2 tpy. Detailed cost effectiveness calculations are included in Appendix B and
vendor quotes are provided in Appendix C
NSPS Certified Engines Combustion Process Modifications
The diesel-fueled emergency generators already comply with NSPS Subpart IIII, thus this control is
considered technically feasible.
12.2.3 Steps 3-5 – Select RACT
Operation of an NSPS certified engine that incorporates combustion process modifications is the only
remaining control technology. Thus, operation of a NSPS certified engine is proposed as VOC RACT for
the diesel-fueled emergency generators.
28
12.2.4 Monitoring, Recordkeeping, and Reporting
WZ will follow the monitoring, recordkeeping, and recording requirements described in Section
12.1.4.
29
13.RACT ANALYSIS FOR FUGITIVE MIBK
Process fugitive VOC emissions can occur from leaks in valves, pump seals, flanges, connectors, and
compressor seals that service MIBK delivery to the separations process.
13.1 Steps 1-5 – Select RACT
The only technically feasible and cost effect method of controlling fugitive VOC emissions of this size is
Leak Detection and Repair (LDAR). LDAR is a work practice designed to identify leaking equipment
and repairing leaks promptly. LDAR can reduce fugitive VOC emissions by 30-97 percent depending on
frequency, leak definition threshold, and repair requirements.39 As Leak Checking is the only identified
control technology, it is proposed as VOC RACT for the fugitive MIBK source.
13.2 Monitoring, Recordkeeping, and Reporting
WZ will visually inspect components in MIBK service quarterly. Leaking components will be repaired as
soon as practicable. WZ will maintain records of leaks and repairs.
39 Pergam USA (2021). A Practical Approach to LDAR Efficiency Evaluation.
https://pergamusa.com/articles/ldar#:~:text=LDAR%20efficiency%20is%20defined%20as,definition%20threshold
%20and%20repair%20requirements.
30
14.SUMMARY OF PROPOSED RACT
The following tables summarize the technically feasible control options, cost effectiveness of
technically feasible controls (if applicable), and the proposed RACT for each unit. Table 3 includes the
proposed RACT for sources of NOX emissions and Table 4 includes the proposed RACT for sources of
VOC emissions.
Table 3: Western Zirconium Proposed RACT for NOX
Equipment
Technically
Feasible
Controls
Cost Effectiveness
($/ton) Proposed RACT
Separations Zr Oxide
Kiln GCP N/A GCP
Separations Hf Oxide
Kiln GCP N/A GCP
Separations System
Vents GCP N/A GCP
Reduction Process
Furnaces GCP N/A GCP
Reduction Process
Ovens GCP N/A GCP
Pre-Evacuation
Furnaces GCP N/A GCP
Lances GCP N/A GCP
Pickling Operations GMP N/A GMP
Hot Mill Vent GCP N/A GCP
Paint/Spray Booth GCP N/A GCP
Boilers ULNB, LNB,
and GCP
ULNB: $24,797
LNB: $32,123 GCP
Natural Gas Emergency
Generators
Certification
and GCP N/A NSPS
Certification/GCP
Diesel Emergency
Generators
Certification
and GCP N/A NSPS
Certification/GCP
Propane Vaporizer GCP N/A GCP
31
Table 4: Western Zirconium Proposed RACT for VOC
Equipment
Technically
Feasible
Controls
Cost Effectiveness
($/ton)
Proposed
RACT
Chlorination Control Stack GMP N/A GMP
Separations Zr Oxide Kiln GCP N/A GCP
Separations Hf Oxide Kiln GCP N/A GCP
Separations System Vents TO N/A TO
MIBK Storage Tank GMP N/A GMP
Reduction Process
Furnaces GCP N/A GCP
Reduction Process Ovens GCP N/A GCP
Pre-Evacuation Furnaces GCP N/A GCP
Lances GCP N/A GCP
Hot Mill Vent GCP N/A GCP
Paint/Spray Booth GMP and VOC
Limit N/A GMP and VOC
Limit
Boilers GCP N/A GCP
Natural Gas Emergency
Generators
Oxidation
Catalyst, NSPS
Certification, and
GCP
N/A
NSPS
Certification and
GCP
Diesel Emergency
Generators
DOC, NSPS
Certification, and
GCP
DOC: $17,312
NSPS
Certification and
GCP
Diesel Storage GMP N/A GMP
Gasoline Storage GMP N/A GMP
Propane Vaporizer GCP N/A GCP
Fugitive MIBK LDAR N/A LDAR
APPENDIX A:
Summary of RBLC Search Results
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Boilers and Heaters
(natural gas and diesel
fired)
29.29
MMBtu/hr
Natural Gas and
Diesel 13.9 P - Good Combustion Practices
0.0015 lb/MMBtu (ULSD, 3-hr
avg.), 0.0054 lb/MMBtu (NG, 3-hr
avg.)
BACT-PSD
Two (2) Heaters (natural
gas and diesel fired)
16.5
MMBtu/hr Natural Gas 13.9 P - Good Combustion Practices
0.0015 lb/MMBtu (ULSD, 3-hr
avg.), 0.0054 lb/MMBtu (NG, 3-hr
avg.)
BACT-PSD
Twelve (12) Large
ULSD/Natural Gas-Fired
Internal Combustion
Engines
143.5
MMBtu/hr
Diesel and Natural
Gas 17.11 B - Oxidation Catalyst and Good Combustion Practices 0.21 g/kW-hr (ULSD, 3-hr avg.),
0.09 g/kW-hr (NG, 3-hr avg.)BACT-PSD
Reformer 1552
MMBtu/hr
5 ppm (annual), 10.16 tpy
(annual)BACT-PSD
Boiler 950 MMBtu/hr 14 tpy (annual)BACT-PSD
5 Heaters 24.3
MMBtu/hr 2.44 tpy (annual)BACT-PSD
Heater 8 MMBtu/hr 0.16 tpy (annual)BACT-PSD
Heater 45 MMBtu/hr 0.59 tpy (annual)BACT-PSD
Petroleum Refinery TX-0673 1/22/2014 5055
MMBtu/hr Fuel or Natural Gas 50.003 VOC
B - Emission controls include Heaters, Cooling towers, Flares,
Vapor combustors, SRU incinerators, Storage tanks, and Carbon
adsorption systems. Piping Fugitive emissions will be controlled
with an inspection and maintenance (I&M) program. There will
be uncontrolled emissions from Emergency Engines, Wastewater
collection system, and Wastewater roofless tanks. These meet
BACT guidelines.
2769.58 lb/hr, 1404.09 tpy BACT-PSD
Charge Heaters, H-1 andH-
2
153 MMBtu/hr
(max)50.999 P - Good combustion practices will limit VOC emissions to 0.005
lb per 1000 scf. Fuel flow will be measured.0.005 lb/1000 SCF (each heater)BACT-PSD
Boilers, BL-1 and BL-2 37 MMBtu/hr
(max)15.21 P - Good combustion practices will limit VOC emissions to 0.005
lb per 1000 scf. Fuel flow will be measured.0.005 lb/1000 SCF (each boiler)BACT-PSD
Firewater Pumps TX-0930 10/19/2021 800 HP Natural Gas or Fuel
Gas 17.13 VOC
P - Use of well-designed and properly maintained engines. Good
combustion practices. Limited to 52 hours per year of non-
emergency operation. Equipped with non-resettable runtime
meter.
N/A BACT-PSD
Table A-1
Carbon Adsorption for Natural Gas-Fired Equipment, VOC Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
AK-0084 6/30/2017 VOC
P - Good Combustion Practices
TX-0756 6/19/2015 Natural Gas VOC
TX-0657 5/16/2014 Natural Gas and Plant
Gas 50.002 VOC
# Confidential Pg. 1 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
SN-106 Cold Mill 1 Diesel Fired
Emergency Generator AR-0171 2/14/2019 1073 BHP Diesel 17.21 VOC P - Good operating practices 1 g/kW-hr BACT-PSD
SN-230 Galvanizing Line No, 2
Emergency Generator AR-0177 11/21/2022 3634 HP Diesel 17.11 VOC N 0.8 g/kW-hr BACT-PSD
Emergency generator EU-6006 IN-0317 6/11/2019 2800 HP Diesel 17.11 VOC P - Tier II Diesel Engine 6.4 g/kW-hr (Tier II NOx + NMHC
limit)BACT-PSD
Emergency Generator (CC-GEN1)3000 HP 17.11 P - Certified engine 0.32 g/HP-hr
Emergency Generator (CC-GEN2)500 HP 17.21 P - Certified engine 1.13 g/HP-hr
EP 10-02 - North Water System
Emergency Generator 2922 HP 17.11
EP 10-03 - South Water System
Emergency Generator 2922 HP 17.11
EP 11-01 - Melt Shop Emergency
Generator 260 HP 17.21
EP 11-02 - Reheat Furnace
Emergency Generator 190 HP 17.21
EP 10-07 - Air Separation Plant
Emergency Generator 700 HP 17.11
EP 10-01 - Caster Emergency
Generator 2922 HP 17.11
EP 11-03 - Rolling Mill Emergency
Generator 440 HP 17.21
EP 11-04 - IT Emergency Generator 190 HP 17.21
EP 11-05 - Radio Tower Emergency
Generator 61 HP 17.21
Emergency generator engines (6
units)LA-0316 2/17/2017 3353 HP Diesel 17.11 VOC P - Complying with 40 CFR 60 Subpart IIII N/A BACT-PSD
Emergency Generator Diesel Engines LA-0364 1/6/2020 550 HP Diesel 17.11 VOC
P - Compliance with the limitations imposed by
40 CFR 63 Subpart IIII and operating the engine
in accordance with the engine manufacturer's
instructions and/or written procedures designed
to maximize combustion efficiency and minimize
fuel usage.
N/A BACT-PSD
3U-10 - Utility Emergency Generator 760 HP 2.03 lb/hr, 0.07 tpy, 6.4 g/kW-hr
3U-11 - Substation Emergency
Generator 70 HP 0.14 lb/hr, 0.007 tpy, 4.7 g/kW-hr
3U-12 - VCM/CA/UT CCR Emergency
Generator 760 HP 2.03 lb/hr, 0.07 tpy, 6.4 g/kW-hr
3U-13 - LTY Emergency Generator 333.3 HP 0.66 lb/hr, 0.02 tpy, 4.7 g/kW-hr
3C-6A - C/A Emergency Generators
A 2346 HP
3C-6B - C/A Emergency Generators
B 2346 HP
P - Comply with 40 CFR 60 Subpart IIII using
Non-Methane hydrocarbon + NOx as a surrogate
for VOC NOx
BACT-PSD
6.27 lb/hr, 6.4 g/kW-hr
VOC
Table A-2
Diesel Emergency Generators, VOC Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
IN-0359 3/30/2023 Diesel VOC BACT-PSD
N/A BACT-PSDKY-0110 7/23/2020 Diesel VOC P - This EP is required to have a Good
Combustion and Operating Practices (GCOP) Plan.
LA-0389 10/20/2022 Diesel 63.036
# Confidential Pg. 2 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Table A-2
Diesel Emergency Generators, VOC Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
3C-6C - C/A Emergency Generators
C 2346 HP
3M-11A - VCM Emergency
Generators A 2346 HP
3M-11B - VCM Emergency
Generators B 2346 HP
GEN-1 - Emergency Generator No. 1 750 HP
GEN-2 - Emergency Generator No. 2 750 HP
Emergency Generator (P009)OH-0368 4/19/2017 5000 HP Diesel 17.11 VOC
P - Good combustion control and operating
practices and engines designed to meet the
stands of 40 CFR Part 60, Subpart IIII
1.6 lb/hr, 0.08 tpy (per rolling 12
month period)BACT-PSD
Emergency generator (P003)OH-0370 9/7/2017 1529 HP Diesel 17.11 VOC P - State-of-the-art combustion design 2 lb/hr, 0.5 tpy (per rolling 12
month period)BACT-PSD
Emergency generator (P003)OH-0372 9/27/2017 1529 HP Diesel 17.11 VOC P - State-of-the-art combustion design 3 lb/hr, 0.5 tpy (per rolling 12
month period), 0.59 g/BHP-hr BACT-PSD
Emergency Generators (2 identical,
P004 and P005)OH-0374 10/23/2017 2206 HP Diesel 17.11 VOC
P - Certified to the meet the emissions standards
in 40 CFR 89.112 and 89.113 pursuant to 40 CFR
60.4205(b) and 60.4202(a)(2). Good combustion
practices per the manufacturer's operating
manual.
23.21 lb/hr (NMHC+NOx), 1.16
tpy (NMHC+NOx), 4.77 g/BHP-hr
(NMHC+NOx)
BACT-PSD
1,000 kW Emergency Generators
(P008 - P010)OH-0378 12/21/2018 1341 HP Diesel 17.11 VOC
P - certified to the meet the emissions standards
in Table 4 of 40 CFR Part 60, Subpart IIII, shall
employ good combustion practices per the
manufacturer's operating manual
14.96 lb/hr, 0.75 tpy (per rolling
12 month period)BACT-PSD
5,051 bhp (3,768 kWm) Diesel-Fired
Emergency Generators: P001
through P046
OH-0387 9/20/2022 5051 HP Diesel 17.11 VOC P - Certified to meet Tier 2 standards and good
combustion practices
0.4 g/kWh, 0.3 lb/hr (each gen),
0.06 tpy (rolling 12-month period
for each gen)
BACT-PSD
Emergency Generator OK-0176 7/19/2017 400 HP Diesel 17.21 VOC
P - Equipped with non-resettable hour meter.
Fired with ultra-low sulfur diesel fuel (0.015 % or
less by wt. sulfur)
217.24 tpy/facility (12-month)BACT-PSD
EMERGENCY GENERATOR TX-0939 3/13/2023 18.7
MMBtu/hr Diesel 17.11 VOC P - GOOD COMBUSTION PRACTICES, LIMITED TO
100 HR/YR 0.001 lb/HP-hr BACT-PSD
P - Comply with 40 CFR 60 Subpart IIII using
Non-Methane hydrocarbon + NOx as a surrogate
for VOC NOx
VOC BACT-PSD6.27 lb/hr, 6.4 g/kW-hrLA-0389 Diesel 63.036
1.98 lb/hr, 0.08 tpy BACT-PSDLA-0390 5/10/2022 Diesel 17.11 VOC
P - Good combustion practices and maintenance
and compliance with applicable 40 CFR 60
Subpart JJJJ limitation for VOC.
10/20/2022
# Confidential Pg. 3 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Auxiliary Boiler LA-0346 1/4/2018 773 MMBtu/hr Natural gas 11.31 NOx P - LNB + FGR N/A BACT-PSD
EUAUXBOILER (Auxiliary boiler)MI-0427 11/17/2017 182 MMBtu/hr Natural gas 12.31 NOx B - LNB that incorporate internal (within the
burner) FGR and good combustion practices.
0.04 lb/MMBtu (30 day rolling
avg.)BACT-PSD
EUSTMBOILER MI-0440 5/22/2019 300 MMBtu/hr Natural gas 11.31 NOx P - Low-NOx burners and internal flue gas
recirculation (FGR)
0.04 lb/MMBtu (30 day rolling
avg.), 0.07 lb/MMBtu (30 day
rolling avg. when firing No. 2 fuel
oil)
BACT-PSD
EUAUXBOILER--nat gas fired
auxiliary boiler MI-0447 1/7/2021 50 MMBtu/hr Natural gas 13.31 NOx
B - Low NOx burners (LNB) or flue gas
recirculation (FGR) along with good combustion
practices.
30 ppm (at 3% O2, hourly)BACT-PSD
EUAUXBOILER--natural-gas fired
auxiliary boiler, rated at less than or
equal to 99 MMBTU/H
MI-0454 12/20/2022 50 MMBtu/hr Natural gas 13.31 NOx
B - Low NOx Burners (LNB) or Flue Gas
Recirculation (FGR) along with good combustion
practices.
30 ppm (hourly)BACT-PSD
Package Boilers (2 identical, B003
and B004)OH-0368 4/19/2017 265 MMBtu/hr Natural gas 11.31 NOx B - Low NOx burners and flu gas recirculation
(FGR)
3.3 lb/hr, 14.5 tpy (per rolling 12-
month period), 0.0125 lb/MMBtu BACT-PSD
Auxiliary Boiler (B001)OH-0370 9/7/2017 37.8
MMBtu/hr Natural gas 13.31 NOx A - ultra-low NOx burners (ULNB) and flue gas
recirculation (FGR)
0.76 lb/hr, 0.76 tpy (per rolling 12-
month period), 0.02 lb/MMBtu BACT-PSD
Natural Gas and Ethane-Fired Steam
Boilers (B007 - B009)OH-0378 12/21/2018 400 MMBtu/hr Natural gas and
ethane 11.39 NOx A - ultra-low NOx burners (ULNB) and flue gas
recirculation (FGR)
0.02 lb/MMBtu (during startup and
shutdown), 4 lb/hr (as rolling 30-
day avg.), 0.01 lb/MMBtu (as
rolling 30-day avg.)
BACT-PSD
Curing Oven ES25A WV-0027 9/15/2017 6.67 tons/hr Natural Gas 90.015 NOx P - LNB w/ FGR 0.59 lb/ton glass pulled (3-hr avg.)BACT-PSD
Auxiliary Boiler *WV-0029 3/27/2018 77.8
MMBtu/hr Natural Gas 13.31 NOx P - LNB, FGR, Good Combustion Practices 0.86 lb/hr, 1.96 tpy, 0.011
lb/MMBtu BACT-PSD
Unit 6 Calciner 235 MMBtu/hr A - Low NOx burners with FGR 9.5 lb/hr (3-hr avg.), 0.04
lb/MMBtu (3-hr avg.)
Unit 7 Calciner 365 MMBtu/hr A - Low NOx burners and FGR 14 lb/hr (3-hr avg.), 0.04
lb/Mmbtu (3-hr avg.)
Table A-3
FGR for Natural Gas-Fired Equipment, NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
BACT-PSD*WY-0078 3/27/2017 Natural Gas 90.017 NOx
# Confidential Pg. 4 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel
Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Diesel Fire Pump Engine 27.9 gal/hr 17.11 3.6 g/HP-hr, 500 hr/yr
Auxiliary Air Compressor Engine 14.6 gal/hr 17.21 0.45 g/HP-hr, 500 hr/yr
SN-230 Galvanizing Line No, 2
Emergency Generator AR-0177 11/21/2022 3634 HP Diesel 17.11 NOx N 5.6 g/kW-hr BACT-PSD
Emergency Engines 1250 kW 17.11 6.4 g/kW-hr
Fire Water Pump Engine 320 HP 17.21 4 g/kW-hr
Emergency generator EU-6006 IN-0317 6/11/2019 2800 HP Diesel 17.11 NOx P - Tier II diesel engine 6.4 g/kWh (Tier II NOx+NMHC
limit)BACT-PSD
Emergency Generator (CC-GEN1)3000 HP 17.11 4.8 g/HP-hr
Emergency Generator (CC-GEN2)500 HP 17.21 3 g/HP-hr
EP 10-02 - North Water System
Emergency Generator 2922 HP 17.11 4.77 g/HP-hr (NMHC+NOx)
EP 10-03 - South Water System
Emergency Generator 2922 HP 17.11 4.77 g/HP-hr (NMHC+NOx)
EP 11-01 - Melt Shop Emergency
Generator 260 HP 17.21 2.98 g/HP-hr (NMHC+NOx)
EP 11-02 - Reheat Furnace
Emergency Generator 190 HP 17.21 2.98 g/HP-hr (NMHC+NOx)
EP 10-07 - Air Separation Plant
Emergency Generator 700 HP 17.11 4.77 g/HP-hr (NMHC+NOx)
EP 10-01 - Caster Emergency
Generator 2922 HP 17.11 4.77 g/HP-hr (NMHC+NOx)
EP 11-03 - Rolling Mill Emergency
Generator 440 HP 17.21 2.98 g/HP-hr (NMHC+NOx)
EP 11-04 - IT Emergency Generator 190 HP 17.21 2.98 g/HP-hr (NMHC+NOx)
EP 11-05 - Radio Tower Emergency
Generator 61 HP 17.21 3.5 g/HP-hr (NMHC+NOx)
New Pumphouse (XB13) Emergency
Generator #1 (EP 08-05)2922 HP 17.11 4.8 g/BHP-hr (NMHC+NOx)
Tunnel Furnace Emergency
Generator (EP 08-06)2937 HP 17.11 4.8 g/BHP-hr (NMHC+NOx)
Caster B Emergency Generator (EP
08-07)2937 HP 17.11 4.8 g/BHP-hr (NMHC+NOx)
Air Separation Unit Emergency
Generator (EP 08-08)700 HP 17.11 4.8 g/BHP-hr (NMHC+NOx)
Cold Mill Complex Emergency
Generator (EP 09-05)350 HP 17.21 3 g/BHP-hr (NMHC+NOx)
Emergency Generator Diesel Engines LA-0364 1/6/2020 550 HP Diesel Fuel 17.11 NOx
P - Compliance with the limitations imposed by 40
CFR 63 Subpart IIII and operating the engine in
accordance with the engine manufacturer's
instructions and/or written procedures designed to
maximize combustion efficiency and minimize fuel
usage.
N/A BACT-PSD
Table A-4
Diesel Internal Combustion Engines, NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
BACT-PSD
AK-0088 7/7/2022 Diesel NOx P - Good Combustion Practices; Limited Operation;
40 CFR 60 Subpart IIII BACT-PSD
IL-0133 7/29/2022 Ultra-Low Sulfur Diesel NOx N
BACT-PSD
IN-0359 3/30/2023 diesel NOx P - certified engine BACT-PSD
KY-0110 7/23/2020 Diesel NOx P - This EP is required to have a Good Combustion
and Operating Practices (GCOP) Plan.
KY-0115 4/19/2021 Diesel NOx P - The permittee must develop a Good
Combustion and Operating Practices (GCOP) Plan BACT-PSD
# Confidential Pg. 5 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel
Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Table A-4
Diesel Internal Combustion Engines, NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
Emergency Diesel Generator Engine 2937 HP 17.11 4.8 g/HP-hr
Emergency Diesel Fired Water Pump
Engine 355 HP 17.21 3 g/HP-hr
FGEMENGINE MI-0442 8/21/2019 1100 kW Diesel 17.11 NOx N 5.3 g/HP-hr (hourly; each engine)BACT-PSD
Emergency diesel generator engine
(EUEMRGRICE1 in FGRICE)500 hr/yr 17.11 21.2 lb/hr (hourly)
Emergency diesel generator engine
(EUEMRGRICE2 in FGRICE)500 hr/yr 17.11 4.4 lb/hr (hourly)
Diesel fire pump engine
(EUFIREPUMP in FGRICE)500 hr/yr 17.11 3.53 lb/hr (hourly)
EUFPENGINE (North Plant): Fire
Pump Engine 300 HP 17.21 3 g/BHP-hr (hourly)
EUEMENGINE (North Plant):
Emergency engine 1341 HP 17.11 6.4 g/kW-hr (hourly)
EUEMENGINE (South Plant):
Emergency engine 1341 HP 17.11 6.4 g/kW-hr (hourly)
EUFPENGINE (South Plant): Fire
pump engine 300 HP 17.21 3 g/BHP-hr (hourly)
EUFPRICE--A 315 HP diesel-fueled
emergency engine MI-0454 12/20/2022 2.5 MMBtu/hr Diesel 17.21 NOx P - Good combustion practices.3 g/HP-hr (hourly)BACT-PSD
Black Start Generator (P007)158 HP 17.21 0.104 lb/hr, 5.2 tpy, 0.3 g/BHP-hr
Emergency Generators (P005 and
P006)3131 HP 17.11 3.45 lb/hr, 0.17 tpy, 0.5 g/BHP-hr
5,051 bhp (3,768 kWm) Diesel-Fired
Emergency Generators: P001
through P046
5051 HP 17.11 P - Certified to meet Tier 2 standards and good
combustion practices
6.4 g/kW-hr (NOx+NMHC), 65.7
lb/hr (each gen), 15.8 tpy (rolling
12-month period, each gen)
275 hp (205 kW) Diesel-Fired
Emergency Fire Pump Engine 275 HP 17.21
P - Certified to meet the standards in Table 4 of
40 CFR Part 60, Subpart IIII and good combustion
practices
4 g/kW-hr (NOx+NMHC), 8.5 lb/hr,
2.1 tpy (rolling 12-month period)
Emergency Diesel Generator - 300
kW VA-0332 6/24/2019 500 hr/yr Ultra Low Sulfur Diesel 17.11 NOx
P - good combustion practices, high efficiency
design, and the use of ultra low sulfur diesel (S15
ULSD) fuel oil with a maximum sulfur content of
15 ppmw.
4.8 g/HP-hr, 11.7 tpy (12 month
rolling avg.)BACT-PSD
Emergency Diesel Generator (P07) WI-0300 9/1/2020 1490 HP Diesel 17.11 NOx
P - Operation limited to 500 hours/year and
operate and maintain according to the
manufacturer's recommendations.
4.8 g/HP-hr BACT-PSD
BACT-PSDLA-0391 6/3/2022 Diesel NOx
P - Compliance with 40 CFR 60 Subpart IIII, good
combustion practices, and use of ultra-low sulfur
diesel fuel.
BACT-PSD
MI-0448 12/18/2020 Diesel NOx P - Certified engines, limited operating hours BACT-PSD
MI-0451 6/23/2022 Diesel NOx P - Good combustion practices and meeting NSPS
Subpart IIII requirements.
BACT-PSD
MI-0452 6/23/2022 Diesel NOx P - Good combustion practices and meeting NSPS
Subpart IIII requirements.BACT-PSD
OH-0379 2/6/2019 Diesel fuel NOx
P - Tier IV engine
Tier IV NSPS standards certified by engine
manufacturer.
OH-0387 9/20/2022 Diesel fuel NOx BACT-PSD
# Confidential Pg. 6 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
VOC P - Good combustion practices 0.81 lb/hr, 3.54 tpy, 0.0054
lb/MMBtu
NOx P - Low NOx burners 10.5 lb/hr, 45.99 tpy, 0.07
lb/MMBtu
Table A-5
Hot Mills, VOC and NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
BACT-PSDHot Mill Tunnel Furnace *WV-
0034 5/5/2022 150 MMBtu/hr Pipeline Natural Gas 81.23
# Confidential Pg. 7 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
PROPANE VAPORIZERS (ID15)5 MMBtu/hr VOC 0.04 lb/hr, 0.04 tpy
PROPANE VAPORIZERS (ID15)5 MMBtu/hr NOx 1.2 lb/hr, 1.2 tpy
PROPANE VAPORIZERS (ID 14)5 MMBtu/hr VOC 0.04 lb/hr, 0.04 tpy
PROPANE VAPORIZERS (ID 14)5 MMBtu/hr NOx 1.2 lb/hr, 1.2 tpy
Table A-6
Propane Vaporizers, VOC and NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
BACT-PSD
SC-0114 11/25/2008 Propane 13.31
P - TUNE-UPS AND INSPECTIONS WILL BE
PERFORMED AS OUTLINED IN THE GOOD
MANAGEMENT PRACTICE PLAN.
BACT-PSD
SC-0115 2/10/2009 Propane 13.31
P - TUNE-UPS AND INSPECTIONS WILL BE
PERFORMED AS OUTLINED IN THE GOOD
MANAGEMENT PRACTICE PLAN.
# Confidential Pg. 8 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
VOC 2.4 lb/ton Si (one hour), 9.26 lb/hr
(one hour)
NOx 45 lb/ton Si (one hour), 174 lb/hr
(one hour)
VOC 2.4 lb/ton Si (one hour), 9.26 lb/hr
(one hour)
NOx 45 lb/ton Si (one hour), 174 lb/hr
(one hour)
VOC 0.0054 lb/MMBtu (one hour),
0.054 lb/hr (one hour)
NOx 0.098 lb/MMBtu (one hour), 0.98
lb/hr (one hour)
VOC 0.0054 lb/MMBtu (one hour),
0.054 lb/hr (one hour)
NOx 0.098 lb/MMBtu (one hour), 0.98
lb/hr (one hour)
VOC 0.0054 lb/MMBtu (one hour),
0.054 lb/hr (one hour)
NOx 0.098 lb/MMBtu (one hour), 0.98
lb/hr (one hour)
VOC 5.9 lb/hr (one hour), 1 g/HP-hr
(one hour)
NOx 7.1 lb/hr (one hour), 1.2 g/HP-hr
(one hour)
Diesel Fuel Storage Tank ----82.999 VOC N N/A BACT-PSD
Table A-7
SIC Code 3339, VOC and NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
N BACT-PSD
Submerged Arc Furnace (SAF) #2 ----82.999 N BACT-PSD
Submerged Arc Furnace (SAF) #1
TN-0183 4/25/2022
3.86 tons/hr --82.999
Ladle Preheater #1 10 MMBtu/hr N BACT-PSD
Ladle Preheater #2 10 MMBtu/hr Natural Gas 82.999 N BACT-PSD
Natural Gas 82.999
BACT-PSD
Ladle Preheater #3 10 MMBtu/hr Natural Gas 82.999 N BACT-PSD
Emergency natural gas-fired engine 2682 HP Natural Gas 17.13 N
# Confidential Pg. 9 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel
Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Ammonia Plant CO2 Vent AK-0086 3/26/2021
90 tons per
hour of NH3 Natural Gas 62.999 VOC P - Good Combustion Practices 11.4 LB/HR (THREE-HOUR
AVERAGE)BACT-PSD
Reformer Natural Gas Fired AR-0173 1/31/2022
1591
MMBtu/hr Natural Gas 12.31 VOC
B - Scrubber, Low Combustion of Natural Gas, and Good Combustion Practices NOX
Burners,35.6 TPY BACT-PSD
Dual Path Kiln #4 120000
MBf/yr Sawdust 30.8 VOC 62 LB/HR, 228 tpy, 3.8 lb/MBF
Dual Path Kiln #4 Abort Stack 365 gal/yr Diesel 30.999 VOC
0.2 LB/HR, 0.1 tpy, 0.017
lb/MMBtu
Non-fuel grade Ethanol Distillation
69000 gallons
of 190 proof
ethanol/hr
VOC
A - scrubber CE008 and regenerative thermal oxidizer (RTO) CE009. During RTO
downtime, emissions from the distillation process are controlled by the scrubber CE008
and exhausted to atmosphere through RTO bypass stack SV008.
0.13 LBS (HOUR)
Non-fuel grade ethanol loadout 72000 gallons VOC A - enclosed flare 7.76 LB (HR)
RV Assembly Area (RV-5) IN-0335 6/7/2021 5 vehicles/hr --49.999 VOC
P - Cleaners and solvents limit: 6.5 lbs/gal and use non-HAP based cleaners and
solvents; Use HVLP spray applicators; Best management practices for VOC 119.81 TPY, 6.6 lb/gal BACT-PSD
Continuous Casters CC #1 and CC
#2
502 tons/hour
(total)81.35 VOC P - good operating practices 0.24 LB/HR FOR STEAM VENT
Electrostatic Oiler for Galvanizing
Line
76 tons per
hour 81.29 VOC P - use of low VOC oils and good operating practices 0.0009 LB/HOUR, 9 wt% VOC in oil
Sheet Metal Coating Line with Ovens
and RTO
73.9 tons per
hour 81.29 VOC A - recuperative thermal oxidizer (RTO)4 POUNDS PER HOUR
EP 128 & 134 (9033 & 9037)
Decoaters A & B
20 tons Al/hr
each Natural Gas VOC
B - Emissions from these decoaters are controlled by an integral afterburner for VOC.
The afterburner has a burner rating of 30.2 MMBtu/hr, a combustion chamber
temperature of at least 1400 °F, and a minimum residence time of 1.0 seconds.
The permittee shall prepare and maintain for EP128 and EP134, within 90 days of
startup, a good combustion and operation practices plan (GCOP) that defines,
measures and verifies the use of operational and design practices determined as BACT
for minimizing NOx, CO, VOC, and GHG emissions. Any revisions requested by the
Division shall be made and the revisions shall be maintained on site. The permittee
shall operate according to the provisions of this plan at all times, including periods of
startup, shutdown, and malfunction. The plan shall be incorporated into the plant
standard operating procedures (SOP) and shall be made available for the Division's
inspection. The plan shall include, but not be limited to: [401 KAR 51:017]
i. A list of combustion optimization practices and a means of verifying the practices
have occurred.
ii. A list of combustion and operation practices to be used to lower energy consumption
and a means of verifying the practices have occurred.
iii. A list of the design choices determined to be BACT and verification that designs
were implemented in the final construction.
1.99 LB/HR (METHOD 25A STACK
TEST REQUIRED), 8.72 tpy (12
month rolling avg.)
EP 07 (2015-1) Reversing Mill 287 ton of
Al/hr --VOC
P - The permittee shall prepare written operating instructions and procedures that
specify good operating and maintenance practices and includes, at a minimum, the
following specific practices targeting VOC emissions minimization: [401 KAR 51:017]
i. Controlling coolant application rates per unit of production to remain within targeted
ranges for ensuring process conditions are maintained at optimum levels while
simultaneously preventing wasted coolant from entering the system.
ii. Maintaining the supplied coolant temperature within required temperature ranges to
prevent overheated coolant from being exposed to aluminum slab/strip and
work/backup rolls.
iii. Performing periodic physical/chemical analysis of coolant package to assess coolant
conditions and evaluate excessive degradation or out of range specifications for key
coolant properties.
10 LB/HR (METHOD 25A STACK
TEST REQUIRED), 32.82 tpy (12
month rolling avg.)
Table A-8
VOC Emissions from Various Equipment - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
AR-0176 11/1/2022 N BACT-PSD
IN-0323 4/9/2021 --
BACT-PSDKY-0103 12/27/2020 82.129
--
70.19 BACT-PSD
IN-0359 3/30/2023 BACT-PSD
Confidential Pg. 10 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel
Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Table A-8
VOC Emissions from Various Equipment - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
EP 08 (2015-2) Finishing Mill 270 tons can
body stock/yr --VOC
P - The permittee shall prepare written operating instructions and procedures that
specify good operating and maintenance practices and includes, at a minimum, the
following specific practices targeting VOC emissions minimization: [401 KAR 51:017]
i. Controlling coolant application rates per unit of production and kerosene usage rates
for the slab threading process to remain within targeted ranges for ensuring process
conditions are maintained at optimum levels while simultaneously preventing wasted
coolant/kerosene from entering the system.
ii. Maintaining the supplied coolant temperature within required temperature ranges to
prevent overheated coolant from being exposed to aluminum slab/strip and
work/backup rolls.
iii. Performing periodic physical/chemical analysis of coolant package to assess coolant
conditions and evaluate excessive degradation or out†ofâ€range specifications for key
coolant properties.
iv. Spill prevention and other waste reduction measures to ensure the coolant supplied
to the system remains within the bounds of the storage, circulation, filtration, and
treatment systems.
73.2 LB/HR (METHOD 25A STACK
TEST REQUIRED), 239.2 tpy (12
month rolling avg.)
EP 161-01/02 (3050-1) Cold Mill 4
with Heavy Oil Scrubber
350 tons
aluminum/hr --VOC
B - This unit is equipped with a Heavy Oil Scrubber (HOS), where the roll coolant (in
the form of mist and vapor emissions) will be recovered for reuse.
For the Heavy Oil Scrubber, the permittee shall install operate, maintain, and
calibrate, according to the manufacturer's instructions, a continuous parametric
monitoring system for the HOS to monitor, at a minimum, the following parameters:
i. Washing oil flow rate,
ii. Washing oil supply temperature to the adsorber column, and
iii. Distillation column vacuum pressure.
The permittee shall maintain the overall capture efficiency of the fume exhaust system
at or above 98%.
The permittee shall prepare written operating instructions and procedures that specify
good operating and maintenance practices and includes, at a minimum, the following
specific practices targeting VOC emissions minimization: [401 KAR 51:017]
i. Controlling coolant application rates per unit of production using an automated
flatness system for ensuring process conditions are maintained at optimum levels.
ii. Maintaining the supplied coolant temperature within required temperature ranges to
prevent overheated coolant from being exposed to aluminum slab/strip and
work/backup rolls.
iii. Performing periodic physical/chemical analysis of coolant package to assess coolant
conditions and evaluate excessive degradation or out ofrange specifications for key
coolant properties.
iv. Spill prevention and other waste reduction measures to ensure the coolant supplied
to the system remains within the bounds of the storage, circulation, filtration, and
treatment systems.
6.88 LB/HR (METHOD 25A STACK
TEST REQUIRED), 30.13 tpy (12
month rolling avg.)
Cold Mill Complex Cleaning Tank (EP
21-20)
80 gallon
capacity --49.008 VOC P - Cover, operational requirements to minimize evaporative losses.0.032 TON/YR (12-MONTH
ROLLING)
Pickling Line #2 Electrostatic Oiler
(EP 21-06)
1314000
tons/yr --81.6 VOC
P - The permittee must develop a Good Work Practices (GWP) Plan to minimize
emissions. Max oil VOC content is 9.6% by weight.
0.0016 LB/HR, 0.007 tpy (12
month rolling avg.)
Galv Line #2 Temper Mill (EP 21-12)876000
tons/yr --81.6 VOC
P - The permittee must develop a Good Work Practices (GWP) Plan to minimize
emissions.
1.34 LB/HR, 5.88 tpy (12 month
rolling avg.)
Galv Line #2 Electrostatic Oiler (EP
21-14)
876000
tons/yr --81.6 VOC
P - The permittee must develop a Good Work Practices (GWP) Plan to minimize
emissions. Max oil VOC content limit is 9.4% by weight.
0.002 LB/HR, 0.008 tpy (12 month
rolling avg.)
Cold Reduction Mill Roof Vents (EP
21-17)
1000000
tons/yr --81.6 VOC
P - The permittee must develop a Good Work Practices (GWP) Plan to minimize
emissions.
0.085 LB/HR, 0.37 tpy (12 month
rolling avg.)
Skin Pass Mill #2 (EP 21-18)1314000
tons/yr --81.6 VOC
P - The permittee must develop a Good Work Practices (GWP) Plan to minimize
emissions.
1.64 LB/HR, 7.18 tpy (12 month
rolling avg.)
Galvanizing Line #2 Stenciling (EP
21-13)
876000 tons
steel/yr --41.999 VOC N 0.67 LB/HR (3-HR AVERAGE), 2.96
tpy (12 month rolling avg.)
KY-0115 BACT-PSD
BACT-PSD
4/19/2021
KY-0103 12/27/2020 82.129
Confidential Pg. 11 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel
Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Table A-8
VOC Emissions from Various Equipment - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
A-Line Caster Spray Vent (EP 01-14)2000000 tons
steel cast/yr --81.23 VOC
P - The permittee must develop a Good Work Practices (GWP) Plan to minimize
emissions.
0.4 LB/HR (3-HR AVERAGE), 1.75
tpy (12 month rolling avg.)
B-Line Caster Spray Vent (EP 20-11)2000000 tons
steel cast/yr --81.23 VOC
P - The permittee must develop a Good Work Practices (GWP) Plan to minimize
emissions.
0.8 LB/HR (3-HR AVERAGE), 3.5
tpy (12 month rolling avg.)
Vacuum Degasser (incl. pilot
emissions) (EP 20-12)
700000 tons
steel/yr Natural Gas 81.22 VOC
P - The permittee must develop a Good Combustion and Operating Practices (GCOP)
Plan and a Good Work Practices (GWP) Plan to minimize emissions.
1.91 LB/HR, 2.03 tpy (12 month
rolling avg.)
2-Stand Roughing Mill (EP 02-04)3500000 tons
steel/yr --81.29 VOC
P - The permittee must develop a Good Work Practices (GWP) Plan to minimize
emissions.
1.81 LB/HR (3-HR AVERAGE), 7.9
tpy (12 month rolling avg.)
6-Stand Finishing Mill (EP 02-05)3500000 tons
steel/yr --81.29 VOC
P - The permittee must develop a Good Work Practices (GWP) Plan to minimize
emissions.
6.78 LB/HR (3-HR AVERAGE),
23.71 tpy (12 month rolling avg.)
EU 029 - Decoater 27.6 tons/hr 82.129 VOC B - Afterburner & Good Combustion & Operation Practices (GCOP) Plan 4.57 LB/HR (3-HR AVERAGE),
20.04 tpy (12 month rolling total)
EU 037 - Sow Dryer 20 MMBtu/hr 13.31 VOC P - Good Combustion & Operation Practices (GCOP) Plan 0.11 LB/HR (MONTHLY AVERAGE),
0.48 tpy (12 month rolling total)
EU 041a - Direct-Fired Building
Heating Systems
53 MMBtu/hr
(total)13.31 VOC P - Good Combustion & Operation Practices (GCOP) Plan 0.29 LB/HR (MONTHLY AVERAGE),
1.28 tpy (12 month rolling total)
EU 041b - Indirect-Fired Building
Heating Systems ≤ 1 MMBtu
3 MMBtu/hr
(total)13.31 VOC P - Good Combustion & Operation Practices (GCOP) Plan 0.02 LB/HR (MONTHLY AVERAGE),
0.07 tpy (12 month rolling total)
EU 041c - Indirect-Fired Building
Heating Systems > 1 MMBtu
19.2
MMBtu/hr
(total)
13.31 VOC P - Good Combustion & Operation Practices (GCOP) Plan 0.11 LB/HR (MONTHLY AVERAGE),
0.46 tpy (12 month rolling total)
Scrubber C LA-0379 5/4/2021 815 mm lb/yr --63.036 VOC A - Wet scrubber 10.42 LB/HR BACT-PSD
Firewater Pump Engine No. 1 and 2 LA-0388 2/25/2022 575 hp Diesel 17.11 VOC P - Compliance with 40 CFR 60 Subpart IIII 0.32 LB/HR, 0.01 tpy BACT-PSD
3U-3 - Boiler C 250 MM
BTU/hr --63.036 VOC P - Good combustion practices 0.78 LB/HR, 0.0026 lb/MMBtu
3U-7A - Fire Water Pump A 552
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 0.93 LB/HR, 3 g/HP-hr
3U-7B - Fire Water Pump B 552
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 0.93 LB/HR, 3 g/HP-hr
3U-7C - Fire Water Pump C 552
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 0.93 LB/HR, 3 g/HP-hr
3U-10 - Utility Emergency Generator 760
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 2.03 LB/HR, 0.07 tpy, 6.4 g/kW-hr
3U-11 - Substation Emergency
Generator
70
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx
0.14 LB/HR, 0.007 tpy, 4.7 g/kW-
hr
3U-12 - VCM/CA/UT CCR Emergency
Generator
760
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 2.03 LB/HR, 0.07 tpy, 6.4 g/kW-hr
3U-13 - LTY Emergency Generator 333.3
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 0.66 LB/HR , 0.02 tpy, 4.7 g/kW-hr
4H-1 - Hydrochloric Acid Production
Furnace 51 MM BTU/hr --63.036 VOC P - Good combustion practices 0.87 LB/HR, 3.18 tpy, 0.0141
lb/MMBtu
2P-16 - Reactors 1860 MM
lbs/yr --63.036 VOC P - Compliance with 40 CFR 63 Subpart HHHHHHH 6.57 LB/HR, 0.33 tpy
2P-18F - PVC Emergency Combustion
Equipment F
402
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 0.22 LB/HR, 4 g/kW-hr
BACT-PSD10/20/2022LA-0389
KY-0115
KY-0116
BACT-PSD4/19/2021
BACT-PSDNatural Gas7/25/2022
Confidential Pg. 12 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel
Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Table A-8
VOC Emissions from Various Equipment - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
3U-4 - Boiler D 250 MM
BTU/hr --63.036 VOC P - Good combustion practices 0.78 LB/HR, 0.0026 lb/MMBtu
3C-6A - C/A Emergency Generators A 2346
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 6.27 LB/HR, 6.4 g/kW-hr
3C-6B - C/A Emergency Generators B 2346
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 6.27 LB/HR, 6.4 g/kW-hr
3C-6C - C/A Emergency Generators C 2346
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 6.27 LB/HR, 6.4 g/kW-hr
3M-1 - Cracking Furnace A 90 MM BTU/hr --63.036 VOC P - Good combustion practices 0.58 LB/HR, 2.13 tpy, 0.005
lb/MMBtu
3M-2 - Cracking Furnace B 90 MM BTU/hr --63.036 VOC P - Good combustion practices 0.58 LB/HR, 2.13 tpy, 0.005
lb/MMBtu
3M-3 - Cracking Furnace C 90 MM BTU/hr --63.036 VOC P - Good combustion practices 0.58 LB/HR, 2.13 tpy, 0.005
lb/MMBtu
3M-4 - Cracking Furnace D 90 MM BTU/hr --63.036 VOC P - Good combustion practices 0.58 LB/HR, 2.13 tpy, 0.005
lb/MMBtu
3M-5 - Gas Thermal Oxidizer A 72 MM BTU/hr --63.036 VOC P - Good operating practices 1.1 LB/HR, 99.99% DRE
3M-6 - Gas Thermal Oxidizer B 72 MM BTU/hr --63.036 VOC P - Good operating practices 1.1 LB/HR, 99.99% DRE
3M-11A - VCM Emergency
Generators A
2346
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 6.27 LB/HR, 6.4 g/kW-hr
3M-11B - VCM Emergency
Generators B
2346
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 6.27 LB/HR, 6.4 g/kW-hr
3M-11C - VCM Emergency Pump A 200
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 0.33 LB/HR, 4 g/kW-hr
3M-11D - VCM Emergency Pump B 200
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 0.33 LB/HR, 4 g/kW-hr
3M-11E - VCM Emergency Pump C 200
horsepower Diesel 63.036 VOC
P - Comply with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx as a
surrogate for VOC NOx 0.33 LB/HR, 4 g/kW-hr
3M-17 - Cracking Furnace E 90 MM BTU/hr --63.036 VOC P - Good combustion practices 0.58 LB/HR, 2.13 tpy, 0.005
lb/MMBtu
3U-1 - Boiler A 250 MM
BTU/hr --63.036 VOC P - Good combustion practices 0.78 LB/HR, 0.0026 lb/MMBtu
3U-2 - Boiler B 250 MM
BTU/hr --63.036 VOC P - Good combustion practices 0.78 LB/HR, 0.0026 lb/MMBtu
2P-1 - Scrubber A 930 MM lbs/yr --63.036 VOC P - Steam Strippers and compliance with applicable 40 CFR 63 Subpart HHHHHHH 9.53 LB/HR, 25.58 tpy, 89.8 ppm
2P-2 - Scrubber B 930 MM lbs/yr --63.036 VOC
P - Steam stripping and compliance with applicable provisions of 40 CFR 63 Subpart
HHHHHHH 9.53 LB/HR, 25.58 tpy, 89.8 ppm
2P-35 - PVC Plant Thermal Oxidizer A 5.37 MM
BTU/hr --19.2 VOC P - Good combustion practices 0.12 LB/HR, 0.43 tpy, 99.9% DRE
2P-36 - PVC Plant Thermal Oxidizer B 5.37 MM
BTU/hr --19.2 VOC P - Good combustion practices 0.12 LB/HR, 0.43 tpy, 99.9% DRE
2P-18A - PVC Emergency
Combustion Equipment A
100
horsepower --17.23 VOC
P - Compliance with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx
as a surrogate to VOC and NOx 0.28 LB/HR, 4 g/kW-hr
2P-18C - PVC Emergency
Combustion Equipment C
50
horsepower --17.23 VOC
P - Compliance with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx
as a surrogate to VOC and NOx 0.14 LB/HR, 4 g/kW-hr
2P-18E - Emergency Combustion
Equipment E
268
horsepower --17.23 VOC
P - Compliance with 40 CFR 60 Subpart IIII using Non-Methane hydrocarbon + NOx
as a surrogate to VOC and NOx 0.75 LB/HR, 6.4 g/kW-hr
LA-0389 10/20/2022 BACT-PSD
Confidential Pg. 13 off18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel
Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Table A-8
VOC Emissions from Various Equipment - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
ENG1 - Emergency Fire Water Pump 500
horsepower Diesel 17.21 VOC 1.85 LB/HR, 0.08 tpy
GEN-1 - Emergency Generator No. 1 750
horsepower Diesel 17.11 VOC 1.98 LB/HR, 0.08 tpy
GEN-2 - Emergency Generator No. 2 750
horsepower Diesel 17.11 VOC 1.98 LB/HR, 0.08 tpy
GEN-3 - Emergency Generator No. 2 750
horsepower --17.11 VOC 1.98 LB/HR, 0.08 tpy
Atmospheric Drains Tank 5475 gal --99.999 VOC A - Equip with a submerged fill pipe.0.05 T/YR
Combined Cycle Gas Turbine Startup
and Shutdown
5081 mm
BTU/h Natural Gas 15.21 VOC P - Good combustion practices.520 LB/HR
EUCTGSC1-natural gas fired simple
cycle CTG MI-0447 1/7/2021 667 MMBTU/H Natural gas 15.11 VOC P - Good combustion practices 5 LB/H (HOURLY; EXCEPT DURING
STARTUP/SHUTDOWN)BACT-PSD
EUAUXBOILER--nat gas fired
auxiliary boiler MI-0447 1/7/2021 50 MMBTU/H Natural gas 13.31 VOC P - Good combustion practices 0.3 LB/H (HOURLY)BACT-PSD
2 Natural gas fired rotary dryers
(EUDRYER1, EUDRYER2 in
FGDRYERRTO)
139.9
MMBTU/H natural gas 30.53 VOC B - Good combustion practices, RTO 7.1 LB/H (HOURLY)
Thermal energy plant (EUENERGY in
FGDRYERRTO)110 MMBTU/H wood-derived fuel and
biomass 12.12 VOC B - Good combustion practices and RTO 7.1 LB/H (HOURLY)
2 Paper Treating Lines (EUPTL1 and
EUPTL2 in FGPTL)3.4 MMBTU/H Natural gas 30.54 VOC P - Good Design and Operating Practices and Low VOC Coatings 4.3 LB/H (HOURLY), 19 tpy (12
month rolling period)
EU1227-1: Paper Machine MI-0450 7/14/2022 1800 ADTFP Natural gas 30.241 VOC N 42.71 T/YR (12-MO ROLLING TIME
PERIOD)BACT-PSD
EUFPENGINE (North Plant): Fire
Pump Engine 300 HP Diesel 17.21 VOC 0.75 LB/H (HOURLY)
EUEMENGINE (North Plant):
Emergency engine 1341 HP Diesel 17.11 VOC 0.86 LB/H (HOURLY)
EUEMENGINE (South Plant):
Emergency engine 1341 HP Diesel 17.11 VOC 0.86 LB/H (HOURLY)
EUFPENGINE (South Plant): Fire
pump engine 300 HP Diesel 17.21 VOC 0.75 LB/H (HOURLY)
EUCTGSC1--A nominally rated 667
MMBTU/H natural gas-fired simple
cycle CTG
667 MMBTU/H Natural gas 15.11 VOC
5 LB/H (HOURLY EXCEPT DURING
SU/SD)
EUAUXBOILER--natural-gas fired
auxiliary boiler, rated at less than or
equal to 99 MMBTU/H
50 MMBTU/H Natural gas 13.31 VOC 0.3 LB/H (HOURLY)
45.6 MMBtu/hr Natural Gas-Fired
Nitrogen Vaporizers: B029 through
B032
45.6
MMBTU/H Natural gas 13.31 VOC P - Good combustion practices and the use of natural gas
1.29 T/YR (PER ROLLING 12
MONTH PERIOD COMBINED),
0.005 lb/MMBtu
29.4 MMBtu/hr Natural Gas-Fired
Boilers: B001 through B028
29.4
MMBTU/H Natural gas 13.31 VOC P - Good combustion practices and the use of natural gas
4.86 T/YR (PER ROLLING 12
MONTH PERIOD B001 TO B014),
4.86 tpy (per rolling 12 month
period B015 to B028), 0.005
lb/MMBtu
275 hp (205 kW) Diesel-Fired
Emergency Fire Pump Engine 275 HP Diesel fuel 17.21 VOC
P - Certified to meet the standards in Table 4 of 40 CFR Part 60, Subpart IIII and good
combustion practices
0.7 LB/H, 0.2 tpy (per rolling 12
month period)
Auxiliary Natural Gas Burner SC-0203 8/26/2022
150
mmbtu/hr Natural gas 30.53 VOC A - Exhausts through Dryer #3 to RTO 116.39 TPY (TOTAL FOR STACKS
H1 AND H2)BACT-PSD
Emergency natural gas-fired engine TN-0183 4/25/2022 2682 HP Natural Gas 17.13 VOC N 5.9 LB/HR (ONE HOUR), 1 g/HP-hr
(one hour)BACT-PSD
Reciprocating Internal Combustion
Engine (RICE) (P101-P107)WI-0314 3/10/2022
152.3
MMBTU/H Natural Gas 17.13 VOC B - Use of good combustion practices and use of an oxidation catalyst.4.49 LB/H BACT-PSD
12/18/2020 BACT-PSD
OH-0387 9/20/2022 BACT-PSD
MI-0454 12/20/2022 P - Good combustion practices.BACT-PSD
LA-0390 5/10/2022
P - Good combustion practices and maintenance and compliance with applicable 40
CFR 60 Subpart JJJJ limitation for VOC.BACT-PSD
MI-0452 6/23/2022 P - Good combustion practices.BACT-PSD
MI-0448
MI-0451 6/23/2022 P - Good combustion practices.BACT-PSD
LA-0391 6/3/2022 BACT-PSD
Confidential Pg. 14 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Four Combined Cycle Gas-Fired
Turbines 384 MMBtu/hr 15.21
Six Simle Cycle Gas-Fired Turbines 1113 MMBtu/hr 15.11
Two 744 MW Combined Cycle Units AL-0328 11/9/2020 744 MW Natural Gas 15.21 NOx A - SCR 2 PPM (3 HOUR AVG / @15% O2),
39.1 LB/HR (3 HOUR AVG)BACT-PSD
Galvanizing Line #2 Furnace 150.5 MMBtu/hr 13.31 0.035 LB/MMBTU
Decarburizing Line Furnace Section 58 MMBtu/hr 13.31 0.1 LB/MMBTU
Annealing Pickling Line Furnace
Section 66 MMBtu/hr 13.29 0.1 LB/MMBTU
Annealing and Coating Line Furnace
Section 13 MMBtu/hr 81.29 0.1 LB/MMBTU
Flattening Coating Lines, Furnace
Sections 64 MMBtu/hr 81.29 0.1 LB/MMBTU
SN-219 Galvanizing Line No, 2
Furnace AR-0171 2/14/2019 128 MMBTU/hr Natural Gas 81.29 NOx A - Low Nox Burners, SCR/SNCR 0.0075 LB/MMBTU (3-HR), 0.063
LB/MMBTU (3-HR)BACT-PSD
Reformer Natural Gas Fired AR-0173 1/31/2022 1591 MMBtu/hr Natural Gas 12.31 NOx B - Scrubber, Low Combustion of Natural Gas, and
Good Combustion Practices NOX Burners,383.3 TPY BACT-PSD
GE 7HA.02 Combustion Turbine and
HRSG with Duct Firing FL-0371 6/7/2021 3622.1
MMBtu/hour Natural Gas 15.21 NOx A - Dry low-NOX combustors and Selective
Catalytic Reduction (SCR)
2 PPMVD AT 15% O2 (24-HOUR
BLOCK AVERAGE BASIS (BACT)),
15 PPMVD AT 15% O2 (30-
OPERATING-DAY ROLLING AVG.
(NSPS))
BACT-PSD
Combined-Cycle Combustion
Turbines IL-0133 7/29/2022 3647
mmBtu/hour Natural Gas 15.21 NOx
A - Dry low-NOx combustion with ultra-low NOx
combustors; low-NOx duct burners; and selective
catalytic reduction (SCR)
2 PPMV @ 15% O2 BACT-PSD
Block 7000 reformers IN-0317 6/11/2019 838.6 MMBTU/H natural gas 50.999 NOx
B - Units shall burn only gaseous fuels
Units shall use low-NOx burners
Units shall use selective catalytic reduction (SCR)
for NOx control
0.0065 LB/MMBTU BACT-PSD
Galvanizing Line #2 Radiant Tube
Furnace (EP 21-08B)36 MMBtu/hr
7.5 LB/MMSCF (3-HR AVERAGE),
1.16 TON/YR (12-MONTH
ROLLING)
Galvanizing Line #2 Preheat Furnace
(EP 21-08A)94 MMBtu/hr
7.5 LB/MMSCF (3-HR AVERAGE),
3.03 TON/YR (12-MONTH
ROLLING)
Process Heater PH-1 LA-0345 6/13/2019 923 mm btu/hr natural gas 11.31 NOx B - Low NOx fuels, LNB + SCR 0.007 LB/MM BTU BACT-PSD
PR Reactor Charge Heater 277 mm btu/h 11.31 A - SCR and LNB 0.01 LB/MMBTU (12-MONTH
ROLLING AVERAGE)
Boilers 1200 mm btu/h 11.31 A - SCR and LNB 0.01 LB/MMBTU (12-MONTH
ROLLING AVERAGE)
Table A-9
SCR for Natural Gas-Fired Equipment, NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
BACT-PSDAK-0088 7/7/2022 Natural Gas NOx A - SCR, DLN combustors, and good combustion
practices 2 PPMV @ 15% O2 (3-HOURS)
AR-0168 3/17/2021 Natural Gas NOx BACT-PSD
B - SCR, Low NOx burners
Combustion of clean fuel
Good Combustion Practices
B - The permittee must develop a Good
Combustion and Operating Practices (GCOP) Plan.
This unit is also equipped with a SCR/SNCR
system to control emissions. During a cold start,
SCR does not reach operating temperature for
approximately 30 minutes. During this time, only
low-NOx burners are controlling emissions of NOx.
NSG estimates the unit may undergo 1 cold start
every two (2) weeks.
BACT-PSD
BACT-PSD13.31 NOxKY-0115 4/19/2021 Natural Gas
NOxNatural Gas1/6/2020LA-0364
# Confidential Pg. 15 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Table A-9
SCR for Natural Gas-Fired Equipment, NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
Pyrolysis Furnaces 372 mm btu/h 11.31 A - SCR and LNB 0.02 LB/MMBTU (12-MONTH
ROLLING AVERAGE)
Cogeneration Units 2222 mm btu/h 15.21 A - Dry low NOx combustor design along with
SCR.
2 PPMVD (12-MONTH ROLLING
AVERAGE)
PR Waste Heat Boiler 94 mm btu/h 13.31 A - SCR and LNB 14.41 LB/H (12-MONTH ROLLING
AVERAGE)
Combined Cycle Gas Turbine w/ Duct
Burners and HRSG LA-0391 6/3/2022 5081 mm BTU/h Natural Gas 15.21 NOx
B - Dry low-NOx combustor design, selective
catalytic reduction (SCR), and good combustion
practices.
2 PPMVD (24-HR ROLLING AVG
BASED ON 1-HR AVG)BACT-PSD
FGCTGHRSG MI-0442 8/21/2019 625 MW Natural gas 15.21 NOx B - Good combustion practices, dry low NOx
burners and selective catalytic reduction (SCR).
2 PPM (EACH; 24-HR ROLL.AVG
EXCEPT START/SHUT), 190 LB/H
(EACH; HOURLY INCLUDING
STARTUP/SHUTDOWN)
BACT-PSD
EUCTGHRSG (North Plant): A
combined cycle natural gas fired
combustion turbine generator with
heat recovery steam generator
MI-0451 6/23/2022 3064 MMBTU/H Natural gas 15.21 NOx A - SCR with DLNB (Selective catalytic reduction
with Dry low NOx burners)
2.5 PPM (24-HR ROLLING AVG),
29.2 LB/H (24-HR ROLLING AVG)BACT-PSD
EUCTGHRSG (South Plant): A
combined-cycle natural gas-fired
combustion turbine generator with
heat recovery steam generator.
MI-0452 6/23/2022 3064 MMBTU/H Natural gas 15.21 NOx A - SCR with DLNB [Selective Catalytic Reduction
with Dry Low NOx Burners]
2 PPM (24-HR ROLLING AVG), 29.2
LB/H (24-HR ROLLING AVG EXCEPT
SU/SD)
BACT-PSD
Process Heaters TX-0865 9/9/2019 202 MMBtu/hr natural gas, process
gas 19.6 NOx A - SCR 5 PPMVD (3% O2 3-HR AVG)BACT-PSD
Isomar Charge Heater 220.4 MMBTU/H
B - The heater is equipped with ultra-low NOx
burners and a SCR1.
Fuel usage is monitored continuously and exiting
emission are monitored via CEMS.
Good combustion practices will be used to reduce
emissions including maintain proper air-to-fuel
ratio, necessary residence time, temperature and
turbulence. Combustion of pipeline-quality natural
gas.
0.035 LB/MMBTU (HOURLY)
REFORMATE HEATER 353.4 MMBtu
B - The heater equipped with ultra-low NOx
burners and a SCR.
Fuel usage is monitored continuously and exiting
emissions are monitored via CEMS.
0.035 LB/MMBTU (HOURLY), 5 PPM
(ANNUAL)
RAFFINATE HEATER 750 MMBTU/H
B - ULTRA LOW NOX BURNERS AND SCR.
Good combustion practices will be used to reduce
emissions including maintain proper air-to-fuel
ratio, necessary residence time, temperature and
turbulence. Combustion of pipeline-quality natural
gas.
0.035 LB/MMBTU (HORULY)
STRIPPER HEATER 117.3 MMBTU/H
B - The heater is equipped with ultra-low NOx
burners.
Tier III cost analysis determined $140,596 per
controlled. SCR is not considered economically
feasible. No SCR equipped.
Fuel usage is monitored continuously and exiting
emission are monitored via CEMS.
0.035 LB/MMBTU
1/6/2020LA-0364
TX-0873 2/4/2020 natural gas 19.6 NOx BACT-PSD
BACT-PSDNOxNatural Gas
# Confidential Pg. 16 of 18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
Table A-9
SCR for Natural Gas-Fired Equipment, NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
Simple Cycle Electrical Generation
Gas Turbines TX-0878 9/15/2022 34 MW natural gas 15.25 NOx A - SCR 5 PPM BACT-PSD
BOILERS TX-0888 4/23/2020 250 MMBTU Natural gas, ethane,
fuel, or vent gas 11.31 NOx A - SCR 0.015 LB/MMBTU (HOURLY), 0.01
LB/MMBTU (ANNUAL)BACT-PSD
Simple Cycle Turbine TX-0908 8/27/2021 230 MW natural gas 15.21 NOx A - Dry Low NOx Burners and SCR 2.5 PPMVD BACT-PSD
Three (3) Mitsubishi Hitachi Power
Systems combustion turbine
generators
VA-0332 6/24/2019 35000 MMCF/YR natural gas 15.21 NOx A - Controlled by dry, low NOx burners and
selective catalytic reduction (SCR).
2 PPMVD 15% O2 (1 HR AVG),
128.4 TONS/YR (12-MO ROLLING
AVG)
BACT-PSD
COMBUSTION TURBINE
GENERATORS, (3) with Alternate
Operating Scenario - Turbine Tuning
3442 MMBTU/H
COMBUSTION TURBINE
GENERATORS, (3) with Alternate
Operating Scenario - Turbine Blade
Water Washing
3442 MMBTU/H
Natural-Gas-Fired Combined-Cycle
Turbine (P01)WI-0300 9/1/2020 4671 MMBTU/H Natural Gas 15.21 NOx B - Selective Catalytic Reduction (SCR), low-NOx
burners, Water injection when firing diesel fuel oil.
2 PPM AT 15% O2 (24-HR
ROLLING AVG., NATURAL GAS), 6
PPM AT 15% O2 (24-HR ROLLING
AVG., DIESEL)
BACT-PSD
VA-0334 12/1/2020 natural gas 15.21 NOx 604 LBS (CALENDAR DAY/PER
TURBINE)BACT-PSD
P - Dry, low NOx burners and selective catalytic
reduction (SCR) with a NOx performance of 2.0
ppmvd at 15% O2.
# Confidential Pg. 17 off18
RBLC Listed Process RBLC ID
Permit
Issuance
Date
Throughput Primary Fuel Process
Code Pollutant Control Technology Type Emission Limits Case-by-
case Basis
SN-219 Galvanizing Line No, 2
Furnace AR-0171 2/14/2019 128 MMBTU/hr Natural Gas 81.29 NOx A - Low Nox Burners, SCR/SNCR 0.0075 LB/MMBTU (3-HR), 0.063
LB/MMBTU (3-HR)BACT-PSD
Kiln IN-0312 6/27/2019 7716 tons
clinker/day
natural gas, coal,
coke, Fuel oils 90.028 NOx A - low NOx burners and selective non-catalytic
reduction (SNCR)
1.5 LB/TON CLINKER (30-DAY
ROLLING AVERAGE)BACT-PSD
Galvanizing Line #2 Radiant Tube
Furnace (EP 21-08B)36 MMBtu/hr
7.5 LB/MMSCF (3-HR AVERAGE),
1.16 TON/YR (12-MONTH
ROLLING)
Galvanizing Line #2 Preheat Furnace
(EP 21-08A)94 MMBtu/hr
7.5 LB/MMSCF (3-HR AVERAGE),
3.03 TON/YR (12-MONTH
ROLLING)
Primary Reformer Heater (B002)OH-0368 4/19/2017 740 MMBTU/H Natural gas 11.31 NOx B - SNCR and low NOx burners
9.25 LB/H (PER 30 DAY ROLLING
AVERAGE. SEE NOTES.), 42.4
T/YR (PER ROLLING 12 MONTH
PERIOD.), 0.0125 LB/MMBTU
BACT-PSD
Table A-10
SNCR for Natural Gas-Fired Equipment, NOx Emissions - RBLC Search Results Summary
Western Zirconium, Inc
Ogden, Utah
BACT-PSDKY-0115 4/19/2021 Natural Gas 13.31 NOx
B - The permittee must develop a Good
Combustion and Operating Practices (GCOP) Plan.
This unit is also equipped with a SCR/SNCR
system to control emissions. During a cold start,
SCR does not reach operating temperature for
approximately 30 minutes. During this time, only
low-NOx burners are controlling emissions of NOx.
NSG estimates the unit may undergo 1 cold start
every two (2) weeks.
# Confidential Pg. 18 of 18
APPENDIX B:
Supporting Cost Calculations
Page 1 of 6
Table 1a. Boiler Parameters
Parameter Value Units Notes
17 MMBtu/hr
Maximum boiler input rating for each of the two (2)
boilers.
500 HP Conversion.
Boiler NOx Emissions 7.1 tpy NOx emissions for each boiler. Provided by WZ.
Table 1a. Low-NOx Burners (LNB) Retrofit
Parameter Value Units Notes
Annualized Capital Cost
Major Equipment Cost 467,859 $Vendor Quote. Includes new burner, economizer,
and combustion chamber.1
Other Direct Costs 522,358 $
Vendor Quote. Includes demo, civil work, concrete,
steel/arch, mechanical equipment, piping,
insulation, and electrical equipment.1
Total Direct Cost (DC)990,218 $ Sum of all direct costs.
Total Indirect Costs (IC) 476,207 $
Vendor Quote. Includes consumables, supervision,
engineering, construction equipment, construction,
mobilization, demobilization, freight, taxes, permits,
and surveying.1
Contingency 146,642 $Vendor Quote. 10% of labor costs.1
Total Capital Investment (TCI) 1,613,067 $ TCI = DC + IC + Contingency.
Capital Recovery Factor (CRF) 0.086 --
From EPA Air Pollution Control Cost Manual, Section
1, Chapter 2 - Cost Estimation: Concepts and
Methodology.2 7.0% interest over 25 years.
Capital Recovery (CR)138,417 $ CR = TCI*CRF
Indirect Annual Cost (IAC) 138,417 $Capital recovery is only indirect annual cost
considered.
Cost Effectiveness
Total Annualized Cost (TAC) 138,417 $/yr Not considering direct annual costs. TAC = IAC.
Annual NOx Emissions 7.1 tpy Provided by WZ.
LNB Control Efficiency 60%--Base case (44 ppmv) to Low-NOx (17 ppmv) boiler
control efficiency.
LNB NOx Removed 4.3 tpy Calculated from LNB control efficiency and Annual
NOx Emissions.
LNB Cost Effectiveness 32,123 $/ton of NOx Divided TAC by LNB NOx Removed.
UDAQ Cost Effectiveness
Threshold for NOx 10,000 $/ton of NOx
Utah Air Quality Board Meeting Agenda for
September 12, 2023, Appendix A, Table 1. Cost
threshold for >2 TPY NOx reduction.3
Table B-1
Natural Gas Boilers - RACT Cost Analysis
Western Zirconium Inc.
Ogden, Utah
Boiler Input Rating
Page 2 of 6
Table B-1
Natural Gas Boilers - RACT Cost Analysis
Western Zirconium Inc.
Ogden, Utah
Table 1b. Ultra Low-NOx Burners (ULNB) Retrofit
Parameter Value Units Notes
Annualized Capital Cost
Major Equipment Cost 527,911 $Vendor Quote. Includes new burner, economizer,
and combustion chamber.1
Other Direct Costs 528,857 $
Vendor Quote. Includes demo, civil work, concrete,
steel/arch, mechanical equipment, piping,
insulation, and electrical equipment.1
Total Direct Cost (DC)1,056,768 $ Sum of all direct costs.
Total Indirect Costs (IC)501,330 $
Vendor Quote. Includes consumables, supervision,
engineering, construction equipment, construction,
mobilization, demobilization, freight, taxes, permits,
and surveying.1
Contingency 155,810 $Vendor Quote. 10% of labor costs.1
Total Capital Investment (TCI) 1,713,908 $ TCI = DC + IC + Contingency.
Capital Recovery Factor (CRF) 0.086 --
From EPA Air Pollution Control Cost Manual, Section
1, Chapter 2 - Cost Estimation: Concepts and
Methodology.2 7.0% interest over 25 years.
Capital Recovery (CR)147,070 $ CR = TCI*CRF
Indirect Annual Cost (IAC) 147,070 $Capital recovery is only indirect annual cost
considered.
Cost Effectiveness
Total Annualized Cost (TAC) 147,070 $/yr Not considering direct annual costs. TAC = IAC.
Annual NOx emissions 7.1 tpy Provided by WZ.
ULNB Control Efficiency 83%--Base case (44 ppmv) to Ultra Low-NOx (7.4 ppmv)
boiler control efficiency.
ULNB NOx Removed 5.9 tpy Calculated from ULNB control efficiency and Annual
NOx Emissions.
ULNB Cost Effectiveness 24,797 $/ton of NOx Divided TAC by ULNB NOx Removed.
UDAQ Cost Effectiveness
Threshold for NOx 15,000 $/ton of NOx
Utah Air Quality Board Meeting Agenda for
September 12, 2023, Appendix A, Table 1. Cost
threshold for >5 TPY NOx reduction.3
Notes:
1.
2.
3.Utah Department of Air Quality (2023). Utah Air Quality Board Meeting Tentative Agenda, Tuesday, September 12,
2023. Appendix A, Table 1. https://documents.deq.utah.gov/air-quality/board/2023/DAQ-2023-006610.pdf
Cleaver Brooks Ghost Solutions Business Proposal (2024) Vendor Quote.
EPA.gov (2017). EPA Air Pollution Control Cost Manual Section 1, Chapter 2 - Cost Estimation: Concepts and
Methodology. https://www.epa.gov/sites/default/files/2017-
12/documents/epaccmcostestimationmethodchapter_7thedition_2017.pdf
Page 3 of 6
Table B-1
Natural Gas Boilers - RACT Cost Analysis
Western Zirconium Inc.
Ogden, Utah
Abbreviations:
CRF - capital recovery factor NOx - nitrogen oxides
EPA - Environmental Protection Agency tpy - tons per year
˚F - degrees Fahrenheit UDAQ - Utah Department of Air Quality
hr - hours ULNB - ultra-low NOx burner
kW - kilowatts yr - years
LNB - low-NOx burner RACT - reasonably available control technology
MMBtu - million British thermal units
Page 4 of 6
Table 2a. Diesel Emergency Generator Parameters
Parameter Value Units Notes
757 hp Maximum design rating for diesel emergency
generators.
564 kW Conversion.
0.0024 lb/hp-hr AP-42 Table 3.3-1.1
100 hr/yr Annual run-time limit.
182 lb/yr VOC PTE lbs per year.
0.091 tpy VOC PTE tons per year.
Table 2b. Diesel Oxidation Catalyst (DOC)
Parameter Value Units Notes
Capital Cost
Basic Equipment Cost (EC) 7,230 $Miratech Ventor Quote.2
Instrumentation 723 $
0.10*EC. Typical cost for instrumentation, EPA Air
Pollution Control Cost Manual, Section 1, Chapter 2 -
Cost Estimation: Concepts and Methodology, Table
2.4.5
Sales Tax 506 $ 0.07*EC. 7% is the typical sales tax in Utah.
Freight 362 $
0.05*EC. Typical cost for instrumentation, EPA Air
Pollution Control Cost Manual, Section 1, Chapter 2 -
Cost Estimation: Concepts and Methodology, Table
2.4.5
Purchased Equipment Cost
(PEC)8,821 $
1.22*EC. Combined EC with instrumentation, sales tax,
and freight costs. Assumed no direct installation costs,
site preparation or building costs.
Contractor Fees 600 $ 0.068*PEC.
Performance Test 88 $ 0.01*PEC. EPA Air Pollution Control Cost Manual.
Contingencies 882 $ 0.10*PEC. EPA Air Pollution Control Cost Manual.
Total Install Cost (TIC)1,570 $Sum of contractor fees, performance test, and
contingencies.
Total Capital Investment
(TCI)10,391 $ TCI = DC + TIC
Table B-2
Diesel Emergency Generators - RACT Cost Analysis
Western Zirconium Inc.
Ogden, Utah
VOC Emissions
Max. Design Capacity
Page 5 of 6
Table B-2
Diesel Emergency Generators - RACT Cost Analysis
Western Zirconium Inc.
Ogden, Utah
Operating Cost
Capital Recovery Factor (CRF) 0.086 --
From EPA Air Pollution Control Cost Manual, Section 1,
Chapter 2 - Cost Estimation: Concepts and
Methodology.4 7.0% interest over 25 years.
Capital Recovery (CR)892 $/yr CR = TCI * CRF
Indirect Annual Cost (IAC)892 $/yr Only indirect annual cost considered is capital recovery
Maintenance 52 $/yr 0.5% of TCI. Conservatively based on EPA Air Pollution
Control Cost Manual.3
Catalyst Replacement 0 $/yr Assume no cost.
Direct Annual Cost (DAC) 52 $/yr Sum of maintenance and catalyst replacement
costs.
Cost Effectiveness
Total Annualized Cost (TAC) 944 $/yr TAC = DAC + IAC.
Annual VOC emissions 0.091 tpy
DOC Control Efficiency 60%--VOC control efficiency per Miratech vendor quote.2
DOC VOC Removed 0.055 tpy Calculated from DOC control efficiency and annual VOC
Emissions.
DOC Cost Effectiveness 17,312 $/ton of VOC
Divided Annual Equipment Cost by LNB VOC
Removed.
UDAQ Cost Effectiveness
Threshold for VOC 5,000 $/ton of VOC
Utah Air Quality Board Meeting Agenda for
September 12, 2023, Appendix A, Table 1. Cost
threshold for <2 TPY VOC reduction.5
Notes:
1.
2.
3.
4.
5.Utah Department of Air Quality (2023). Utah Air Quality Board Meeting Tentative Agenda, Tuesday, September 12, 2023.
Appendix A, Table 1. https://documents.deq.utah.gov/air-quality/board/2023/DAQ-2023-006610.pdf
EPA.gov (1996). AP 42, Fifth Edition, Volume I Chapter 3: Stationary Internal Combustion Sources. 3.3 Gasoline and
Diesel Industrial Engines. Table 3.3-1. https://www.epa.gov/sites/default/files/2020-10/documents/c03s03.pdf
Janurary 2024, Miratech vendor quote for diesel oxidation catalyst system without silencer on 564 kW diesel engine.
EPA.gov (2017). EPA Air Pollution Control Cost Manual Section 4, Chapter 2 - Selective Catalytic Reduction.
https://www.epa.gov/sites/default/files/2017-12/documents/scrcostmanualchapter7thedition_2016revisions2017.pdf
EPA.gov (2017). EPA Air Pollution Control Cost Manual Section 1, Chapter 2 - Cost Estimation: Concepts and
Methodology. https://www.epa.gov/sites/default/files/2017-
12/documents/epaccmcostestimationmethodchapter_7thedition_2017.pdf
Page 6 of 6
Table B-2
Diesel Emergency Generators - RACT Cost Analysis
Western Zirconium Inc.
Ogden, Utah
Abbreviations:
DOC - diesel oxidative catalyst lb - pounds
hp - horsepower tpy - tons per year
hr - hours VOC - volatile organic compounds
kW - kilowatts
APPENDIX C:
Vendor Quotes
LNB/ULNB Quote
SUMMARY OF COSTS
Western Zirconium: East &
West Boiler Low NOx Burner
Conversion [2 - SBR-30
Burners]
Western Zirconium: East &
West Boiler Ultra Low NOx
Burner Conversion [2 - SBR-5
Burners]
DIRECTS:1,980,435$ 2,113,536$
Major Equipment[New Boilers w/ Economizers & DAs or New Burners, Economizers, & Combustion Chambers]935,718$ 1,055,821$
Demo 38,705$ 38,705$
Civil Work 49,842$ 49,842$
Concrete 45,388$ 45,388$
Steel / Arch 191,094$ 191,094$
Mech Equipment 134,505$ 142,401$
Piping 225,766$ 227,774$
Insulation 10,660$ 13,753$
Electrical Equipment 348,758$ 348,758$
INDIRECTS:952,414$ 1,002,660$
TOTAL(DIRECTS+INDIRECTS):2,932,849$ 3,116,196$
CONTINGENCY 293,285$ 311,620$
TOTAL:3,226,134$ 3,427,815$
Ghost Solutions LLC Project:Western Zirconium: East & West Boiler Low NOx Burner Conversion [2 - SBR-30 Burners]
Item Quantity Unit MH/Unit MHRS Rate Cost Unit Cost Subtotal Total
Efficiency Factor/Craft Rate 0.90 120$
BOILER PLANT
CLEAVER BROOKS PROFIRE SBR-30; SIZE: 500 BHP; HEAT INPUT=21.0 MMBTU/HR;
RECOMMENDED: FURNANCE DIAMETER 45 INCH, FURNANCE LENGTH 146 INCH.
FAN MTR=40HP. EMISSIONS: NOx<30 PPM; CO<50 PPM;TURNDOWN UP TO 4:1 WITH
FGR. INCLUDES HAWK 1000 BMS.2 LS 611.55 1,359.0 120$ 163,080$ 192,809.10$ 385,618$ 548,698$
DEMO
DEMO EXISTING BOILER BURNER ASSEMBLY & PIPING FOR NEW INSTALL 2 EA 80.00 177.8 120$ 21,333$ 1,000.00$ 2,000$ 23,333$
DEMO FOUNDATIONS/SLAB FOR NEW BURNER PAD/ECONOMIZER SUPPORTS 12 CY 2.24 29.9 120$ 3,584$ 54.98$ 660$ 4,244$
DEMO SITE PREP ON GRADE 411 SQYD 0.20 91.4 120$ 10,963$ 0.40$ 164$ 11,127$
CIVIL WORK
SITE
GRADING - BUILDING EXTENSION 900 SF 0.04 40.0 120$ 4,800$ 3.00$ 2,700$ 7,500$
DITCH/DRAIN FOR BOILER PLANT- CONCRETE 60 LF 1.50 100.0 120$ 12,000$ 275.00$ 16,500$ 28,500$
ROADWAY 100 LF 0.40 44.4 120$ 5,333$ 45.00$ 4,500$ 9,833$
GRAVEL 3,700 SF 0.00 10.3 120$ 1,233$ 0.75$ 2,775$ 4,008$
CONCRETE
CONCRETE REINFORCED - BURNER EQUIPMENT FOUNDATION/BASES 20 CY 9.00 200.0 120$ 24,000$ 325.00$ 6,500$ 30,500$
CONCRETE GENERAL FLOOR W/ BAR 10 CY 8.00 90.2 120$ 10,828$ 400.00$ 4,060$ 14,888$
STEEL / ARCHITECTURAL
BOILER PLT BUILDING NORTH EXT. FOR NEW BUNRERS/CHAMBERS(50'Lx16'Wx14'H)
STRUCTURAL STEEL 10,000 LB 0.02 233.3 120$ 28,000$ 0.58$ 5,750$ 33,750$
SIDING (1,148 SF FOR BLDG EXTENSION)1,148 FT2 0.15 191.3 120$ 22,960$ 0.48$ 551$ 23,511$
ROOF (800 SF FOR EXTENSION)800 FT2 0.20 177.8 120$ 21,333$ 0.50$ 400$ 21,733$
ROLL UP DOOR - INSULATED, MOTORIZED, W/ SIDE BRUSH SEAL 2 EA 32.00 71.1 120$ 8,533$ 5,950.00$ 11,900$ 20,433$
TROLLY BEAMS FOR MAINTEANCE ACCESS -PREFABRICATED TRUSS / BEAM ARRAN 200 LF 0.25 55.6 120$ 6,667$ 425.00$ 85,000$ 91,667$
MECHANICAL EQUIPMENT
MAJOR EQUIPMENT
ECONOMIZER FOR 500 BHP BOILER-CAIN RTR ECONOMIZER (48 IN DIA. X 38 IN H) ~2 EA 120.00 266.7 120$ 32,000$ 48,000.00$ 96,000$ 128,000.00$
BOILER EXHAUST PERFORATED 310SS 1/4" TK PLATE 2 EA 96.00 213.3 120$ 25,600$ 3,722.40$ 7,445$ 33,044.80$
60 IN DIA. FURNANCE CHAMBER (12.5 LF PER CHAMBER)25 LF 39.11 1,086.4 120$ 130,367$ 735.00$ 18,375$ 148,742$
60 IN DIA. FURNANCE REFRACTORY - 6 INCH THICK W/ ANCHORS (~88.4 CF/CHAMB 177 CF 2.05 402.3 120$ 48,273$ 350.32$ 62,006$ 110,278.62$
60 IN TO 78 IN DIA TRANSITION DUCT TO EXISTING BOILER(1 FT PER T DUCT)2 LF 39.11 86.9 120$ 10,429$ 955.50$ 1,911$ 12,340$
78 IN DIA. TRANSITION DUCT REFRACTORY - 6 INCH THICK W/ ANCHORS (~13.6 CF 28 CF 2.05 63.6 120$ 7,636$ 350.32$ 9,809$ 17,445.21$
18 INCH DIA.- FGR DUCT 45 LF 5.85 292.5 120$ 35,100$ 189.80$ 8,541$ 43,641$
FIRE PROTECTION - TIE IN
8" FIRE WATER LINE-HDPE, SDR11, 40'100 LF 0.05 5.6 180$ 1,000$ 12.00$ 1,200$ 2,200$
POST INDICATOR VALVES 1 EA 8.00 8.9 130$ 1,156$ 1,900.00$ 1,900$ 3,056$
FITTINGS 6 EA 3.00 20.0 180$ 3,600$ 280.00$ 1,680$ 5,280$
HYDRANTS 1 EA 8.00 8.9 130$ 1,156$ 4,300.00$ 4,300$ 5,456$
EXCAVATION 132 LF 0.24 35.2 130$ 4,576$ -$ 4,576$
MISC HOSES, HOSE REELS, FIRE EXT, MOUNTING, SIGNAGE, ETC.1 LS 24.00 26.7 130$ 3,467$ 4,000.00$ 4,000$ 7,467$
PIPING
2 IN DIA, SCH 40 - NATURAL GAS AG INSIDE 150 LF 1.34 223.3 120$ 26,800$ 20.00$ 3,000$ 29,800$
2 IN DIA, SCH 40 - SMALL BORE BOP PIPING 100 LF 1.34 148.9 120$ 17,867$ 20.00$ 2,000$ 19,867$
3 IN DIA, SCH 40 - NATURAL GAS AG INSIDE 150 LF 1.51 251.7 120$ 30,200$ 21.88$ 3,281$ 33,481$
3 IN DIA, SCH 40 - SMALL BORE BOP PIPING 100 LF 1.51 167.8 120$ 20,133$ 21.88$ 2,188$ 22,321$
VALVES
SMALL BORE BOP VALVES CLASS 600, GLOBE MISCELLANEOUS -15 PER NEW BURNE 30 EA 8.05 268.3 120$ 32,200$ 275.00$ 8,250$ 40,450$
GAS SAFETY SHUTOFF VALVES, MISCELLANEOUS ASSUMED 3 PER NEW BURNER 6 EA 8.05 53.7 120$ 6,440$ 3,500.00$ 21,000$ 27,440$
PIPE SUPPORTS, HANGERS
SINGLE ROD SUPPORT W/ BEAM FOR 2 IN PIPE 25 EA 4.02 111.7 120$ 13,400$ 102.00$ 2,550$ 15,950$
SINGLE ROD SUPPORT W/ BEAM FOR 3 IN PIPE 25 EA 4.02 111.7 120$ 13,400$ 102.00$ 2,550$ 15,950$
SINGLE ROD SUPPORT W/ BEAM FOR 18 IN DUCT 5 EA 11.00 55.0 120$ 6,600$ 170.00$ 765$ 7,365$
PIPE SUPPORTS, RACK
U-BOLT FOR 2 IN DIA PIPE 25 EA 1.80 50.0 120$ 6,000$ 2.18$ 55$ 6,055$
U-BOLT FOR 3 IN DIA PIPE 25 EA 2.10 58.3 120$ 7,000$ 3.49$ 87$ 7,087$
INSULATION
1 IN THICK, 2 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.31 - 120$ -$ 9.84$ -$ -$
1.5 IN THICK, 3 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.38 - 120$ -$ 15.17$ -$ -$
1.5 IN THICK, 4 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.42 - 120$ -$ 17.63$ -$ -$
2 IN THICK, 6 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.53 - 120$ -$ 28.74$ -$ -$
4 IN THICK, 6 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.65 - 120$ -$ 48.59$ -$ -$
4 IN THICK, 8 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.75 - 120$ -$ 54.56$ -$ -$
2 IN THICK, 18 IN PIPE-MINERAL WOOL W/SS JACKETING 45 LF 1.13 56.5 120$ 6,780$ 86.22$ 3,880$ 10,660$
2 IN THICK, 24 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 1.43 - 120$ -$ 114.96$ -$ -$
2 IN THICK, EQUIPMENT-MINERAL WOOL W/SS JACKETING - SF 0.09 - 120$ -$ 4.88$ -$ -$
ELECTRICAL EQUIPMENT
ELECTRICAL GROUNDING & LIGHTNING PROTECTION
#2 CU BARE STRANDED GROUND WIRE 198 LF 0.02 4.7 120$ 562$ 1.12$ 222$ 784$
#1/0 CU BARE STRANDED GROUND WIRE 198 LF 0.03 5.9 120$ 705$ 2.94$ 582$ 1,287$
#4/0 CU BARE STRANDED GROUND WIRE 1,188 LF 0.03 42.4 120$ 5,091$ 4.25$ 5,049$ 10,140$
#4/0 CU INSULATED STRANDED GROUND WIRE 163 LF 0.04 7.6 120$ 914$ 4.95$ 808$ 1,722$
EXOTHERMIC WELD 10 EA 2.29 25.4 120$ 3,052$ 15.00$ 150$ 3,202$
COPPER CLAD GROUND ROD, 15' LONG, 3/4 " DIA.8 EA 2.30 20.4 120$ 2,453$ 150.00$ 1,200$ 3,653$
COMPRESSION CONNECTION 25 EA 1.15 31.9 120$ 3,822$ 6.00$ 150$ 3,972$
TEST AND DOCUMENTATION 43 EA 0.35 16.7 120$ 2,007$ -$ -$ 2,007$
LIGHTING
BUILDING HIGH BAY LIGHTING 9 EA 2.00 20.0 120$ 2,400$ 1,300.00$ 11,700$ 14,100$
EXTERIOR FLOOD LIGHTING/ SUPPORT POLES 2 EA 8.00 17.8 120$ 2,133$ 1,550.00$ 3,100$ 5,233$
ELECTRICAL EQUIPMENT, RACEWAY, CABLE TRAY, & CONDUIT
MCC COMPLETE
480V, MOTOR CONTROL CENTER, 1200A, 5 VERTICAL SECTIONS 1 EA 69.00 76.7 120$ 9,200$ 50,000.00$ 50,000$ 59,200$
POWER TRANSFORMERS
DISTRIBUTION TRANSFORMER 208/120V 75 KVA, DRY TYPE 1 EA 55.00 61.1 120$ 7,333$ 10,000.00$ 10,000$ 17,333$
CONDUIT, FLEXIBLE SEAL TIGHT
FLEXIBLE SEALTIGHT 1-1/2 IN DIA, 3 FT LONG INCLUDING (2) CONNECTORS 30 EA 1.43 47.8 120$ 5,733$ 21.28$ 639$ 6,372$
Labor Material
Ghost Solutions LLC Project:Western Zirconium: East & West Boiler Low NOx Burner Conversion [2 - SBR-30 Burners]
Item Quantity Unit MH/Unit MHRS Rate Cost Unit Cost Subtotal Total
Efficiency Factor/Craft Rate 0.90 120$
BOILER PLANT
Labor Material
FLEXIBLE SEALTIGHT 2 IN DIA, 3 FT LONG INCLUDING (2) CONNECTORS 2 EA 1.90 4.2 120$ 508$ 22.70$ 45$ 553$
CONDUIT, RGS
3/4 IN DIA INCLUDING ELBOWS, UNISTRUT SUPPORTS, AND MISC HARDWARE 640 LF 0.22 158.7 120$ 19,039$ 4.74$ 3,034$ 22,073$
1 IN DIA INCLUDING ELBOWS, UNISTRUT SUPPORTS, AND MISC HARDWARE 320 LF 0.28 97.8 120$ 11,738$ 7.05$ 2,256$ 13,993$
1-1/2 IN DIA INCLUDING ELBOWS, UNISTRUT SUPPORTS, AND MISC HARDWARE 160 LF 0.33 58.1 120$ 6,966$ 7.75$ 1,240$ 8,206$
2 IN DIA INCLUDING ELBOWS, UNISTRUT SUPPORTS, AND MISC HARDWARE 32 LF 0.40 14.4 120$ 1,726$ 9.95$ 318$ 2,045$
CABLE CONTROL/INSTRUMENTATION/COMM.-CABLE & TERMINATION
600V #16 1 TRIAD AWG 336 LF 0.02 7.5 120$ 896$ 0.51$ 171$ 1,067$
600V #16 2 TRIAD AWG 336 LF 0.06 22.0 120$ 2,643$ 1.99$ 669$ 3,312$
600V #16 4 TRIAD AWG 336 LF 0.06 22.0 120$ 2,643$ 1.99$ 669$ 3,312$
600V #16 1 TW PR AWG 560 LF 0.02 10.7 120$ 1,286$ 0.14$ 78$ 1,365$
600V #16 2 TW PR AWG 560 LF 0.03 16.4 120$ 1,973$ 0.61$ 342$ 2,315$
600V #16 4 TW PR AWG 560 LF 0.03 20.7 120$ 2,489$ 0.87$ 487$ 2,976$
600V #14 3/C AWG 560 LF 0.02 14.4 120$ 1,727$ 0.50$ 280$ 2,007$
600V #14 5/C AWG 560 LF 0.03 16.5 120$ 1,975$ 0.76$ 426$ 2,401$
600V #14 7/C AWG 560 LF 0.03 18.6 120$ 2,234$ 1.03$ 577$ 2,811$
600V #14 9/C AWG 448 LF 0.03 17.2 120$ 2,061$ 1.25$ 560$ 2,621$
600V #14 12/C AWG 336 LF 0.04 15.0 120$ 1,801$ 1.61$ 541$ 2,342$
600V #14 19/C AWG 280 LF 0.06 18.7 120$ 2,240$ 2.14$ 599$ 2,839$
CAT 6E PATCH CABLES 90 LF 0.11 11.1 120$ 1,333$ 1.00$ 90$ 1,423$
ETHERNET SWITCH 2 EA 0.50 1.1 120$ 133$ 4,000.00$ 8,000$ 8,133$
COMMUNICATION CABINET 1 EA 40.00 44.4 120$ 5,333$ 3,500.00$ 3,500$ 8,833$
CAT6 ETHERNET CABLE 450 FT 0.02 10.0 120$ 1,200$ 2.00$ 900$ 2,100$
TERMINATION - COMPRESSION LUG, #16 AND SMALLER, 1 HOLE, COPPER 192 EA 0.06 12.2 120$ 1,469$ 1.20$ 230$ 1,699$
TERMINATION - COMPRESSION LUG, #14, 1 HOLE, COPPER 144 EA 0.12 18.4 120$ 2,210$ 1.70$ 245$ 2,455$
TEST AND DOCUMENTATION 336 EA 0.06 21.4 120$ 2,572$ -$ -$ 2,572$
600V CABLE & TERMINATION
600V #12 2/C CU W/G 576 LF 0.02 14.7 120$ 1,765$ 0.52$ 300$ 2,064$
600V #12 3/C CU W/G 576 LF 0.03 16.9 120$ 2,026$ 0.67$ 386$ 2,412$
600V #10 2/C CU W/G 230 LF 0.03 6.8 120$ 811$ 1.28$ 295$ 1,106$
600V #10 3/C W/G CU 230 LF 0.03 7.1 120$ 847$ 1.61$ 371$ 1,218$
600V #8 2/C CU W/G 230 LF 0.03 7.7 120$ 922$ 1.52$ 350$ 1,272$
600V #8 3/C W/G CU 230 LF 0.04 10.0 120$ 1,201$ 2.30$ 530$ 1,730$
600V #6 3/C W/G CU 230 LF 0.05 13.8 120$ 1,653$ 3.29$ 758$ 2,411$
600V #4 3/C W/G CU 230 LF 0.06 15.9 120$ 1,905$ 4.73$ 1,090$ 2,994$
TERMINATION - COMPRESSION LUG, #12, 1 HOLE, COPPER 144 EA 0.17 27.6 120$ 3,313$ 1.90$ 274$ 3,586$
TERMINATION - COMPRESSION LUG, #10, 1 HOLE, COPPER 96 EA 0.29 30.7 120$ 3,681$ 2.20$ 211$ 3,892$
TERMINATION - COMPRESSION LUG, #8, 2 HOLE, COPPER 24 EA 0.35 9.3 120$ 1,111$ 6.50$ 156$ 1,267$
TERMINATION - COMPRESSION LUG, #6, 2 HOLE, COPPER 24 EA 0.47 12.4 120$ 1,493$ 9.00$ 216$ 1,709$
TERMINATION - COMPRESSION LUG, #4, 2 HOLE, COPPER 24 EA 0.57 15.2 120$ 1,818$ 9.25$ 222$ 2,040$
TEST AND DOCUMENTATION 312 EA 0.30 104.0 120$ 12,480$ -$ -$ 12,480$
INSTRUMENTATION
FT-FLOW INSTRUMENT & INSTALLATION 2 EA 13.80 30.7 120$ 3,680$ 5,000.00$ 10,000$ 13,680$
LT-LEVEL TRANSMITTER & INSTALLATION - EA 4.50 - 120$ -$ 3,500.00$ -$ -$
PT-PRESSURE TRANSMITTER & INSTALLATION 3 EA 4.50 15.0 120$ 1,800$ 3,500.00$ 10,500$ 12,300$
PI-PRESSURE GAUGE INSTALLATION 5 EA 2.00 11.1 120$ 1,333$ 300.00$ 1,500$ 2,833$
LG-LEVEL GAUGE GLASS INSTALLATION - EA 5.00 - 120$ -$ 2,000.00$ -$ -$
DPT-DIFFERENTAIL PRESSURE TRANSMITTER & INSTALLATION 2 EA 4.50 10.0 120$ 1,200$ 4,000.00$ 8,000$ 9,200$
TT-TEMPERATURE TRANSMITTER & INSTALLATION 2 EA 3.00 6.7 120$ 800$ 2,500.00$ 5,000$ 5,800$
TI-TEMPERATURE SENSOR INSTALLATION 4 EA 2.00 8.9 120$ 1,067$ 300.00$ 1,200$ 2,267$
THERMOCOUPLE/TERMOWELLS 6 EA 2.00 13.3 120$ 1,600$ 500.00$ 3,000$ 4,600$
1/2" STAINLES STEEL INSTRUMENT TUBING INCLUDING SUPPORT 80 LF 0.15 13.3 120$ 1,600$ 6.10$ 488$ 2,088$
CONTINUOUS EMISSION MONITORING SYSTEM (CEMS)- EA 350.00 - 120$ -$ 250,000.00$ -$ -$
CEMS-SELLER'S COMMISSIONING SUPPORT - LS 400.00 - 150$ -$ 75,000.00$ -$ -$
INSTRUMENTATION BENCH TESTING & CALIBRATION 18 EA 1.20 24.0 120$ 2,880$ 100.00$ 1,800$ 4,680$
I/O POINTS/LOOP CHECKS 18 EA 1.75 35.0 120$ 4,200$ 100.00$ 1,800$ 6,000$
TESTING AND COMMISSIONING
TESTING AND COMMISSIONING - TRNSFMR 1 LS 80.00 88.9 120$ 10,667$ 2,000.00$ 2,000$ 12,667$
Sub-Total Directs 1,025,282$ 955,153$ 1,980,435$
Consumables / Small Tools 1.25 %24,755$ 24,755$
Field Supervision 640 MH 160$ 102,400$ 102,400$
Project Engineering 640 MH 160$ 102,400$ 102,400$
Construction Equipment 2 %39,609$ 39,609$
Temporary Construction & Utilities 1 %19,804$ 19,804$
Mobilization / Demobilization 1 %19,804$ 19,804$
Freight 1.5 %29,707$ 29,707$
Taxes, Permits 6 %118,826$ 118,826$
Engineering, Surveying 25 %495,109$ 495,109$
Sub-Total 1,230,082$ 1,702,768$ 2,932,849$
CONTINGENCY 10 %123,008$ 170,277$ 293,285$
TOTAL 1,353,090$ 1,873,045$ 3,226,134$
INDIRECTS
Ghost Solutions LLC Project:Western Zirconium: East & West Boiler Ultra Low NOx Burner Conversion [2 - SBR-5 Burners]
Item Quantity Unit MH/Unit MHRS Rate Cost Unit Cost Subtotal Total
Efficiency Factor/Craft Rate 0.90 120$
BOILER PLANT
CLEAVER BROOKS PROFIRE SBR-5; SIZE: 500 BHP; HEAT INPUT=21.0 MMBTU/HR;
RECOMMENDED: FURNANCE DIAMETER 45 INCH, FURNANCE LENGTH 146 INCH.
FAN MTR=40HP. EMISSIONS: NOx<9 PPM; CO<50 PPM;TURNDOWN UP TO 4:1 WITH
FGR. INCLUDES HAWK 4000 BMS.2 LS 611.55 1,359.0 120$ 163,080$ 252,860.52$ 505,721$ 668,801$
DEMO
DEMO EXISTING BOILER BURNER ASSEMBLY & PIPING FOR NEW INSTALL 2 EA 80.00 177.8 120$ 21,333$ 1,000.00$ 2,000$ 23,333$
DEMO FOUNDATIONS/SLAB FOR NEW BURNER PAD/ECONOMIZER SUPPORTS 12 CY 2.24 29.9 120$ 3,584$ 54.98$ 660$ 4,244$
DEMO SITE PREP ON GRADE 411 SQYD 0.20 91.4 120$ 10,963$ 0.40$ 164$ 11,127$
CIVIL WORK
SITE
GRADING - BUILDING EXTENSION 900 SF 0.04 40.0 120$ 4,800$ 3.00$ 2,700$ 7,500$
DITCH/DRAIN FOR BOILER PLANT- CONCRETE 60 LF 1.50 100.0 120$ 12,000$ 275.00$ 16,500$ 28,500$
ROADWAY 100 LF 0.40 44.4 120$ 5,333$ 45.00$ 4,500$ 9,833$
GRAVEL 3,700 SF 0.00 10.3 120$ 1,233$ 0.75$ 2,775$ 4,008$
CONCRETE
CONCRETE REINFORCED - BURNER EQUIPMENT FOUNDATION/BASES 20 CY 9.00 200.0 120$ 24,000$ 325.00$ 6,500$ 30,500$
CONCRETE GENERAL FLOOR W/ BAR 10 CY 8.00 90.2 120$ 10,828$ 400.00$ 4,060$ 14,888$
STEEL / ARCHITECTURAL
BOILER PLT BUILDING NORTH EXT. FOR NEW BUNRERS/CHAMBERS(50'Lx16'Wx14'H)
STRUCTURAL STEEL 10,000 LB 0.02 233.3 120$ 28,000$ 0.58$ 5,750$ 33,750$
SIDING (1,148 SF FOR BLDG EXTENSION)1,148 FT2 0.15 191.3 120$ 22,960$ 0.48$ 551$ 23,511$
ROOF (800 SF FOR EXTENSION)800 FT2 0.20 177.8 120$ 21,333$ 0.50$ 400$ 21,733$
ROLL UP DOOR - INSULATED, MOTORIZED, W/ SIDE BRUSH SEAL 2 EA 32.00 71.1 120$ 8,533$ 5,950.00$ 11,900$ 20,433$
TROLLY BEAMS FOR MAINTEANCE ACCESS -PREFABRICATED TRUSS / BEAM ARRAN 200 LF 0.25 55.6 120$ 6,667$ 425.00$ 85,000$ 91,667$
MECHANICAL EQUIPMENT
MAJOR EQUIPMENT
ECONOMIZER FOR 500 BHP BOILER-CAIN RTR ECONOMIZER (48 IN DIA. X 38 IN H) ~2 EA 120.00 266.7 120$ 32,000$ 48,000.00$ 96,000$ 128,000$
BOILER EXHAUST PERFORATED 310SS 1/4" TK PLATE 2 EA 96.00 213.3 120$ 25,600$ 3,722.40$ 7,445$ 33,045$
60 IN DIA. FURNANCE CHAMBER (12.5 LF PER CHAMBER)25 LF 39.11 1,086.4 120$ 130,367$ 735.00$ 18,375$ 148,742$
60 IN DIA. FURNANCE REFRACTORY - 6 INCH THICK W/ ANCHORS (~88.4 CF/CHAMB 177 CF 2.05 402.3 120$ 48,273$ 350.32$ 62,006$ 110,279$
60 IN TO 78 IN DIA TRANSITION DUCT TO EXISTING BOILER(1 FT PER T DUCT)2 LF 39.11 86.9 120$ 10,429$ 955.50$ 1,911$ 12,340$
78 IN DIA. TRANSITION DUCT REFRACTORY - 6 INCH THICK W/ ANCHORS (~13.6 CF 28 CF 2.05 63.6 120$ 7,636$ 350.32$ 9,809$ 17,445$
24 INCH DIA.- FGR DUCT 45 LF 7.01 350.5 120$ 42,060$ 210.60$ 9,477$ 51,537$
FIRE PROTECTION - TIE IN
8" FIRE WATER LINE-HDPE, SDR11, 40'100 LF 0.05 5.6 180$ 1,000$ 12.00$ 1,200$ 2,200$
POST INDICATOR VALVES 1 EA 8.00 8.9 130$ 1,156$ 1,900.00$ 1,900$ 3,056$
FITTINGS 6 EA 3.00 20.0 180$ 3,600$ 280.00$ 1,680$ 5,280$
HYDRANTS 1 EA 8.00 8.9 130$ 1,156$ 4,300.00$ 4,300$ 5,456$
EXCAVATION 132 LF 0.24 35.2 130$ 4,576$ -$ 4,576$
MISC HOSES, HOSE REELS, FIRE EXT, MOUNTING, SIGNAGE, ETC.1 LS 24.00 26.7 130$ 3,467$ 4,000.00$ 4,000$ 7,467$
PIPING
2 IN DIA, SCH 40 - NATURAL GAS AG INSIDE 150 LF 1.34 223.3 120$ 26,800$ 20.00$ 3,000$ 29,800$
2 IN DIA, SCH 40 - SMALL BORE BOP PIPING 100 LF 1.34 148.9 120$ 17,867$ 20.00$ 2,000$ 19,867$
3 IN DIA, SCH 40 - NATURAL GAS AG INSIDE 150 LF 1.51 251.7 120$ 30,200$ 21.88$ 3,281$ 33,481$
3 IN DIA, SCH 40 - SMALL BORE BOP PIPING 100 LF 1.51 167.8 120$ 20,133$ 21.88$ 2,188$ 22,321$
VALVES
SMALL BORE BOP VALVES CLASS 600, GLOBE MISCELLANEOUS -15 PER NEW BURNE 30 EA 8.05 268.3 120$ 32,200$ 275.00$ 8,250$ 40,450$
GAS SAFETY SHUTOFF VALVES, MISCELLANEOUS ASSUMED 3 PER NEW BURNER 6 EA 8.05 53.7 120$ 6,440$ 3,500.00$ 21,000$ 27,440$
PIPE SUPPORTS, HANGERS
SINGLE ROD SUPPORT W/ BEAM FOR 2 IN PIPE 25 EA 4.02 111.7 120$ 13,400$ 102.00$ 2,550$ 15,950$
SINGLE ROD SUPPORT W/ BEAM FOR 3 IN PIPE 25 EA 4.02 111.7 120$ 13,400$ 102.00$ 2,550$ 15,950$
SINGLE ROD SUPPORT W/ BEAM FOR 24 IN DUCT 5 EA 14.25 71.3 120$ 8,550$ 183.00$ 824$ 9,374$
PIPE SUPPORTS, RACK
U-BOLT FOR 2 IN DIA PIPE 25 EA 1.80 50.0 120$ 6,000$ 2.18$ 55$ 6,055$
U-BOLT FOR 3 IN DIA PIPE 25 EA 2.10 58.3 120$ 7,000$ 3.49$ 87$ 7,087$
INSULATION
1 IN THICK, 2 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.31 - 120$ -$ 9.84$ -$ -$
1.5 IN THICK, 3 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.38 - 120$ -$ 15.17$ -$ -$
1.5 IN THICK, 4 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.42 - 120$ -$ 17.63$ -$ -$
2 IN THICK, 6 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.53 - 120$ -$ 28.74$ -$ -$
4 IN THICK, 6 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.65 - 120$ -$ 48.59$ -$ -$
4 IN THICK, 8 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 0.75 - 120$ -$ 54.56$ -$ -$
2 IN THICK, 18 IN PIPE-MINERAL WOOL W/SS JACKETING - LF 1.13 - 120$ -$ 86.22$ -$ -$
2 IN THICK, 24 IN PIPE-MINERAL WOOL W/SS JACKETING 45 LF 1.43 71.5 120$ 8,580$ 114.96$ 5,173$ 13,753$
2 IN THICK, EQUIPMENT-MINERAL WOOL W/SS JACKETING - SF 0.09 - 120$ -$ 4.88$ -$ -$
ELECTRICAL EQUIPMENT
ELECTRICAL GROUNDING & LIGHTNING PROTECTION
#2 CU BARE STRANDED GROUND WIRE 198 LF 0.02 4.7 120$ 562$ 1.12$ 222$ 784$
#1/0 CU BARE STRANDED GROUND WIRE 198 LF 0.03 5.9 120$ 705$ 2.94$ 582$ 1,287$
#4/0 CU BARE STRANDED GROUND WIRE 1,188 LF 0.03 42.4 120$ 5,091$ 4.25$ 5,049$ 10,140$
#4/0 CU INSULATED STRANDED GROUND WIRE 163 LF 0.04 7.6 120$ 914$ 4.95$ 808$ 1,722$
EXOTHERMIC WELD 10 EA 2.29 25.4 120$ 3,052$ 15.00$ 150$ 3,202$
COPPER CLAD GROUND ROD, 15' LONG, 3/4 " DIA.8 EA 2.30 20.4 120$ 2,453$ 150.00$ 1,200$ 3,653$
COMPRESSION CONNECTION 25 EA 1.15 31.9 120$ 3,822$ 6.00$ 150$ 3,972$
TEST AND DOCUMENTATION 43 EA 0.35 16.7 120$ 2,007$ -$ -$ 2,007$
LIGHTING
BUILDING HIGH BAY LIGHTING 9 EA 2.00 20.0 120$ 2,400$ 1,300.00$ 11,700$ 14,100$
EXTERIOR FLOOD LIGHTING/ SUPPORT POLES 2 EA 8.00 17.8 120$ 2,133$ 1,550.00$ 3,100$ 5,233$
ELECTRICAL EQUIPMENT, RACEWAY, CABLE TRAY, & CONDUIT
MCC COMPLETE
480V, MOTOR CONTROL CENTER, 1200A, 5 VERTICAL SECTIONS 1 EA 69.00 76.7 120$ 9,200$ 50,000.00$ 50,000$ 59,200$
POWER TRANSFORMERS
DISTRIBUTION TRANSFORMER 208/120V 75 KVA, DRY TYPE 1 EA 55.00 61.1 120$ 7,333$ 10,000.00$ 10,000$ 17,333$
CONDUIT, FLEXIBLE SEAL TIGHT
FLEXIBLE SEALTIGHT 1-1/2 IN DIA, 3 FT LONG INCLUDING (2) CONNECTORS 30 EA 1.43 47.8 120$ 5,733$ 21.28$ 639$ 6,372$
Labor Material
Ghost Solutions LLC Project:Western Zirconium: East & West Boiler Ultra Low NOx Burner Conversion [2 - SBR-5 Burners]
Item Quantity Unit MH/Unit MHRS Rate Cost Unit Cost Subtotal Total
Efficiency Factor/Craft Rate 0.90 120$
BOILER PLANT
Labor Material
FLEXIBLE SEALTIGHT 2 IN DIA, 3 FT LONG INCLUDING (2) CONNECTORS 2 EA 1.90 4.2 120$ 508$ 22.70$ 45$ 553$
CONDUIT, RGS
3/4 IN DIA INCLUDING ELBOWS, UNISTRUT SUPPORTS, AND MISC HARDWARE 640 LF 0.22 158.7 120$ 19,039$ 4.74$ 3,034$ 22,073$
1 IN DIA INCLUDING ELBOWS, UNISTRUT SUPPORTS, AND MISC HARDWARE 320 LF 0.28 97.8 120$ 11,738$ 7.05$ 2,256$ 13,993$
1-1/2 IN DIA INCLUDING ELBOWS, UNISTRUT SUPPORTS, AND MISC HARDWARE 160 LF 0.33 58.1 120$ 6,966$ 7.75$ 1,240$ 8,206$
2 IN DIA INCLUDING ELBOWS, UNISTRUT SUPPORTS, AND MISC HARDWARE 32 LF 0.40 14.4 120$ 1,726$ 9.95$ 318$ 2,045$
CABLE CONTROL/INSTRUMENTATION/COMM.-CABLE & TERMINATION
600V #16 1 TRIAD AWG 336 LF 0.02 7.5 120$ 896$ 0.51$ 171$ 1,067$
600V #16 2 TRIAD AWG 336 LF 0.06 22.0 120$ 2,643$ 1.99$ 669$ 3,312$
600V #16 4 TRIAD AWG 336 LF 0.06 22.0 120$ 2,643$ 1.99$ 669$ 3,312$
600V #16 1 TW PR AWG 560 LF 0.02 10.7 120$ 1,286$ 0.14$ 78$ 1,365$
600V #16 2 TW PR AWG 560 LF 0.03 16.4 120$ 1,973$ 0.61$ 342$ 2,315$
600V #16 4 TW PR AWG 560 LF 0.03 20.7 120$ 2,489$ 0.87$ 487$ 2,976$
600V #14 3/C AWG 560 LF 0.02 14.4 120$ 1,727$ 0.50$ 280$ 2,007$
600V #14 5/C AWG 560 LF 0.03 16.5 120$ 1,975$ 0.76$ 426$ 2,401$
600V #14 7/C AWG 560 LF 0.03 18.6 120$ 2,234$ 1.03$ 577$ 2,811$
600V #14 9/C AWG 448 LF 0.03 17.2 120$ 2,061$ 1.25$ 560$ 2,621$
600V #14 12/C AWG 336 LF 0.04 15.0 120$ 1,801$ 1.61$ 541$ 2,342$
600V #14 19/C AWG 280 LF 0.06 18.7 120$ 2,240$ 2.14$ 599$ 2,839$
CAT 6E PATCH CABLES 90 LF 0.11 11.1 120$ 1,333$ 1.00$ 90$ 1,423$
ETHERNET SWITCH 2 EA 0.50 1.1 120$ 133$ 4,000.00$ 8,000$ 8,133$
COMMUNICATION CABINET 1 EA 40.00 44.4 120$ 5,333$ 3,500.00$ 3,500$ 8,833$
CAT6 ETHERNET CABLE 450 FT 0.02 10.0 120$ 1,200$ 2.00$ 900$ 2,100$
TERMINATION - COMPRESSION LUG, #16 AND SMALLER, 1 HOLE, COPPER 192 EA 0.06 12.2 120$ 1,469$ 1.20$ 230$ 1,699$
TERMINATION - COMPRESSION LUG, #14, 1 HOLE, COPPER 144 EA 0.12 18.4 120$ 2,210$ 1.70$ 245$ 2,455$
TEST AND DOCUMENTATION 336 EA 0.06 21.4 120$ 2,572$ -$ -$ 2,572$
600V CABLE & TERMINATION
600V #12 2/C CU W/G 576 LF 0.02 14.7 120$ 1,765$ 0.52$ 300$ 2,064$
600V #12 3/C CU W/G 576 LF 0.03 16.9 120$ 2,026$ 0.67$ 386$ 2,412$
600V #10 2/C CU W/G 230 LF 0.03 6.8 120$ 811$ 1.28$ 295$ 1,106$
600V #10 3/C W/G CU 230 LF 0.03 7.1 120$ 847$ 1.61$ 371$ 1,218$
600V #8 2/C CU W/G 230 LF 0.03 7.7 120$ 922$ 1.52$ 350$ 1,272$
600V #8 3/C W/G CU 230 LF 0.04 10.0 120$ 1,201$ 2.30$ 530$ 1,730$
600V #6 3/C W/G CU 230 LF 0.05 13.8 120$ 1,653$ 3.29$ 758$ 2,411$
600V #4 3/C W/G CU 230 LF 0.06 15.9 120$ 1,905$ 4.73$ 1,090$ 2,994$
TERMINATION - COMPRESSION LUG, #12, 1 HOLE, COPPER 144 EA 0.17 27.6 120$ 3,313$ 1.90$ 274$ 3,586$
TERMINATION - COMPRESSION LUG, #10, 1 HOLE, COPPER 96 EA 0.29 30.7 120$ 3,681$ 2.20$ 211$ 3,892$
TERMINATION - COMPRESSION LUG, #8, 2 HOLE, COPPER 24 EA 0.35 9.3 120$ 1,111$ 6.50$ 156$ 1,267$
TERMINATION - COMPRESSION LUG, #6, 2 HOLE, COPPER 24 EA 0.47 12.4 120$ 1,493$ 9.00$ 216$ 1,709$
TERMINATION - COMPRESSION LUG, #4, 2 HOLE, COPPER 24 EA 0.57 15.2 120$ 1,818$ 9.25$ 222$ 2,040$
TEST AND DOCUMENTATION 312 EA 0.30 104.0 120$ 12,480$ -$ -$ 12,480$
INSTRUMENTATION
FT-FLOW INSTRUMENT & INSTALLATION 2 EA 13.80 30.7 120$ 3,680$ 5,000.00$ 10,000$ 13,680$
LT-LEVEL TRANSMITTER & INSTALLATION - EA 4.50 - 120$ -$ 3,500.00$ -$ -$
PT-PRESSURE TRANSMITTER & INSTALLATION 3 EA 4.50 15.0 120$ 1,800$ 3,500.00$ 10,500$ 12,300$
PI-PRESSURE GAUGE INSTALLATION 5 EA 2.00 11.1 120$ 1,333$ 300.00$ 1,500$ 2,833$
LG-LEVEL GAUGE GLASS INSTALLATION - EA 5.00 - 120$ -$ 2,000.00$ -$ -$
DPT-DIFFERENTAIL PRESSURE TRANSMITTER & INSTALLATION 2 EA 4.50 10.0 120$ 1,200$ 4,000.00$ 8,000$ 9,200$
TT-TEMPERATURE TRANSMITTER & INSTALLATION 2 EA 3.00 6.7 120$ 800$ 2,500.00$ 5,000$ 5,800$
TI-TEMPERATURE SENSOR INSTALLATION 4 EA 2.00 8.9 120$ 1,067$ 300.00$ 1,200$ 2,267$
THERMOCOUPLE/TERMOWELLS 6 EA 2.00 13.3 120$ 1,600$ 500.00$ 3,000$ 4,600$
1/2" STAINLES STEEL INSTRUMENT TUBING INCLUDING SUPPORT 80 LF 0.15 13.3 120$ 1,600$ 6.10$ 488$ 2,088$
CONTINUOUS EMISSION MONITORING SYSTEM (CEMS)- EA 350.00 - 120$ -$ 250,000.00$ -$ -$
CEMS-SELLER'S COMMISSIONING SUPPORT - LS 400.00 - 150$ -$ 75,000.00$ -$ -$
INSTRUMENTATION BENCH TESTING & CALIBRATION 18 EA 1.20 24.0 120$ 2,880$ 100.00$ 1,800$ 4,680$
I/O POINTS/LOOP CHECKS 18 EA 1.75 35.0 120$ 4,200$ 100.00$ 1,800$ 6,000$
TESTING AND COMMISSIONING
TESTING AND COMMISSIONING - TRNSFMR 1 LS 80.00 88.9 120$ 10,667$ 2,000.00$ 2,000$ 12,667$
Sub-Total Directs 1,035,992$ 1,077,544$ 2,113,536$
Consumables / Small Tools 1.25 %26,419$ 26,419$
Field Supervision 640 MH 160$ 102,400$ 102,400$
Project Engineering 640 MH 160$ 102,400$ 102,400$
Construction Equipment 2 %42,271$ 42,271$
Temporary Construction & Utilities 1 %21,135$ 21,135$
Mobilization / Demobilization 1 %21,135$ 21,135$
Freight 1.5 %31,703$ 31,703$
Taxes, Permits 6 %126,812$ 126,812$
Engineering, Surveying 25 %528,384$ 528,384$
Sub-Total 1,240,792$ 1,875,404$ 3,116,196$
CONTINGENCY 10 %124,079$ 187,540$ 311,620$
TOTAL 1,364,871$ 2,062,944$ 3,427,815$
INDIRECTS
Stream Number 1 2 4 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 24 25 29 32 33
Description
Boile r M/U
Feed Water BFW to DA BFW from DA
to Boiler
FGR to
Burner
Boiler Flue
Gas
Flue Gas to
Stack Natural Gas Combustion
Air from ATM
Burner
Exhaust
Combustion
Gas
Boiler
Blowdown
Boiler Steam
Generation
110# Stm to
DA PRV
Boiler Stm to
Plant
Boiler
Blowdown
Flash Stm
Boiler
Blowdown
Liquid
Plant Steam to
Plt Demands
for Cond Rtn
Plant Steam to
Plt Demands
No Cond Rtn
Cooling Water
for Sim. Stm
Loads
Plant Cond
Rtn
Cooling Water
In for Sim. Stm
Loads
Flue Gas
Stack Exhaust
DA Steam
Ve nt
25# Stm to
DA
Mass Flow Rate, lb/hr 7,719.82 14,619.79 15,828.03 - 19,652.91 19,652.91 876.31 18,776.59 19,652.91 791.40 15,036.63 1,236.68 13,799.94 114.59 676.81 6,899.97 6,899.97 357,289.99 6,899.97 357,289.99 19,652.91 28.44 1,236.68
GPM Flow, GPM 15.42 29.47 32.78 - 75,943.43 89.20 2,932.45 37,331.27 #########1.77 7,107.43 584.55 6,522.88 448.92 1.41 3,261.44 3,261.44 714.95 14.26 717.13 89.20 109.52 1,859.13
Pressure, PSIG 75.00 75.00 110.00 - - - - - - - 110.00 110.00 110.00 - - 110.00 110.00 - 110.00 - - - 25.00
Pressure, PSIA 87.59 87.59 122.59 12.59 12.59 12.59 12.59 12.59 12.59 12.59 122.59 122.59 122.59 12.59 12.59 122.59 122.59 12.59 122.59 12.59 12.59 12.59 37.59
Temperature, F 40.00 110.87 195.80 550.00 550.00 550.00 77.00 77.00 3,132.58 342.85 342.85 342.85 342.85 204.29 204.29 342.85 342.85 70.00 190.00 90.00 550.00 195.80 308.27
Viscosity, cP 1.411 0.662 0.305 - - - - - - 0.247 - - - - 0.281 - - 0.983 0.322 0.817 - - -
Density, lb/ft3 62.4262 61.8494 60.2063 - 0.0323 27.4677 0.0373 0.0627 0.0091 55.8542 0.2638 0.2638 0.2638 0.0318 60.0023 0.2638 0.2638 62.3056 60.3431 62.1160 27.4677 0.0324 0.0829
Liquid Phase:
Mass Flow, lb/hr 7,719.82 14,619.79 15,828.03 - - - - - - 791.40 - - - - 676.81 - - 357,289.99 6,899.97 357,289.99 - - -
Mass Density, lb/ft3 62.43 61.85 60.21 - - - - - - 55.85 - - - - 60.00 - - 62.31 60.34 62.12 - - -
Specific Gravity, SG 1.00 0.99 0.96 - - - - - - 0.89 - - - - 0.96 - - 1.00 0.97 0.99 - - -
Actual Volume Flow, USGPM 15.42 29.47 32.78 - - - - - - 1.77 - - - - 1.41 - - 714.95 14.26 717.13 - - -
Elemental Assay Liquid
Cation
B aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Ca aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
K aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Li aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Mg aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Na aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Si aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Anion
CO3 aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Cl aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
HCO3 aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
OH aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
SO4 aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Component Assay Liquid
H2O aq, ppm 1,000,000 1,000,000 1,000,000 - - - - - - 1,000,000 - - - - 1,000,000 - - 1,000,000 1,000,000 1,000,000 - - -
CaCl2 aq. ppm - - - - - - - - - - - - - - - - - - - - - - -
CaCO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
Ca(OH)2 aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
CaSO4 aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
MgCl2 aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
MgSO4 aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
NaCl aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
Na2CO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
NaHCO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
NaOH aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
Na2SO4 aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
Na2SiO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - -
Gas Phase:
Mass Flow, lb/hr - - - - 19,652.91 19,652.91 876.31 18,776.59 19,652.91 - 15,036.63 1,236.68 13,799.94 114.59 - 6,899.97 6,899.97 - - - 19,652.91 28.44 1,236.68
Mass Density, lb/ft3 - - - - 0.03 27.47 0.04 0.06 0.01 - 0.26 0.26 0.26 0.03 - 0.26 0.26 - - - 27.47 0.03 0.08
Actual Gas Flow, ACFM - - - - 10,152.15 11.92 392.01 4,990.46 36,121.65 - 950.12 78.14 871.98 60.01 - 435.99 435.99 - - - 11.92 14.64 248.53
Standard Gas Flow, SCFM - - - - 4,621.45 4,621.45 335.77 4,276.98 4,621.45 - 5,451.68 448.37 5,003.31 41.55 - 2,501.66 2,501.66 - - - 4,621.45 10.31 448.37
Component Assay Gas (Mass Basis)
H2O Gas, ppm(m) - - - - 104,933 104,933 - 10,052 104,933 - 1,000,000 1,000,000 1,000,000 1,000,000 - 1,000,000 1,000,000 - - - 104,933 1,000,000 1,000,000
N2 Gas, ppm(m) - - - - 726,512 726,512 11,398 759,924 726,512 - - - - - - - - - - - 726,512 - -
O2 Gas, ppm(m) - - - - 48,282 48,282 - 230,024 48,282 - - - - - - - - - - - 48,282 - -
CO2 Gas, ppm(m) - - - - 120,084 120,084 18,613 - 120,084 - - - - - - - - - - - 120,084 - -
CO Gas, ppm(m) - - - - 86 86 - - 86 - - - - - - - - - - - 86 - -
NO Gas, ppm(m) - - - - 29.9 29.9 - - 29.9 - - - - - - - - - - - 30 - -
NO2 Gas, ppm(m) - - - - 72.2 72.2 - - 72.2 - - - - - - - - - - - 72 - -
SO2 Gas, ppm(m) - - - - 0.5 0.5 - - 0.5 - - - - - - - - - - - 1 - -
H2S Gas, ppm(m) - - - - - - 6 - - - - - - - - - - - - - - - -
CH4 Gas, ppm(m) - - - - - - 882,372 - - - - - - - - - - - - - - - -
C2H6 Gas, ppm(m) - - - - - - 79,993 - - - - - - - - - - - - - - - -
C3H8 Gas, ppm(m) - - - - - - 7,619 - - - - - - - - - - - - - - - -
Component Assay Gas (Volume Basis)
H2O Gas, ppm(v) - - - - 161,786 161,786 - 16,000 161,786 - 1,000,000 1,000,000.0 1,000,000.0 1,000,000.0 - 1,000,000.0 1,000,000.0 - - - 161,785.9 1,000,000.0 #########
N2 Gas, ppm(v) - - - - 720,358 720,358 6,936 777,870 720,358 - - - - - - - - - - - 720,357.6 - -
O2 Gas, ppm(v) - - - - 41,911 41,911 - 206,130 41,911 - - - - - - - - - - - 41,910.7 - -
CO2 Gas, ppm(v) - - - - 75,789 75,789 7,209 - 75,789 - - - - - - - - - - - 75,789.2 - -
CO Gas, ppm(v) - - - - 85 85 - - 85 - - - - - - - - - - - 85.1 - -
NO Gas, ppm(v) - - - - 27.7 27.7 - - 27.7 - - - - - - - - - - - 27.7 - -
43.6-- - - - 43.6 43.6 - - 43.6 - - - - - - - - - - - 43.6 - -
SO2 Gas, ppm(v) - - - - 0.2 0.2 - - 0.2 - - - - - - - - - - - 0.2 - -
H2S Gas, ppm(v) - - - - - - 3.2 - - - - - - - - - - - - - - - -
CH4 Gas, ppm(v) - - - - - - 937,559.6 - - - - - - - - - - - - - - - -
C2H6 Gas, ppm(v) - - - - - - 45,347.1 - - - - - - - - - - - - - - - -
C3H8 Gas, ppm(v) - - - - - - 2,945.2 - - - - - - - - - - - - - - - -
# Confidential
Stream Number 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 24 25 29 32 33
Description Boile r M/U
Feed Water BFW to DA BFW to
Economizer
Exit Flue Gas
from
Economizer
BFW from
Economizer to
Boiler
FGR to
Burner
Boiler Flue
Gas
Flue Gas to
Stack Natural Gas Combustion
Air from ATM
Burner
Exhaust
Combustion
Gas
Boiler
Blowdown
Boiler Steam
Generation
110# Stm to
DA PRV
Boiler Stm to
Plant
Boiler
Blowdown
Flash Stm
Boiler
Blowdown
Liquid
Plant Steam to
Plt Demands
for Cond Rtn
Plant Steam to
Plt Demands
No Cond Rtn
Cooling Water
for Sim. Stm
Loads
Plant Cond
Rtn
Cooling Water
In for Sim. Stm
Loads
Flue Gas
Stack
Exhaust
DA Steam
Ve nt
25# Stm to DA
Mass Flow Rate, lb/hr 8,036.34 15,219.22 16,477.00 33,035.53 16,477.00 15,310.20 33,035.53 17,725.33 876.31 16,849.02 33,035.53 823.85 15,653.15 1,287.39 14,365.76 119.29 704.56 7,182.88 7,182.88 371,939.38 7,182.88 371,939.38 17,725.33 29.61 1,287.39
GPM Flow, GPM 16.05 30.68 34.12 #########36.24 54,818.15 #########75.70 2,932.45 33,498.91 #########1.84 7,398.84 608.52 6,790.33 467.33 1.46 3,395.16 3,395.16 744.27 14.84 746.54 75.70 114.01 1,935.36
Pressure, PSIG 75.00 75.00 110.00 - 110.00 - - - - - - - 110.00 110.00 110.00 - - 110.00 110.00 - 110.00 - - - 25.00
Pressure, PSIA 87.59 87.59 122.59 12.59 122.59 12.59 12.59 12.59 12.59 12.59 12.59 12.59 122.59 122.59 122.59 12.59 12.59 122.59 122.59 12.59 122.59 12.59 12.59 12.59 37.59
Temperature, F 40.00 110.87 195.80 472.74 318.35 472.74 687.51 472.74 77.00 77.00 2,100.00 342.85 342.85 342.85 342.85 204.29 204.29 342.85 342.85 70.00 190.00 90.00 472.74 195.80 308.27
Viscosity, cP 1.411 0.662 0.305 - 0.249 - - - - - - 0.247 - - - - 0.281 - - 0.983 0.322 0.817 - - -
Density, lb/ft3 62.4262 61.8494 60.2063 0.0348 56.6818 0.0348 0.0283 29.1933 0.0373 0.0627 0.0127 55.8542 0.2638 0.2638 0.2638 0.0318 60.0023 0.2638 0.2638 62.3056 60.3431 62.1160 29.1933 0.0324 0.0829
Liquid Phase:
Mass Flow, lb/hr 8,036.34 15,219.22 16,477.00 - 16,477.00 - - - - - - 823.85 - - - - 704.56 - - 371,939.38 7,182.88 371,939.38 - - -
Mass Density, lb/ft3 62.43 61.85 60.21 - 56.68 - - - - - - 55.85 - - - - 60.00 - - 62.31 60.34 62.12 - - -
Specific Gravity, SG 1.00 0.99 0.96 - 0.91 - - - - - - 0.89 - - - - 0.96 - - 1.00 0.97 0.99 - - -
Actual Volume Flow, USGPM 16.05 30.68 34.12 - 36.24 - - - - - - 1.84 - - - - 1.46 - - 744.27 14.84 746.54 - - -
Elemental Assay Liquid
Cation
B aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Ca aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
K aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Li aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Mg aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Na aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Si aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Anion
CO3 aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Cl aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
HCO3 aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
OH aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
SO4 aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Component Assay Liquid
H2O aq, ppm 1,000,000 1,000,000 1,000,000 - 1,000,000 - - - - - - 1,000,000 - - - - 1,000,000 - - 1,000,000 1,000,000 1,000,000 - - -
CaCl2 aq. ppm - - - - - - - - - - - - - - - - - - - - - - - - -
CaCO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Ca(OH)2 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
CaSO4 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
MgCl2 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
MgSO4 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
NaCl aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Na2CO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
NaHCO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
NaOH aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Na2SO4 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Na2SiO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Gas Phase:
Mass Flow, lb/hr - - - 33,035.53 - 15,310.20 33,035.53 17,725.33 876.31 16,849.02 33,035.53 - 15,653.15 1,287.39 14,365.76 119.29 - 7,182.88 7,182.88 - - - 17,725.33 29.61 1,287.39
Mass Density, lb/ft3 - - - 0.03 - 0.03 0.03 29.19 0.04 0.06 0.01 - 0.26 0.26 0.26 0.03 - 0.26 0.26 - - - 29.19 0.03 0.08
Actual Gas Flow, ACFM - - - 15,812.22 - 7,328.12 19,456.09 10.12 392.01 4,478.15 43,413.39 - 989.08 81.35 907.73 62.47 - 453.87 453.87 - - - 10.12 15.24 258.72
Standard Gas Flow, SCFM - - - 7,794.81 - 3,612.48 7,794.81 4,182.34 335.77 3,837.91 7,794.81 - 5,675.21 466.76 5,208.45 43.25 - 2,604.23 2,604.23 - - - 4,182.34 10.74 466.76
Component Assay Gas (Mass Basis)
H2O Gas, ppm(m) - - - 115,251 - 115,251 115,251 115,251 - 10,052 115,251 - 1,000,000 1,000,000 1,000,000 1,000,000 - 1,000,000 1,000,000 - - - 115,251 1,000,000 1,000,000
N2 Gas, ppm(m) - - - 722,906 - 722,906 722,906 722,906 11,398 759,924 722,906 - - - - - - - - - - - 722,906 - -
O2 Gas, ppm(m) - - - 28,537 - 28,537 28,537 28,537 - 230,024 28,537 - - - - - - - - - - - 28,537 - -
CO2 Gas, ppm(m) - - - 133,227 - 133,227 133,227 133,227 18,613 - 133,227 - - - - - - - - - - - 133,227 - -
CO Gas, ppm(m) - - - 42 - 42 42 42 - - 42 - - - - - - - - - - - 42 - -
NO Gas, ppm(m) - - - 8.0 - 8.0 8.0 8.0 - - 8.0 - - - - - - - - - - - 8 - -
NO2 Gas, ppm(m) - - - 28.7 - 28.7 28.7 28.7 - - 28.7 - - - - - - - - - - - 29 - -
SO2 Gas, ppm(m) - - - 0.6 - 0.6 0.6 0.6 - - 0.6 - - - - - - - - - - - 1 - -
H2S Gas, ppm(m) - - - - - - - - 6 - - - - - - - - - - - - - - - -
CH4 Gas, ppm(m) - - - - - - - - 882,372 - - - - - - - - - - - - - - - -
C2H6 Gas, ppm(m) - - - - - - - - 79,993 - - - - - - - - - - - - - - - -
C3H8 Gas, ppm(m) - - - - - - - - 7,619 - - - - - - - - - - - - - - - -
Component Assay Gas (Volume Basis)
H2O Gas, ppm(v) - - - 177,092 - 177,092 177,092 177,092 - 16,000 177,092 - 1,000,000.0 1,000,000.0 1,000,000.0 1,000,000.0 - 1,000,000.0 1,000,000.0 - - - 177,092.5 1,000,000.0 1,000,000.0
N2 Gas, ppm(v) - - - 714,355 - 714,355 714,355 714,355 6,936 777,870 714,355 - - - - - - - - - - - 714,354.9 - -
O2 Gas, ppm(v) - - - 24,687 - 24,687 24,687 24,687 - 206,130 24,687 - - - - - - - - - - - 24,687.2 - -
CO2 Gas, ppm(v) - - - 83,799 - 83,799 83,799 83,799 7,209 - 83,799 - - - - - - - - - - - 83,799.3 - -
CO Gas, ppm(v) - - - 41 - 41 41 41 - - 41 - - - - - - - - - - - 41.1 - -
NO Gas, ppm(v) - - - 7.4 - 7.4 7.4 7.4 - - 7.4 - - - - - - - - - - - 7.4 - -
NO2 Gas, ppm(v) - - - 17.3 - 17.3 17.3 17.3 - - 17.3 - - - - - - - - - - - 17.3 - -
SO2 Gas, ppm(v) - - - 0.3 - 0.3 0.3 0.3 - - 0.3 - - - - - - - - - - - 0.3 - -
H2S Gas, ppm(v) - - - - - - - - 3.2 - - - - - - - - - - - - - - - -
CH4 Gas, ppm(v) - - - - - - - - 937,560 - - - - - - - - - - - - - - - -
C2H6 Gas, ppm(v) - - - - - - - - 45,347 - - - - - - - - - - - - - - - -
C3H8 Gas, ppm(v) - - - - - - - - 2,945 - - - - - - - - - - - - - - - -
# Confidential
Stream Number 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 24 25 29 32 33
Description Boile r M/U
Feed Water BFW to DA BFW to
Economizer
Exit Flue Gas
from
Economizer
BFW from
Economizer to
Boiler
FGR to
Burner
Boiler Flue
Gas
Flue Gas to
Stack Natural Gas Combustion
Air from ATM
Burner
Exhaust
Combustion
Gas
Boiler
Blowdown
Boiler Steam
Generation
110# Stm to
DA PRV
Boiler Stm to
Plant
Boiler
Blowdown
Flash Stm
Boiler
Blowdown
Liquid
Plant Steam to
Plt Demands
for Cond Rtn
Plant Steam to
Plt Demands
No Cond Rtn
Cooling Water
for Sim. Stm
Loads
Plant Cond
Rtn
Cooling Water
In for Sim. Stm
Loads
Flue Gas
Stack
Exhaust
DA Steam
Ve nt
25# Stm to DA
Mass Flow Rate, lb/hr 7,709.83 14,600.88 15,807.56 43,220.39 15,807.56 25,496.04 43,220.39 17,724.35 876.31 16,848.04 43,220.39 790.38 15,017.18 1,235.08 13,782.09 114.44 675.94 6,891.05 6,891.05 356,827.97 6,891.05 356,827.97 17,724.35 28.41 1,235.08
GPM Flow, GPM 15.40 29.43 32.73 #########34.77 ##################81.83 2,932.45 33,496.96 #########1.76 7,098.24 583.79 6,514.44 448.34 1.40 3,257.22 3,257.22 714.03 14.24 716.21 81.83 109.38 1,856.73
Pressure, PSIG 75.00 75.00 110.00 - 110.00 - - - - - - - 110.00 110.00 110.00 - - 110.00 110.00 - 110.00 - - - 25.00
Pressure, PSIA 87.59 87.59 122.59 12.59 122.59 12.59 12.59 12.59 12.59 12.59 12.59 12.59 122.59 122.59 122.59 12.59 12.59 122.59 122.59 12.59 122.59 12.59 12.59 12.59 37.59
Temperature, F 40.00 110.87 195.80 601.49 318.35 601.49 758.02 601.49 77.00 77.00 1,800.00 342.85 342.85 342.85 342.85 204.29 204.29 342.85 342.85 70.00 190.00 90.00 601.49 195.80 308.27
Viscosity, cP 1.411 0.662 0.305 - 0.249 - - - - - - 0.247 - - - - 0.281 - - 0.983 0.322 0.817 - - -
Density, lb/ft3 62.4262 61.8494 60.2063 0.0306 56.6818 0.0306 0.0267 27.0050 0.0373 0.0627 0.0144 55.8542 0.2638 0.2638 0.2638 0.0318 60.0023 0.2638 0.2638 62.3056 60.3431 62.1160 27.0050 0.0324 0.0829
Liquid Phase:
Mass Flow, lb/hr 7,709.83 14,600.88 15,807.56 - 15,807.56 - - - - - - 790.38 - - - - 675.94 - - 356,827.97 6,891.05 356,827.97 - - -
Mass Density, lb/ft3 62.43 61.85 60.21 - 56.68 - - - - - - 55.85 - - - - 60.00 - - 62.31 60.34 62.12 - - -
Specific Gravity, SG 1.00 0.99 0.96 - 0.91 - - - - - - 0.89 - - - - 0.96 - - 1.00 0.97 0.99 - - -
Actual Volume Flow, USGPM 15.40 29.43 32.73 - 34.77 - - - - - - 1.76 - - - - 1.40 - - 714.03 14.24 716.21 - - -
Elemental Assay Liquid
Cation
B aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Ca aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
K aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Li aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Mg aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Na aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Si aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Anion
CO3 aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Cl aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
HCO3 aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
OH aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
SO4 aq, ppm 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Component Assay Liquid
H2O aq, ppm 1,000,000 1,000,000 1,000,000 - 1,000,000 - - - - - - 1,000,000 - - - - 1,000,000 - - 1,000,000 1,000,000 1,000,000 - - -
CaCl2 aq. ppm - - - - - - - - - - - - - - - - - - - - - - - - -
CaCO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Ca(OH)2 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
CaSO4 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
MgCl2 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
MgSO4 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
NaCl aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Na2CO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
NaHCO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
NaOH aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Na2SO4 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Na2SiO3 aq, ppm - - - - - - - - - - - - - - - - - - - - - - - - -
Gas Phase:
Mass Flow, lb/hr - - - 43,220.39 - 25,496.04 43,220.39 17,724.35 876.31 16,848.04 43,220.39 - 15,017.18 1,235.08 13,782.09 114.44 - 6,891.05 6,891.05 - - - 17,724.35 28.41 1,235.08
Mass Density, lb/ft3 - - - 0.03 - 0.03 0.03 27.00 0.04 0.06 0.01 - 0.26 0.26 0.26 0.03 - 0.26 0.26 - - - 27.00 0.03 0.08
Actual Gas Flow, ACFM - - - 23,545.24 - 13,889.52 27,019.31 10.94 392.01 4,477.89 50,141.44 - 948.90 78.04 870.85 59.93 - 435.43 435.43 - - - 10.94 14.62 248.21
Standard Gas Flow, SCFM - - - 10,197.98 - 6,015.87 10,197.98 4,182.11 335.77 3,837.69 10,197.98 - 5,444.63 447.79 4,996.84 41.49 - 2,498.42 2,498.42 - - - 4,182.11 10.30 447.79
Component Assay Gas (Mass Basis)
H2O Gas, ppm(m) - - - 115,257 - 115,257 115,257 115,257 - 10,052 115,257 - 1,000,000 1,000,000 1,000,000 1,000,000 - 1,000,000 1,000,000 - - - 115,257 1,000,000 1,000,000
N2 Gas, ppm(m) - - - 722,912 - 722,912 722,912 722,912 11,398 759,924 722,912 - - - - - - - - - - - 722,912 - -
O2 Gas, ppm(m) - - - 28,537 - 28,537 28,537 28,537 - 230,024 28,537 - - - - - - - - - - - 28,537 - -
CO2 Gas, ppm(m) - - - 133,248 - 133,248 133,248 133,248 18,613 - 133,248 - - - - - - - - - - - 133,248 - -
CO Gas, ppm(m) - - - 33 - 33 33 33 - - 33 - - - - - - - - - - - 33 - -
NO Gas, ppm(m) - - - - - - - - - - - - - - - - - - - - - - - - -
NO2 Gas, ppm(m) - - - 12.3 - 12.3 12.3 12.3 - - 12.3 - - - - - - - - - - - 12 - -
SO2 Gas, ppm(m) - - - 0.6 - 0.6 0.6 0.6 - - 0.6 - - - - - - - - - - - 1 - -
H2S Gas, ppm(m) - - - - - - - - 6 - - - - - - - - - - - - - - - -
CH4 Gas, ppm(m) - - - - - - - - 882,372 - - - - - - - - - - - - - - - -
C2H6 Gas, ppm(m) - - - - - - - - 79,993 - - - - - - - - - - - - - - - -
C3H8 Gas, ppm(m) - - - - - - - - 7,619 - - - - - - - - - - - - - - - -
Component Assay Gas (Volume Basis)
H2O Gas, ppm(v) - - - 177,101 - 177,101 177,101 177,101 - 16,000 177,101 - 1,000,000.0 1,000,000.0 1,000,000.0 1,000,000.0 - 1,000,000.0 1,000,000.0 - - - 177,100.9 1,000,000.0 1,000,000.0
N2 Gas, ppm(v) - - - 714,360 - 714,360 714,360 714,360 6,936 777,870 714,360 - - - - - - - - - - - 714,359.5 - -
O2 Gas, ppm(v) - - - 24,687 - 24,687 24,687 24,687 - 206,130 24,687 - - - - - - - - - - - 24,687.0 - -
CO2 Gas, ppm(v) - - - 83,812 - 83,812 83,812 83,812 7,209 - 83,812 - - - - - - - - - - - 83,812.0 - -
CO Gas, ppm(v) - - - 33 - 33 33 33 - - 33 - - - - - - - - - - - 32.9 - -
NO Gas, ppm(v) - - - - - - - - - - - - - - - - - - - - - - - - -
NO2 Gas, ppm(v) - - - 7.4 - 7.4 7.4 7.4 - - 7.4 - - - - - - - - - - - 7.4 - -
SO2 Gas, ppm(v) - - - 0.3 - 0.3 0.3 0.3 - - 0.3 - - - - - - - - - - - 0.3 - -
H2S Gas, ppm(v) - - - - - - - - 3.2 - - - - - - - - - - - - - - - -
CH4 Gas, ppm(v) - - - - - - - - 937,560 - - - - - - - - - - - - - - - -
C2H6 Gas, ppm(v) - - - - - - - - 45,347 - - - - - - - - - - - - - - - -
C3H8 Gas, ppm(v) - - - - - - - - 2,945 - - - - - - - - - - - - - - - -
# Confidential
100:WZ Boiler Base Case
TNK
DA
DEA
SUB
Orginal Burner
BRN FTB
STB
FLA
PRV 110#->25#
SUB
SUB
SPS
Plant Steam Loads
HTX-Cond Rtn
FLU
1
2
4
7
8
9
10
11
12
13
14
15
16
17
18
20
21
22
24
25
29
32 33
Stream Number
B
N
D
C
A
N
C
S
C
23
4
5
6
7
8
9
10
11
12
% FGR
Boiler Stm Flow #/Hr
Heat Rate Btu/Hr
CO2 lbs/10^6 SCF
SO2 lbs/10^6 SCF
CO lbs/10^6 SCF
NOx lbs/10^6 SCF
0
15036.628
20925000
117142.5
0.5233
83.6949
99.5744
NO
NO2
CO
Boiler Eff
W.Avg Comb Gas Cp
Avg ACFM Comb Gas Flow
NOx lbs/1E6 SCF
CO lbs/1E6 SCF
SO2 lbs/1E6 SCF
CO2 lbs/1E6 SCF
100:WZ Boiler FGR Low NOx w/ Economizer Case
TNK
DA
DEA Economizer
HTX
SUB
FGR Low NOx Burner
BRN FTB
STB
FLA
PRV 110#->25#
SUB
SUB
SPS
Plant Steam Loads
HTX-Cond Rtn
FLU
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
21
22
24
25
29
32 33
Stream Number
B
N
D
C
A
N
C
S
C %
23
4
5
6
7
8
9
10
11
12
13
% FGR
Boiler Stm Flow #/Hr
Heat Rate Btu/Hr
CO2 lbs/10^6 SCF
SO2 lbs/10^6 SCF
CO lbs/10^6 SCF
NOx lbs/10^6 SCF
46.3446
15653.147
20925000
117216.45
0.5233
36.6302
32.3315
NO
NO2
CO
Boiler Eff
W.Avg Comb Gas Cp
Avg ACFM Comb Gas Flow
NOx lbs/1E6 SCF
CO lbs/1E6 SCF
CO2 lbs/1E6 SCF
Min 75 psig Feed Pressure, Max Out Temp=159.08 C
SO2 lbs/1E6 SCF
100:WZ Boiler ULNOx w/ FGR w/ Economizer Case
TNK
DA
DEA Economizer
HTX
SUB
ULNOx w/ FGR Burner
BRN FTB
STB
FLA
PRV 110#->25#
SUB
SUB
SPS
Plant Steam Loads
HTX-Cond Rtn
FLU
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
21
22
24
25
29
32 33
Stream Number
B
N
D
C
A
N
C
S
C %
23
4
5
6
7
8
9
10
11
12
13
% FGR
Boiler Stm Flow #/Hr
Heat Rate Btu/Hr
CO2 lbs/10^6 SCF
SO2 lbs/10^6 SCF
CO lbs/10^6 SCF
NOx lbs/10^6 SCF
58.9908
15017.179
20925000
117227.96
0.5233
29.3023
10.8286
NO
NO2
CO
Boiler Eff
W.Avg Comb Gas Cp
Avg ACFM Comb Gas Flow
NOx lbs/1E6 SCF
CO lbs/1E6 SCF
CO2 lbs/1E6 SCF
Min 75 psig Feed Pressure, Max Out Temp=159.08 C
SO2 lbs/1E6 SCF
DOC Quote
To:
CC:
From:Phone:
Fax:
Email:
Trisha Victor
Ramboll
4350 North Fairfax Drive, Suite 300
Arlington, VA 22203
Debora Schaberg/MIRATECH
Stewart Matson
MIRATECH
420 S 145th E Ave, Mail Drop A
Tulsa, OK 74108
918-933-6241
918-933-6245
[e-mail]
RACT DOC
SDM-24-000104
1/5/2024
Project Reference:
Proposal Number:
Date:
Prices will be confirmed at time of order
Dear Trisha:
MIRATECH welcomes the opportunity to provide you with a proposal for an NSCR system. We are confident that your organization will benefit from
selecting us for this project for the following reasons:
Experience.
• MIRATECH is the leader in providing Oxidation and Three Way Catalyst, SCR & DPF systems; having more than 24,000 successfully
operating units installed in North America, South America, Europe and Asia.
World-Class Technology.
• Consistently set the standards for Best Available Control Technology (BACT)
• Simple, user-friendly control and communication technology; connects to any building’s communication systems
U.S. & European Field Services & Support.
• Fast-response field service & technical support
• Replacement components in stock in Tulsa, OK & Sinntal, Germany
• In-house engineering & product support
The system offered for this project is in accordance with the engine and technical data received or estimated from your company and is designed to
provide emission reduction for carbon monoxide (CO), and hydrocarbons (NMNEHC) as listed on the Application & Performance Warranty Data page.
MIRATECH warrants the quoted performance based on the engine emission and operating data you have provided us and that is contained in this
proposal. Please note that some engine assumptions might be used and converter size may change based on actual engine data.
Again, thank you for the opportunity to provide this proposal. We are confident that our products will meet your technical needs and provide the best
solution for your investment. If you have any questions, please do not hesitate to contact me. I will call you next week to confirm your receipt and
satisfaction with this proposal.
Best Regards,
Stewart Matson
Eastern Regional Sales Manager
MIRATECH
CONFIDENTIAL Proposal Date: 1/5/2024
Oxidation Base System Content
QTY Price Extended Price
Oxidation Housing & Catalyst –IQ2-18-08 4
IQ, Catalyst-Only Housing with Removable Catalyst(s), Carbon Steel
Nut, Bolt, and Gasket Set –NBG-IQ18-1 4
IQ, Single Layer, Nut, Bolt, and Gasket Set
Catalyst Housing –IQ2-18-08-HSG-0 4
Oxidation Catalyst –APX3-OX-RB1894-1675-0000-291 4
IQ, 3 Year Warranty, Oxidation, Replacement Element
Oxidation Base System Price 4 $ 7,230.00 USD $ 28,920.00 USD
Oxidation Base System Content
QTY Price Extended Price
Oxidation Housing & Catalyst –RCS2-2218-08 4
RCS, Critical Grade Silencer / Catalyst Combination Housing with Removable Catalyst(s), Carbon Steel, End Inlet / End Outlet
Nut, Bolt, and Gasket Set –NBG-IQ18-1 4
IQ, Single Layer, Nut, Bolt, and Gasket Set
Catalyst Housing –RCS2-2218-08-HSG-0 4
Oxidation Catalyst –APX3-OX-RB1894-1675-0000-291 4
IQ, 3 Year Warranty, Oxidation, Replacement Element
Oxidation Base System Price 4 $ 12,400.00 USD $ 49,600.00 USD
Payment Terms
Invoice on shipment, payment net 30 days (subject to account status)
Shipment
All equipment is Ex Works Tulsa, OK
Terms & Conditions
This offer is in strict adherence to the General Terms and Conditions of Sale, located on our website:https://www.miratechcorp.com/terms-conditions
• Quotes are subject to upward adjustment for increases in steel pricing in accordance with the most recent American Metals Market
(www.amm.com) index for Hot Rolled steel or applicable successor index.
• All pricing will be confirmed at time of order, effective for product shipments within 60 days of order date. All shipments scheduled by customer
later than 60 days from order entry may be subject to price adjustment.
• Due to the current volatility of stainless steel costs, Pricing in Effect at the time of order (if released for production) or at release for production
will be applied. Current pricing will be provided at time of order entry or release for production.
• Products are manufactured specifically for your order, as such we are unable to accept returns for reasons other than warranty purposes.
Proposal Number: SDM-24-000104
CONFIDENTIAL Proposal Date: 1/5/2024
Site Location:
Project Name:
Application:
Number Of Engines:
Operating Hours per Year:
Engine Manufacturer:
Model Number:
Rated Speed:
Type of Fuel:
Type of Lube Oil:
Number of Exhaust Manifolds:
Application & Performance Warranty Data
Project Information
USA
RACT DOC
Standby Power
4
100
Engine Specifications
Volvo
TAD 1641
1800 RPM
Ultra-Low Sulfur Diesel (ULSD)
0 sulfated ash or less
1
Engine Cycle Data
Load Speed Power Exhaust
Flow
Exhaust
Temp.Fuel Cons. CO NMNEHC CH2O O2 H2O
%kW acfm (cfm) ° F g/bhp-hr g/bhp-hr g/bhp-hr % %
100 Rated 564 3,899 893 0.26 0.1 0.1 10 12.5
Emission Data (100% Load)
Emission
Raw Engine Emissions Target Outlet Emissions
Calculated
Reductiong/bhp-
hr
tons/yr ppmvd
@ 15%
O2
ppmvd g/kW-hr lb/MW-
hr
g/bhp-
hr
tons/yr ppmvd
@ 15%
O2
ppmvd g/kW-hr lb/MW-
hr
CO 0.26 0.02 40 75 0.349 0.77 0.05 0 8 15 0.07 0.15 80%
NMNEHC* 0.1 0.01 27 50 0.134 0.3 0.04 0 11 20 0.054 0.12 60%
CH2O 0.1 0.01 15 27 0.134 0.3 0.04 0 6 11 0.054 0.12 60%
* MW referenced as CH4. Propane in the exhaust shall not exceed 15% by volume of the NMHC compounds in the exhaust, excluding aldehydes. The 15% (vol.) shall be
established on a wet basis, reported on a methane molecular weight basis. The measurement of exhaust NMHC composition shall be based upon EPA method 320 (FTIR), and
shall exclude formaldehyde.
Proposal Number: SDM-24-000104
CONFIDENTIAL Proposal Date: 1/5/2024
Housing Model Number:
Element Model Number:
Number of Catalyst Layers:
Number of Spare Catalyst Layers:
Design Exhaust Flow Rate:
Design Exhaust Temperature1:
Exhaust Temperature Limits*:
System Pressure Loss:
Housing Model Number:
Element Model Number:
Number of Catalyst Layers:
Number of Spare Catalyst Layers:
Sound Attenuation:
Design Exhaust Flow Rate:
Design Exhaust Temperature1:
Exhaust Temperature Limits**:
System Pressure Loss:
System Specifications
Oxidation System Specifications (IQ2-18-08)
IQ2-18-08-HSG-0
APX3-OX-RB1894-1675-0000-291
1
1
3,899 acfm (cfm)
893° F
550° F – 1250° F (catalyst inlet); 1350° F (catalyst outlet)
5.0 inH2O (Clean)
Oxidation System Specifications (RCS2-2218-08)
RCS2-2218-08-HSG-0
APX3-OX-RB1894-1675-0000-291
1
1
25-30 dBA insertion loss
3,899 acfm (cfm)
893° F
550° F – 1250° F (catalyst inlet); 1350° F (catalyst outlet)
6.0 inH2O (Clean)
* General catalyst temperature operating range. Performance is based on the Design Exhaust Temperature.
** General catalyst temperature operating range. Performance is based on the Design Exhaust Temperature.
Proposal Number: SDM-24-000104
CONFIDENTIAL Proposal Date: 1/5/2024
MIRATECH Scope of Supply & Equipment Details
Model Number Quantity
Oxidation Housing & Catalyst IQ2-18-08 1 / engine
Catalyst Housing IQ2-18-08-HSG-0 1 / engine
• Material Carbon Steel
• Paint Standard High Temperature Black Paint
• Instrumentation Ports 2 inlet/2 outlet (1/2" NPT)
• Oxygen Sensor Ports 1 inlet/1 outlet (18mm)
• Approximate Diameter 16 in
• Inlet Pipe Size & Connection 8 in FF Flange, 150# ANSI standard bolt pattern
• Outlet Pipe Size & Connection 8 in FF Flange, 150# ANSI standard bolt pattern
• Overall Length 34 in
• Weight Without Catalyst 135 lbs
Oxidation Catalyst APX3-OX-RB1894-1675-0000-291 1 / engine
Nut, Bolt, and Gasket Set NBG-IQ18-1 1 / engine
Oxidation Housing & Catalyst RCS2-2218-08 1 / engine
Catalyst Housing RCS2-2218-08-HSG-0 1 / engine
• Material Carbon Steel
• Paint Standard High Temperature Black Paint
• Inlet Location End
• Outlet Location End
• Instrumentation Ports 1 inlet/1 outlet/2 catalyst (1/2" NPT)
• Oxygen Sensor Ports 1 inlet/1 outlet (18mm)
• Approximate Diameter 16 in Catalyst Shell / 22 in Silencer Shell
• Inlet Pipe Size & Connection 8 in FF Flange, 150# ANSI standard bolt pattern
• Outlet Pipe Size & Connection 8 in FF Flange, 150# ANSI standard bolt pattern
• Overall Length 76 in
• Weight Without Catalyst 319 lbs
Oxidation Catalyst APX3-OX-RB1894-1675-0000-291 1 / engine
Nut, Bolt, and Gasket Set NBG-IQ18-1 1 / engine
Customer Scope Of Supply
• Support Structure
• Attachment to Support Structure (Bolts, Nuts, Levels, etc.)
• Expansion Joints
• Exhaust Piping
• Inlet Pipe Bolts, Nuts, & Gasket
• Outlet Pipe Bolts, Nuts, & Gasket
Proposal Number: SDM-24-000104
CONFIDENTIAL Proposal Date: 1/5/2024
Special Notes & Conditions
• A packed silencer installed upstream of the MIRATECH catalyst system will void MIRATECH's limited warranty.
• Final catalyst housings are dependent on engine output and required emission reductions. Changes may be made to optimize the system
design at the time of order.
• Any drawings included with this proposal are preliminary in nature and could change depending on final product selection.
• Any sound attenuation listed in this proposal is based on housing with catalyst elements installed.
• Any emission reductions listed in this proposal are based on housing with catalyst elements installed.
• MIRATECH will confirm shipping location upon placement of order.
1.For housings and exhaust components that are insulated, internally or externally, please refer to the General Terms and Conditions of Sale to
prevent voiding MIRATECH product warranty.
Carbon steel is suitable for temperatures up to 900° F / 482° C continuously, when covered with external insulation or a heat shield. For
continuous operation above 900° F / 482° C, where the equipment is externally insulated or has a heat shield, stainless steel should be used.
Proposal Number: SDM-24-000104
CONFIDENTIAL Proposal Date: 1/5/2024
21.438
19.938
30.00°
16.500 O.D.
17.376 O.D.
FRONT VIEW
(2) 8" FF FLANGE150 lb ANSISTANDARDBOLT PATTERN
7.125 13.438
EXHAUST OUTLETEXHAUST INLET
(4) 1/2" NPTSAMPLE PORTS
(2) LIFTING LUGS
CATALYSTACCESS
RIGHT VIEW
34.000
13.500 O.D.
TYP
8.625 I.D.
TYP
(2) 18 mm FTGOXYGEN SENSORPORTSLEFT VIEW
MATERIAL CONSTRUCTION:
-CARBON STEEL
SCALE 1:16SIZE
DRAWING
A
REV
DO NOT SCALE DRAWING
DRAWN
SHEET 1 OF 1WEIGHT: 175 lb FULLY LOADED
PROPRIETARY AND CONFIDENTIAL
IQ2-18-08 SD 0
IQ2-18-08Sales Drawing
AJM
12/15/2011
DATE
THE INFORMATION CONTAINED IN
THIS DRAWING IS THE SOLE PROPERTY
OF MIRATECH CORPORATION. ANY
REPRODUCTION IN PART OR AS A
WHOLE WITHOUT THE WRITTEN
PERMISSION OF MIRATECH
CORPORATION IS PROHIBITED.
DIMENSIONS ARE
APPROXIMATE IN INCHES
UNLESS OTHERWISE SPECIFIED
SALES ORDER NO.
CUSTOMER P.O.
PROJECT NAME
DATEREVIEWED BY
CDT
12/16/2011
PROPOSAL NUMBER
CO
N
F
I
D
E
N
T
I
A
L
Pr
o
p
o
s
a
l

D
a
t
e
:

1
/
5
/
2
0
2
4
Pa
g
e

7

o
f

8
EXHAUST INLET
19.938
24.037
30°
17.376 O.D.
FRONT VIEW
(2) 8" FF FLANGE150 lb ANSISTANDARDBOLT PATTERN
21.000 22.000
SHELL I.D.
16.500
O.D.
7.125 13.438
EXHAUST OUTLET
RIGHT VIEW
(2) LIFTINGLUG
CATALYSTACCESS
(4) SAMPLE PORT1/2" NPT
76.000
13.500 O.D.
TYP
8.625 I.D.
TYP
LEFT VIEW
OXYGENSENSOR PORT18mm FTG
OXYGENSENSOR PORT18mm FTG
DRAIN PLUG
MATERIAL CONSTRUCTION:
- CARBON STEEL
SCALE 1:16SIZE
DRAWING
A
REV
DO NOT SCALE DRAWING
DRAWN
SHEET 1 OF 1WEIGHT: 359 lb
PROPRIETARY AND CONFIDENTIAL
RCS2-2218-08 SD 0
RCS2-2218-08Sales Drawing
AJM
12/20/2011
DATE
THE INFORMATION CONTAINED IN
THIS DRAWING IS THE SOLE PROPERTY
OF MIRATECH CORPORATION. ANY
REPRODUCTION IN PART OR AS A
WHOLE WITHOUT THE WRITTEN
PERMISSION OF MIRATECH
CORPORATION IS PROHIBITED.
DIMENSIONS ARE
APPROXIMATE IN INCHES
UNLESS OTHERWISE SPECIFIED
SALES ORDER NO.
CUSTOMER P.O.
PROJECT NAME
DATEREVIEWED BY
CDT
12/21/2011
PROPOSAL NUMBER
CO
N
F
I
D
E
N
T
I
A
L
Pr
o
p
o
s
a
l

D
a
t
e
:

1
/
5
/
2
0
2
4
Pa
g
e

8

o
f

8