ipc ww opcosts presentation

8/3/2019 IPC WW OpCosts Presentation

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Determining and Estimating WastewaterTreatment Operating Costs

Identify your daily, weekly, monthly or annualgeneration of wastewater by several methods:

1. Measurements from instruments, e.g., flow meters,

identifying a flow rate, usually gallons-per-minute(GPM)

2. Identifying and itemizing [potable] water supply, forindustrial uses, from your local utility’s billing

statements

3. Best estimate from historical operations and / orcombination of 1 and 2 above



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Identify your waste treatment operating costs:

1. Acid, caustic, sulfide, magox, etc. Any and allmaterials or chemicals used solely in waste

treatment need to be accounted and itemized.2. Additionally, itemize associated costs such as

hazardous waste disposal, laboratory analysis,equipment repair, parts, filters, miscellaneous

supplies, etc.

3. Estimate, if possible, electricity consumption, inKw/Hr., of your waste treatment equipment to derivea $/KwHr. cost



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Benefits:

1. Derivation of a unit cost, ideally in $/gallon,representative of your wastewater treatmentoperations and a representative daily flow or

discharge of wastewater, in gallons/day.

2. Establishing a unit cost baseline that can becompared to existing wastewater dischargestandards as a measure of performance /

compliance.3. An accurate representation of your existing

wastewater treatment costs that will enablerefining and optimizing of your systems

performance.



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Cost Itemization

Using a spreadsheet program, such as Excel,Lotus Notes, etc., will enable you to itemizeand calculate operating cost data. In the

following example, calendar year 2000 hasbeen itemized by certain categories toidentify and generate a $/gallon cost as wellas estimated gallons/day discharged. This

data will be subsequently used to estimateoperating costs for MP&M compliance.



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Examples of cost itemization:

Operating Costs (CY 2000) Jan Feb Mar Apr Ma

Supplies $908 $1,567 $1,416 $1,723 $99

Safety Supplies $2,297 $1,689 $1,727 $1,116 $2,78

Lab Analysis $100 $95 $250 $75 $50

Chemicals (WT) $18,987 $22,286 $21,851 $20,645 $20,4

Haz Waste Disposal $1,620 $4,376 $1,935 $2,453 $98

Total Costs $23,912 $30,013 $27,179 $26,012 $25,2

Wastewater

Gallons 1,815,780 1,755,254 2,133,296 2,202,112 2,024,

Gallons/Day 64,849 70,210 76,189 78,647 77,86

Cost ($ / Gal.) $0.0132 $0.0171 $0.0127 $0.0118 $0.01

Here you can see how monthly operating costs have beenitemized along with wastewater information, including gallonsper day. Monthly totals were obtained from daily flowmetermeasurements and multiplied by the days worked. If flowmeters are unavailable, estimates from [industrial] water billingscan be used as an estimate. To obtain gallons per day frommonthly totals, simply divide the monthly wastewater total by

the number of days worked in the month.



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Examples of cost itemization:

Once you obtain the total monthly operating costs andthe monthly wastewater gallons, divide the total monthly

dollar cost by the monthly gallons to obtain a $/galloncost. In the example above for January, $23,912 dividedby 1,815,780 gallons equals a unit cost of $0.0132 /gallon.

Operating Costs (CY 2000) Jan Feb Mar Apr Ma

Supplies $908 $1,567 $1,416 $1,723 $99

Safety Supplies $2,297 $1,689 $1,727 $1,116 $2,7

Lab Analysis $100 $95 $250 $75 $5

Chemicals (WT) $18,987 $22,286 $21,851 $20,645 $20,4

Haz Waste Disposal $1,620 $4,376 $1,935 $2,453 $98

Total Costs $23,912 $30,013 $27,179 $26,012 $25,2

Wastewater

Gallons 1,815,780 1,755,254 2,133,296 2,202,112 2,024,Gallons/Day 64,849 70,210 76,189 78,647 77,8

Cost ($ / Gal.) $0.0132 $0.0171 $0.0127 $0.0118 $0.01



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Additional costs itemization and cost assumptions:

Costs of MF Unit ($400,000) for Additional Wastewater Treatment (40% of existing wastewat

Ammortization $7,273 $7,273 $7,273 $7,273 $7,273

Gallons [estimate] 726,312 702,102 853,318 880,845 809,784

Operating Cost $14,526 $14,042 $17,066 $17,617 $16,196

(~$0.020 / Gallon)

For purposes of estimating operating costs increases due to the MP&Mrule, on the assumption of recycling wastewater (instead of treatment & discharge), careful identification of wastewater streams for recycling is

paramount. For example, developer and stripper rinses are idealcandidates for recycling in that they are dilute and contain virtually nocopper or other metal constituents.

In the example above, capital costs of the additional microfiltration (MF)treatment / recycling system for developer and stripper rinses have beenidentified and ammortized over 60 months. This equates to a monthly

cost of $7273, which will be later applied to the overall operating costs. Additionally, monthly flow or volume of wastewater to be treated needsto be identified and added to the monthly ammortization costs for a[sub]total cost for this application. In this case 40% of the monthlytotal wastewater flow has been estimated and applied to this situation.The corresponding operating costs will later be added to the overall

operating costs to determine the incremental cost of treatment.



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In this additional example, batch treatment costs need to be

revised to reflect the incremental increase in chemicals andmaterials in response to the proposed MP&M rule. Again,itemize those elements that are critical and in support of thebatch treatment process. Depending on the historicalperformance of your individual batch treatment system,

estimate the increase in material costs to be applied.

Incremental Costs Estimate for WT Process & Chemicals (25% of existing wastewater)

Lab Analysis $500 $500 $500 $500 $500 $

Chemicals $23,734 $27,858 $27,314 $25,806 $25,523 $2

HazWaste Disposal $2,025 $5,470 $2,419 $3,066 $1,234 $2Wastewater 1,089,468 1,053,152 1,279,978 1,321,267 1,214,677 1,2

Total $26,259 $33,828 $30,233 $29,373 $27,256 $2

Additional costs itemization and cost assumptions:



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For example, a 25% cost increase has been estimated for the batch treatmentchemicals and materials. Consequently, we have taken the operating costsand applied a 1.25 factor in order to derive the estimated cost increases. Inorder to accurately account for wastewater, we have subtracted the amount

recycled from developer and stripper rinses with the resulting number beingthe anticipated amounts for batch treatment as a result of the MP&M rule.

The total monthly incremental costs are derived by subtracting theestimated monthly costs, as stated above, from the original monthlyoperating costs. This incremental cost reflects additional batch treatment inorder to comply with the proposed MP&M rule. Diving this incremental costby the volume of wastewater to be treated yields the unit cost ($/gallon) for

this application.

Incremental Costs Estimate for WT Process & Chemicals (25% of existing wastewater)

Lab Analysis $500 $500 $500 $500 $500 $500

Chemicals $23,734 $27,858 $27,314 $25,806 $25,523 $26,4

HazWaste Disposal $2,025 $5,470 $2,419 $3,066 $1,234 $2,77

Wastewater 1,089,468 1,053,152 1,279,978 1,321,267 1,214,677 1,256,5

Total $26,259 $33,828 $30,233 $29,373 $27,256 $29,71

Incremental Cost $2,347 $3,815 $3,054 $3,361 $2,031 $2,52

New Total Cost $26,259 $33,828 $30,233 $29,373 $27,256 $29,71

Incremental Cost ($ / Ga $0.0060 $0.0080 $0.0059 $0.0056 $0.0056 $0.00

Total Cost ($ / Gal.) $0.0392 $0.0451 $0.0386 $0.0374 $0.0381 $0.03



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Summary:

All these $/gallon numbers we have derived for the variouscomponents and assumptions from wastewater treatment operationswill be summed to represent the total operating costs in $/gallon.

Current Treatment Cost / Gallon $0.0160

Increased Cost / Gal. of MF Unit $0.0200

Incremental Treatment Costs ($ / Gal.) $0.0074

New Treatment Cost / Gallon $0.0434

As you can see, we have itemized and summed the originaloperating costs, op costs for the MF unit and incrementaltreatment costs, all in $/gallon, to derive an estimated

treatment cost in response to the proposed MP&M rule.



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Annual Volume of Wastewater 12,656,401

New treatment cost / gallon applied $0.0434

Estimated Operating Costs $549,530

MF Unit Ammortization (60 months) $87,273

Current Annual Operating Costs $314,159

Annual Treatment Costs Increase2 $322,644

Estimated Annual Treatment Costs1 $636,803

Conclusion:

This is the “nitty-gritty” of this exercise. We now have the necessary information

to estimate what the cost of compliance will be for MP&M. The remaining annualvolume of wastewater represents the amount of wastewater requiring treatmentmutiplied by the unit cost and adding the annual costs for the MF unit yields theannual operating costs.

Comparing this number and subtracting it from the original operating costs willderive the incremental cost of compliance for MP&M. You can see that our costs

estimates for MP&M compliance more than double the original or existingoperating costs. This type of information is critical in that the EPA needs tounderstand and accept the financial impact this rule will have on the PCBindustry. We urge you to develop your operating costs estimates in a similarfashion, with emphasis on operating costs, i.e., financial impact, for MP&Mcompliance. Include this information with your formal comments to EPA – they

will be MUCH MORE POWERFUL!



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When and Where To Send Written Comments

EPA must receive comments on the proposal by May 3, 2001. Submit written

comments to:

By mail-

Mr. Michael Ebner,

Office of Water, Engineering and Analysis Division (4303)

U.S. EPA1200 Pennsylvania Ave., NW

Washington, DC 20460

By hand delivery (includes FedEx and UPS)-

Mr. Michael Ebner

U.S. EPA

401 M St., SW, Room 611 West Tower

Washington, DC 20460



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By email-

E-mail to [email protected]

Electronic comments must be identified by the docket number W-

99-23 and must be submitted as an ASCII, or WordPerfect 5/6/7/8/9

or Microsoft Word 97 file avoiding the use of special characters and

any form of encryption. EPA also will accept comments and data ondisks in Word Perfect 5/6/7/8/9, Microsoft Word 97 or ASCII file

format. Electronic comments on this notice may be filed online at

some Federal Depository Libraries.

Please submit any references cited in your comments. EPA requestsan original and three copies of your comments and enclosures

(including references). Commenter who want EPA to acknowledge

receipt of their comments should enclose a self- addressed, stamped

envelope. No facsimiles (faxes) will be accepted.

…Thank You!

mailto:[email protected]

mailto:[email protected]

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