SCR Capital Costs

Description Formula1Value

Boiler Size (MMBtu/hr) QB 1941

NOx Removal Efficiency (%) ηNOx 75.0%

Cost Year 2010

Total Direct Capital Costs ($)2

A $30,507,713

Indirect Installation Costs

 General Facilities ($) 0.05 x A $1,525,386

 Engineering and Home Office Fees ($) 0.10 x A $3,050,771

 Process Contingency ($) 0.05 x A $1,525,386

Total Indirect Installation Costs ($) B = A × (0.05 + 0.10 + 0.05) $6,101,543

Project Contingency ($) C = (A + B)× 0.15 $5,491,388

Total Plant Costs ($) D = A + B+ C $42,100,644

Allowance for Funds During Construction ($) E = 0 (Assumed for SCR) $0

Royalty Allowance ($) F = 0 (Assumed for SCR) $0

Preproduction Cost ($) G = 0.02 × (D + E) $842,013

Inventory Capital* ($) H = Vol reagent (gal) × Cost reagent ($/gal) $15,732

Initial Catalyst and Chemicals ($) I = 0 (Assumed for SCR) $0

Total Capital Investment (TCI) ($) TCI = D + E + F + G + H + I $42,958,390

Total Capital Investment (TCI) ($) Per kW $265

SCR Annual Costs

Direct Annnual Costs

 Maintenance Cost Eq. 2.46 $644,376

 Reagent Cost Eq. 2.47 $284,717

 Electricity Cost Eq. 2.49 $175,671

 Catalyst Cost Eq. 2.50 $121,450

Total Direct Annual Costs DAC (Eq. 2.45) $1,226,214

Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $4,055,272

Total Annual Costs TAC = DAC + IAC (Eq. 2.56) $5,281,486

SOFA Captial Costs

Total Captial Investment for SOFA ($)3

TCI $3,350,365

Total Capital Investment for SOFA ($/kW) Per kW $21

SOFA Annual Costs

Total Direct Annual Costs4

DAC $315,754

Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $330,375

Total Annual Costs TAC = DAC + IAC (Eq. 2.56) $646,129

Cost Effectivness

SOFA NOx Removed (tons/yr) Eq. 2.57 435

SOFA Cost Effectiveness ($/ton removed) Eq. 2.58 $1,487

SCR NOx Removed (tons/yr) Eq. 2.57 885

SCR Cost Effectiveness ($/ton removed) Eq. 2.58 $5,966

SCR+SOFA NOx Removed (tons/yr) Eq. 2.57 1,320

SCR+SOFA Cost Effectiveness ($/ton removed) Eq. 2.58 $4,491

1

Taken from "EPA Control Cost Manual", Section 4.2, Chapter 2, October 2000.

Corette BART Cost Analysis - SCR+SOFA

2Direct capital costs for SCR were derived from "IPM Model – Revisions to Cost and Performance for APC Technologies SCR 

Cost Development Methodology," Sargent & Lundy, August 2010.

3,4Direct capital costs and direct annual costs for SOFA were taken from "Addendum to PPL Montana's J.E. Corette 

Generating Station BART Report," TRC for PPL, June 2008. Direct capital costs were escalated to 2010 using the CEPCI.

(2010 Dollars)
Corette SCR Capital Cost Estimate Worksheet

Variable Designation Units Value Calculation

Unit Size (Gross) A (MW) 162 InputRetrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Heat Rate C (Btu/kWh) 11982 InputNOx Rate D (lb/MMBtu) 0.2 InputSO2 Rate E (lb/MMBtu) 0.6 InputType of Coal F PRB InputCoal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07

Heat Rate Factor H 1.1982 C/10000Heat Input I (Btu/hr) 1.94E+09 A*C*1000Capacity Factor J (%) 69.4 InputNOx Removal Efficiency K (%) 75.0 Input

NOx Removal Factor L 0.9375 K/80NOx Removed M (lb/hr) 291 D*I/106*K/100

Costs are all based on 2009 dollarsCapital Cost Calculation Include: equipment, installation, buildings, foundations, electrical, and retrofit difficulty. BMR ($) = 180000*(B)*(L)0.2*(A*G*H)0.92 $23,668,000 SCR (inlet ductwork, reactor, bypass) island cost

 BMF ($) = 410000*(M)0.25 $1,694,000 Base reagent preparation cost

 BMA ($) = If E >= 3 then 65000*(B)*(A*G*H)0.78; else 0 $0 Air heater modification / SO3 control (bituminous only & > 3 lb/MMbtu)

 BMB ($) = 380000*(B)*(A*G*H)0.42 $3,545,000 ID or booster fans & auxiliary power modification costs

 BM ($) = BMR + BMF + BMA + BMB $28,907,000 Total bare module cost including retrofit factor

 BM ($/kW) $178 Base cost per kWTotal Project Cost A1 = 10% of BM $2,891,000 Engineering and construction management costs

 A2 = 10% of BM $2,891,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $2,891,000 Contractor profit and fees CECC($) = BM+A1+A2+A3 $37,580,000 Capital, engineering and construction cost subtotal

 CECC($/kW) = $232 Capital, engineering and construction cost subtotal per kW

 B1 = 5% of CECC $1,879,000 Owners costs including "home office" costs (owners engineering, manageme

 B2 = 6% of (CECC + B1) $2,368,000 AFUDC (based on approximately 3% per year for a 2 year engineering and co

 TPC ($) = CECC + B1 + B2 $41,827,000 Total project cost

 TPC ($/kW) = $258 Total project cost per kW

Work Sheet adpapted from "IPM Model‐Revisions to Cost And Performance for APC Technologies‐SCR Cost Development Methodology‐FINAL", August 2010 Project 12301‐007, 

prepared by Sargent & Lundy, LLC
PPL Corette

Modified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsNew or Retrofit? RetrofitGeneration capacity (MW gross) 162 TRC BART Report Addendum for PPL, p. 1-1 (June 2008)SCR bypass included? No AssumedFuel High Heating Value (Btu/lb) From EIA for 1999 8,458

Maximum Fuel Consumption Rate (lb/hr) Calculated from 229,487 MMBtu/

1,941 

Average Annual Fuel Consumption (lb) 1.40E+09 Calcuated from 11,802,864 MMBtu/yNumber of SCR Operating Days 365 AssumedPlant Capacity Factor 69% Based on average annual gross load for 2008-2010 from CAMDUncontrolled NOx Concentration (lb/MMBtu) 0.274 Average for 2008-2010 from CAMDSOFA Total Capital Cost $ TRC BART Report for PPl (June 2008) adjust 3,350,365 ed using 2010 CEPC

SOFA Total Annual Cost $ TRC BART Report for PPl (June 2008) adj 632,028 usted using 2010 CEPC

LNB/CCOFA/SOFA outlet = SNCR inlet NOx Concentration (lb/MMBtu) 0.200Required Controlled NOx Concentration (lb/MMBtu) 0.05 IPM Base Case v4.10 Documentation, Appendix 5-2A (August 201Acceptable Ammonia Slip (ppm) 2.0 OAQPS Control Cost ManualFuel Volume Flow Rate (ft3/min/MMBtu/hr) 516 OAQPS Control Cost ManualFuel Sulfur Content 0.30% TRC BART Report for PPL, p. 3 (August 2011)Fuel Ash Content 10.10% From EIA for 1999Number of SCR reactor chambers 2 AssumedNumber of spare catalyst layers 1 AssumedASR 1.05 EPA Control Cost ManualStored Ammonia Concentration 29% EPA Control Cost ManualReagent Molecular Weight (g/mole) 17.03 EPA Control Cost ManualReagent Density (lb/ft3 @ 60F) 56.0 EPA Control Cost ManualReagent Specific Volume (gal/ft3) 7.481 EPA Control Cost ManualNOx Molecular Weight (g/mole) 46.01 EPA Control Cost ManualNumber of Days of Storage for Ammonia 14 EPA Control Cost ManualPressure Drop for SCR Ductwork H2O") 3 EPA Control Cost ManualPressure Drop for each Catalyst Layer (H2O") 1 EPA Control Cost ManualTemperature at SCR Inlet (degrees F) 700 TRC BART Report Addendum for PPL, Table 5.3-3 (June 2008)Equipment Life (years) 20 EPA Control Cost ManualAnnual Interest Rate 7% EPA Control Cost ManualInflation Since 1998 1.41 CEPCI 2010/CEPCI 1998Catalyst Cost, Initial ($/ft3) $ calculated from 170 $ Cichano

6,000

Catalyst Cost, Replacement ($/ft3) $ calculated from 170 $ Cichano

6,000

Electrical Power Cost ($/kWh) $ Typical 0.045

29% Aqueous Ammonia ($/lb) $ calculated from 0.120 $ Fuel Tec

240

Operating Life of Catalyst (hours) EPA Control Cost Manual 24,000Natural gas unit cost ($/mcf) $ EIA 2010 price forecast 4.98

Natural gas for reheat (mcf) NA
Boiler Calculations (from Section 4.2 of EPA Control Cost Manual)

2.3 QB = HVm-dotfuel

QB = 8,458 Btu/lb * 229,487 lb/hr

QB = 1,941 Btu/hr

2.7 CFPlant = actual heat input/maximum annual heat input

CFPlant = 69%

2.8 CFSCR = tSCR/365 days

CFSCR = 365 days/ 365 days

CFSCR = 100%

2.6 CFTotal = CFPlant x CFSCR

CFTotal = 69% * 100%

CFTotal = 69%

2.12 qfluegas = qfuelQB(460+T)/(460+700oF)nSCR

qfluegas = 516 ft3/min/(mmBtu/hr)* 1941 mmBtu/hr*( 460 + 700 )/( 460 + 700 )/ 2

qfluegas = 500,778 acfm

2.9 ηNOx = (NOxin – NOxout) / NOxin

ηNOx = ( 0.20 lb/mmBtu - 0.05 lb/mmBtu)/ 0.20 lb/mmBtu

ηNOx = 75%Uncontrolled NOx emissions tpy 1,625

2.57 NOx Removed = NOxinηNOxQBtop

SOFA NOx Removed = 0.27 * 26.9% * 1,941 * 6081 / 2000

SOFA NOx Removed = 435 tpySCR NOx Removed = 0.20 * 75.0% * 1,941 * 6081 / 2000SCR NOx Removed = 885 tpyOverall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc

( 0.27 - 0.05 )/ 0.27 = 82%

Overall NOx removed = tpy 1,328

Controlled NOx emissions = tpy 297
SCR Reactor Calculations (from Section 4.2 of EPA Control Cost Manual)

2.19 Volcatalyst = 2.81 x QB x ηadj x Slipadj x NOxadj x Sadj x Tadj/NSCR

Volcatalyst = 2.81 * 1941 = 5454.21

2.2 ηadj = 0.2869 + (1.058 x η)

ηadj = 0.2869 +( 1.058 * 0.75 )ηadj = 1.080

2.22 Slipadj = 1.2835 – (0.0567 x Slip)

Slipadj = 1.2835 - ( 0.057 * 2 )

Slipadj = 1.170

2.21 NOxadj = 0.8524 + (0.3208 x NOxin)

NOxadj = 0.8524 + ( 0.321 * 0.20 )

NOxadj = 0.917

2.23 Sadj = 0.9636 + (0.0455 x S)

Sadj = 0.9636 + ( 0.046 * 0.3 )

Sadj = 0.977

2.24 Tadj = 15.16 – (0.03937 x T) + (2.74 x 10-5 x T2)

Tadj = 15.16 - ( 0.039 * 700 ) + 2.74E-05 * 490000

Tadj = 1.027Volcatalyst = 3,171 ft3 each =89.87m3 each

2.25 Acatalyst = qfluegas/(16 ft/sec x 60 sec/min)

Acatalyst = 500,778 /( 16 * 60 )

Acatalyst = 522 ft2

2.26 ASCR = 1.15 x Acatalyst

ASCR = 1.15 * 522

ASCR = 600 ft2

2.27 l = w = ASCR1/2

l = w = 24.5 ft

2.28 nlayer = Volcatalyst/(h’layer x Acatalyst)

nlayer = 3,171 /( 3.1 * 522 )

nlayer = 2.0nlayer = 2.0

2.29 hlayer = [Volcatalyst/(nlayer x Acatalyst)] + 1

hlayer = 3,171 /( 2.0 * 522 ) + 1

hlayer = 4.0

2.3 ntotal = nlayer + nempty

ntotal = 2 + 1

ntotal = 3

2.31 hSCR = ntotal(c1 + hlayer) + c2

hSCR = 3 * ( 7 + 4.0 ) + 9

hSCR = 42 ft
SCR Bypass Calculations (from Section 4.2 of EPA Control Cost Manual)

2.41 f(bypass) = $0/(mmBtu/hr) for no bypass

f(bypass) = - $ /mmBtu/hr * inflation = - $ per Btu/hr

f(bypass) = $0 each SCR reactor

$0 all SCR reactors
Initial Catalyst Calculations (from Section 4.2 of EPA Control Cost Manual)

2.43 f(Volcatalyst) = VolcatalystCCinitial

f(Volcatalyst) = 3171 * 170

f(Volcatalyst) = $539,233 each SCR reactor

$1,078,465 all SCR reactors
Reagant Calculations (from Section 4.2 of EPA Control Cost Manual)

2.32 m-dotreagent = NOxinQBASRηNOxMreagent/MNOx

m-dotreagent = 0.20 * 1941 * 1.05 * 75% * 17.03 / 46.01

m-dotreagent = 113 lb/hr

2.33 m-dotsol = m-dotreagent/Csol

m-dotsol = 113 / 0.29

m-dotsol = 390 lb/hr

2.34 qsol = (m-dotvol/ρsol)Vsol

qsol = 390 * 7.481 / 56

qsol = 52 gph

2.35 Tank Volume = qsolt

Tank Volume = 52 * 14 * 24Tank Volume = 17,514 gal

2.47 Annual Reagent Cost = qreagentCostreagenttop

2.47a top = CFtotal8760hr/yr

top = 69% * 8760

top = 6081

Annual Reagent Cost = 390 * 6081 * 0.120Annual Reagent Cost = $ 284,717
Maintenance Cost Calculations (from Section 4.2 of EPA Control Cost Manual)

2.46 Annual Maintenance Cost = 0.015 * TCI

Annual Maintenance Cost = 0.015 * 42,958,390 $ 

Annual Maintenance Cost = $ 644,376
Electricity Cost Calculations (from Section 4.2 of EPA Control Cost Manual)

2.49 Annual Electricity Cost = Power (Costelect)top2.48 Power = 0.105QB[NOxinηNOx + 0.5(∆Pduct + ntotal∆Pcatalyst)]

Power = 0.105 * 1941 *( 0.20 * 75% + 0.50 * ( 3 + 3 * 1 ))

Power = 642 kW

Annual Electricity Cost = 642 * 6081 * 0.045Annual Electricity Cost = $ 175,671
Catalyst Replacement Cost Calculations (from Section 4.2 of EPA Control Cost Manual)

2.51 Annual Catalyst Replacement Cost = (Catalyst Replacement Cost)FWF

2.5 Catalyst Replacement Cost = nSCRVolcatalystCCreplace/Rlayer

Catalyst Replacement Cost = 2 * 3,171 * 170.0 / 2Catalyst Replacement Cost = $ 539,233

2.52 FWF = i{1/[(1+i)

Y-1]}

2.53 Y = hcatalyst/hyear

Y = 24000 /( 69% * 8760 )Y = 3.95

FWF = 0.07 *( 1 /( 1 + 0.07 )^ 4 - 1 )FWF = 0.23

Annual Catalyst Cost = $ 121,450
STATE

FACILITY_NA

ME

ORISPL 

CODE UNIT ID OP YEAR

SUM OP 

TIME

NUM 

MONTHS 

REPORTE

D

GROSS 

LOAD 

(MWh) SO2 MASS SO2 RATE NOX RATE

NOX 

MASS

HEAT INPUT 

(MMBtu)

MT J E Corette 2187 2 2008 7,314 12 1,086,477 2,817 0.472 0.278 1,658 11,925,734 

MT J E Corette 2187 2 2009 7,824 12 1,141,292 2,832 0.455 0.261 1,641 12,445,152 

MT J E Corette 2187 2 2010 7,401 12 1,025,597 2,519 0.457 0.282 1,575 11,037,706 

Averages 7,513 1,084,455 2,723 0.461 0.27363 1,625 11,802,864 

CAMD Data