# SCR Capital Costs

Description Formula 1 

# Value

Boiler Size (MMBtu/hr) Q B 

# 1941

NOx Removal Efficiency (%) η NOx 

# 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 (A ssumed 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 fo r 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 Costs 4 

# DAC $315,754

Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $33 0,375

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

2 

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

Cost Development Methodology," Sargent & Lundy, Aug ust 2010.

3,4 

# Direct capital costs and direct annual costs for SO FA 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 WorksheetVariable Designation Units Value CalculationUnit Size (Gross) A (MW) 162 InputRetrofit Factor B 1 Input (An "average" retrofit has afactor = 1.0)Heat Rate C (Btu/kWh) 11982 InputNOxRate D (lb/MMBtu) 0.2 InputSO2Rate E (lb/MMBtu) 0.6 InputType of Coal F PRB InputCoal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate Factor H 1.1982 C/10000Heat Input I (Btu/hr) 1.94E+09 A*C*1000Capacity Factor J (%) 69.4 InputNOxRemoval Efficiency K (%) 75.0 InputNOxRemoval Factor L 0.9375 K/80NOxRemoved M (lb/hr) 291D*I/106*K/100Costs are all based on 2009 dollarsCapital Cost CalculationInclude: equipment, installation, buildings, foundations, electrical, and retrofit difficulty.BMR ($) = 180000*(B)*(L)0.2*(A*G*H)0.92$23,668,000 SCR (inlet ductwork, reactor, bypass) island costBMF ($) = 410000*(M)0.25$1,694,000 Base reagent preparation costBMA ($) = If E >= 3 then 65000*(B)*(A*G*H)0.78; else 0$0 Air heater modification / SO3control (bituminous only & > 3 lb/MMbtu)BMB ($) = 380000*(B)*(A*G*H)0.42$3,545,000 ID or booster fans & auxiliary power modification costsBM ($) = BMR + BMF + BMA + BMB$28,907,000 Total bare module cost including retrofit factorBM ($/kW)$178 Base cost per kWTotal Project CostA1 = 10% of BM$2,891,000 Engineering and construction management costsA2 = 10% of BM$2,891,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 10% of BM$2,891,000 Contractor profit and feesCECC($) = BM+A1+A2+A3$37,580,000Capital, engineering and construction cost subtotalCECC($/kW) =$232Capital, engineering and construction cost subtotalper kWB1 = 5% of CECC$1,879,000 Owners costs including "home office" costs (owners engineering, management, and procurementactivities)B2 = 6% of (CECC + B1)$2,368,000 AFUDC (based on approximately 3% per yearfor a 2 year engineering and construction cycle)TPC ($) = CECC + B1 + B2$41,827,000Total project costTPC ($/kW) =$258Total project cost per kWWork Sheet adpapted from "IPM Model‐Revisions to Cost And Performance for APC Technologies‐SCR Cost Development Methodology‐FINAL", August 2010 Project 12301‐007, Perrin Quarles Associates, Inc.,prepared by Sargent & Lundy, LLCPPL CoretteModified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsNew or Retrofit?RetrofitGeneration capacity (MW gross)162 TRC BART Report Addendum for PPL, p. 1-1 (June 2008)SCR bypass included?No AssumedFuel High Heating Value (Btu/lb)8,458From EIA for 1999Maximum Fuel Consumption Rate (lb/hr)229,487Calculated from1,941MMBtu/hr from TRC Report for PPL (June2008)Average Annual Fuel Consumption (lb)1.40E+09 Calcuated from 11,802,864 MMBtu/yr average for 2008-2010 from CAMDNumber of SCR Operating Days365 AssumedPlant Capacity Factor69% Based on average annual gross load for 2008-2010from CAMDUncontrolled NOx Concentration (lb/MMBtu)0.274 Average for 2008-2010 from CAMDSOFA Total Capital Cost3,350,365$ TRC BART Report for PPl (June 2008) adjusted using 2010 CEPCISOFA Total Annual Cost632,028$ TRC BART Report for PPl (June 2008) adjusted using 2010 CEPCILNB/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 2010)Acceptable Ammonia Slip (ppm)2.0 OAQPS Control Cost ManualFuel Volume Flow Rate (ft3/min/MMBtu/hr)516 OAQPS Control Cost ManualFuel Sulfur Content0.30% TRC BART Report for PPL, p. 3 (August 2011)Fuel Ash Content10.10% From EIA for 1999Number of SCR reactor chambers2 AssumedNumber of spare catalyst layers1 AssumedASR1.05 EPA Control Cost ManualStored Ammonia Concentration29% 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 Ammonia14 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 Rate7% EPA Control Cost ManualInflation Since 19981.41 CEPCI 2010/CEPCI 1998Catalyst Cost, Initial ($/ft3)170$ calculated from6,000$ Cichanowicz (Jan 2010)Catalyst Cost, Replacement ($/ft3)170$ calculated from6,000$ Cichanowicz (Jan 2010)Electrical Power Cost ($/kWh)0.045$ Typical29% Aqueous Ammonia ($/lb)0.120$ calculated from240$ Fuel Tech (3/2/2012)Operating Life of Catalyst (hours)24,000EPA Control Cost ManualNatural gas unit cost ($/mcf)4.98$ EIA 2010 price forecastNatural gas for reheat (mcf)NABoiler Calculations (from Section 4.2 of EPA Control Cost Manual)2.3 QB= HVm-dotfuelQB= 8,458Btu/lb * 229,487lb/hrQB= 1,941Btu/hr2.7 CFPlant= actual heat input/maximum annual heat inputCFPlant = 69%2.8 CFSCR= tSCR/365 daysCFSCR= 365 days/ 365 daysCFSCR= 100%2.6 CFTotal= CFPlantx CFSCRCFTotal= 69% * 100%CFTotal= 69%2.12 qfluegas= qfuelQB(460+T)/(460+700oF)nSCRqfluegas= 516 ft3/min/(mmBtu/hr)* 1941 mmBtu/hr*( 460 + 700 )/( 460 + 700 )/ 2qfluegas= 500,778acfm2.9ηNOx= (NOxin– NOxout) / NOxinηNOx= ( 0.20 lb/mmBtu - 0.05 lb/mmBtu)/ 0.20 lb/mmBtuηNOx= 75%Uncontrolled NOx emissions1,625tpy2.57 NOx Removed = NOxinηNOxQBtopSOFA NOx Removed =0.27 * 26.9% * 1,941* 6081 / 2000SOFA 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 =1,328tpyControlled NOx emissions =297tpySCR Reactor Calculations (from Section 4.2 of EPA Control Cost Manual)2.19 Volcatalyst= 2.81 x QBxηadjx Slipadjx NOxadjx Sadjx Tadj/NSCRVolcatalyst= 2.81 * 1941 = 5454.212.2ηadj= 0.2869 + (1.058 xη)ηadj= 0.2869 +( 1.058 * 0.75 )ηadj= 1.0802.22 Slipadj= 1.2835 – (0.0567 x Slip)Slipadj= 1.2835 - ( 0.057 * 2 )Slipadj= 1.1702.21 NOxadj= 0.8524 + (0.3208 x NOxin)NOxadj= 0.8524 + ( 0.321 * 0.20 )NOxadj= 0.9172.23 Sadj= 0.9636 + (0.0455 x S)Sadj= 0.9636 + ( 0.046 * 0.3 )Sadj= 0.9772.24 Tadj= 15.16 – (0.03937 x T) + (2.74 x 10-5x T2)Tadj= 15.16 - ( 0.039 * 700 ) + 2.74E-05 * 490000Tadj= 1.027Volcatalyst= 3,171ft3 each =89.87m3 each2.25 Acatalyst= qfluegas/(16 ft/sec x 60 sec/min)Acatalyst= 500,778/( 16 * 60 )Acatalyst= 522ft22.26 ASCR= 1.15 x AcatalystASCR= 1.15 * 522ASCR= 600ft22.27 l = w = ASCR1/2l = w = 24.5 ft2.28 nlayer= Volcatalyst/(h’layerx Acatalyst)nlayer= 3,171/( 3.1 * 522 )nlayer= 2.0nlayer= 2.02.29 hlayer= [Volcatalyst/(nlayerx Acatalyst)] + 1hlayer= 3,171/( 2.0 * 522 ) + 1hlayer= 4.02.3 ntotal= nlayer+ nemptyntotal= 2 + 1ntotal= 32.31 hSCR= ntotal(c1+ hlayer) + c2hSCR= 3 * ( 7 + 4.0 ) + 9hSCR= 42 ftSCR Bypass Calculations (from Section 4.2 of EPA Control Cost Manual)2.41 f(bypass) = $0/(mmBtu/hr) for no bypassf(bypass) = -$ /mmBtu/hr * inflation = -$ per Btu/hrf(bypass) = $0 each SCR reactor$0all SCR reactorsInitial Catalyst Calculations (from Section 4.2 ofEPA Control Cost Manual)2.43 f(Volcatalyst) = VolcatalystCCinitialf(Volcatalyst) = 3171 * 170f(Volcatalyst) = $539,233 each SCR reactor$1,078,465all SCR reactorsReagant Calculations (from Section 4.2 of EPA Control Cost Manual)2.32 m-dotreagent= NOxinQBASRηNOxMreagent/MNOxm-dotreagent= 0.20 * 1941 * 1.05 *75%* 17.03 / 46.01m-dotreagent= 113 lb/hr2.33 m-dotsol= m-dotreagent/Csolm-dotsol= 113 / 0.29m-dotsol= 390 lb/hr2.34 qsol= (m-dotvol/ρsol)Vsolqsol= 390 * 7.481 / 56qsol= 52 gph2.35 Tank Volume = qsoltTank Volume = 52 * 14 * 24Tank Volume = 17,514gal2.47 Annual Reagent Cost = qreagentCostreagenttop2.47a top= CFtotal8760hr/yrtop= 69% * 8760top= 6081Annual Reagent Cost = 390 * 6081 * 0.120Annual Reagent Cost =284,717$Maintenance Cost Calculations (from Section 4.2 ofEPA Control Cost Manual)2.46 Annual Maintenance Cost = 0.015 * TCIAnnual Maintenance Cost = 0.015 * 42,958,390$Annual Maintenance Cost =644,376$Electricity Cost Calculations (from Section 4.2 ofEPA Control Cost Manual)2.49 Annual Electricity Cost = Power (Costelect)top2.48 Power = 0.105QB[NOxin**η**NOx + 0.5(**∆**Pduct+ ntotal**∆**Pcatalyst)]Power = 0.105 * 1941 *( 0.20 * 75% + 0.50* (3 + 3 * 1 ))Power = 642 kWAnnual 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)FWF2.5 Catalyst Replacement Cost = nSCRVolcatalystCCreplace/RlayerCatalyst Replacement Cost =2 * 3,171* 170.0 / 2Catalyst Replacement Cost =539,233$2.52FWF = i{1/[(1+i)Y-1]}2.53 Y = hcatalyst/hyearY = 24000 /( 69% * 8760 )Y = 3.95FWF = 0.07 *( 1 /( 1 + 0.07 )^ 4 - 1 )FWF = 0.23Annual Catalyst Cost =121,450$STATEFACILITY_NAMEORISPLCODE UNIT ID OP YEARSUM OPTIMENUMMONTHSREPORTEDGROSSLOAD(MWh) SO2 MASS SO2 RATE NOX RATENOXMASSHEAT INPUT(MMBtu)HEATINPUT(MMBtu/hr)MT J E Corette 2187 2 2008 7,314 12 1,086,477 2,817 0.472 0.278 1,658 11,925,734 1,631MT J E Corette 2187 2 2009 7,824 12 1,141,292 2,832 0.455 0.261 1,641 12,445,152 1,591MT J E Corette 2187 2 2010 7,401 12 1,025,597 2,519 0.457 0.282 1,575 11,037,706 1,491Averages 7,5131,084,455 2,723 0.461 0.27363 1,625 11,802,864 1,571CAMD Data