March 22, 2012 

Mr. Robert Irvine 

Supervisor, Strategy Development Unit 

Air Quality Division 

Michigan Department of Environmental Quality 

525 West Allegan Street 

Lansing, Michigan 48909 

Re: NewPage Corporation, Escanaba Paper Company (EPC) Response to U.S. EPA 

Comments on Michigan Regional Haze SIP 

Dear Mr. Irvine, 

This letter is being submitted by the Escanaba Paper Company (EPC) to the Michigan 

Department of Environmental Quality (MDEQ) in response to comments received by the State 

from the U.S. EPA regarding the proposed Michigan State Implementation Plan (SIP) changes to 

address regional haze and the related Best Available Retrofit Technology (BART) analysis 

submitted by EPC in January 2007. The EPC BART analysis was prepared in accordance with 

40 CFR Part 51, Subpart P and Appendix Y to address the regional haze rule requirements. EPC 

believes that U.S. EPA’s conclusion that the Michigan regional haze plan must mandate the 

installation of Selective Catalytic Reduction (SCR) to control NOX emissions from the Escanaba 

Mill’s No. 8 and No. 9 Boilers may have been reached without the benefit of important sitespecific information and as a result is incorrect. EPC’s belief is based on two critical factors; (1) 

the excessive control cost effectiveness associated with installing SCR on the boilers that takes 

into account site-specific technical details, and (2) the imperceptible impact on visibility that 

would result at the Seney Wildlife Refuge and any other Class I areas due to installing such 

controls. The information provided below supports the conclusion that EPC’s original BART 

analysis remains valid and should be included in the State’s regional haze plan. 

1. The original cost estimates for installing SCR on the No. 8 and No. 9 Boilers at the 

Escanaba Mill were prepared in late 2006 using control technology available at that time 

and based on an SCR system vendor quote that was provided to MDEQ (see Attachment 

A). While the vendor provided some operating cost information in the proposal, EPC 
Mr. Robert Irvine 

Response to U.S. EPA Comments on Michigan Regional Haze SIP 

Page 2 of 6 

included additional installation and operating cost data based on site-specific details, 

which included a limited footprint of area in which the equipment can be installed. The 

cost effectiveness analysis used by U.S. EPA to support the conclusion that SCR should 

be installed on the EPC boilers used simple default factors from the agency’s control cost 

handbook that did not account for the Mill’s unique site-specific conditions. EPC 

believes that U.S. EPA’s conclusions would be different when more detailed information 

is considered. For example, EPC does not believe that U.S. EPA had the opportunity to 

review the SCR system vendor quote that provided the cost information and other 

technical data used in the original control cost analyses. 

To confirm that the initial SCR vendor quote is representative, EPC contacted the vendor 

and requested an updated quote (Attachment B). After receiving the updated quote, EPC 

contacted CCA to better understand the differences between the 2006 and revised quotes. 

Since 2006, CCA has gained over five (5) years of experience quoting and actually 

installing SCR systems. During that period, CCA’s experience has indicated that the 

SCR system catalyst is extremely sensitive to fouling which leads to inefficient or 

ineffective NOx removal. CCA has refined the SCR systems that they install in several 

ways to protect the SCR system catalyst and protect the integrity of the system. A key 

component to this is the addition of reverse flow to periodically clean the surface of the 

SCR catalyst. This SCR system design change requires a significant increase in 

construction materials (e.g., ductwork, air nozzles, dampers, etc.). In 2006, the system 

was quoted with a basic “off the shelf” process control system. Since then, CCA’s SCR 

systems have been updated to include a customized process control system that has 

greatly improved system reliability and effectiveness. CCA has even switched the 

catalyst vendors for better SCR system performance and support. All of these 

improvements enhance SCR system performance and reliability, but come at an increased 

cost. Furthermore, the 2006 quote is over five (5) years old and updated quote reflects 

the increase in costs of goods and services since then. For these reasons, it was 

EPC BART Response 3-22-2012.docx
Mr. Robert Irvine 

Response to U.S. EPA Comments on Michigan Regional Haze SIP 

Page 3 of 6 

concluded that the 2006 quote is not completely representative of the actual cost that 

would be incurred to install an SCR system today. 

EPC used the updated quote and incorporated U.S. EPA’s “default” costs assumptions 

into a revised cost effectiveness determination. The revised NOX cost effectiveness 

analyses for the No. 8 and 9 Boilers are attached with this letter (Attachment C). As can 

be seen in these revised analyses, the cost effectiveness associated with the application of 

SCR on either boiler is greater than $10,000 per ton and thus EPC believes that the use of 

SCR is not cost effective on either boiler. EPC further notes that even though the revised 

cost effectiveness analysis incorporated the use of U.S. EPA’s “default” cost 

assumptions, a more detailed engineering analysis would support the position that 

retrofitting SCR to these boilers would require significant additional expense. 

The revised the control cost estimates that are provided in Attachment C reflect the 

following specific changes recommended by U.S. EPA: 

• The direct installation cost multiplier was reduced from 1.85 to 0.85 consistent 

with the U.S. EPA comments. 

• For both boilers the reagent costs have been revised to reflect a current 

$1.75/gallon price and natural gas costs have been revised to reflect a 

$4.15/MMBtu 2012 forecasted annual average price. 

• For both boilers the SCR system life expectancy was adjusted to 15 years and the 

interest rate was adjusted to 7% consistent with U.S. EPA comments. 

• The catalyst life is revised to reflect 25,000 hours consistent with the vendor’s 

revised quote. 

Although EPC incorporated the U.S. EPA default cost assumptions there are several 

factors that would result in additional retrofitting expenses that should be considered and 

would require the use of non-default cost assumptions. The Escanaba Mill has limited 

space available in the immediate vicinity of the two power boilers in which to locate the 

EPC BART Response 3-22-2012.docx
Mr. Robert Irvine 

Response to U.S. EPA Comments on Michigan Regional Haze SIP 

Page 4 of 6 

new SCR systems. As a result, the SCR equipment would need to be installed on 

elevated platforms designed to handle the weight of the new components, significantly 

increasing the installation costs for the SCR systems. As noted by the vendor, the new 

systems would likely require new induced draft fans to overcome the added resistance 

associated with the catalyst systems and associated duct work. Although the revised 

quote did not factor the cost for a new stack, EPC believes that a replacement stack 

would likely be required for the two stacks currently exhausting the No. 9 boiler. U.S. 

EPA appears to believe that 75% of the energy used to reheat the No. 9 Boiler stack gases 

can be readily captured and reused by the Mill for other purposes. Technically, this may 

or may not be accurate, but assuming that it were true, there would be substantial costs to 

recover the heat to make steam and then to pipe the steam to the Mill’s existing supply 

system. None of the costs associated with the items mentioned in this paragraph are 

included in the revised cost effectiveness determinations. 

Of significant importance to consider is that in the five (5) years since the EPC BART 

analysis was submitted to MDEQ, much experience has been gained regarding SCR 

installation and operation. However, EPC has not been able to identify a single wood or 

biomass fired boiler that incorporates SCR technology following a wet scrubber system 

such as that installed on the No. 9 Boiler at the Escanaba Mill. All of the SCR systems 

identified on these types of boilers are installed following dry particulate matter control 

devices such as ESPs or fabric filters. Also it should be noted that the original cost 

effectiveness analysis reflected a 90% NOX removal efficiency and in practice, the actual 

NOX control efficiency is likely between 75% and 80% (based on review of multiple 

applications of SCR to biomass boilers). The updated cost effectiveness analysis reflects 

a 76% NOX control efficiency. 

 

2. In addition to the technical and economic limitations of applying SCR to the No. 9 and 

No. 8 Boilers, the possible reduction of NOX emissions has a minimal effect on 

improving visibility. Visibility modeling that was conducted to support the original 

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Mr. Robert Irvine 

Response to U.S. EPA Comments on Michigan Regional Haze SIP 

Page 5 of 6 

BART submittal in January 2007 as well as follow-up visibility modeling in September 

2007, which reflected use of the new “Improve” equation, both demonstrated that 

visibility improvement associated with a 90% reduction in NOX emissions was minimal. 

As shown in the tables provided to Michigan DEQ in May 2008, the individual baseline 

visibility modeling for the two boilers indicates that the 98th percentile deciview values 

due to emissions of all visibility impairing pollutants (VIP) are less than 0.50 for each 

boiler for each of the three years evaluated. Of special note is that the No. 9 Boiler 98th

percentile deciview values are all less than 0.20 deciviews. When SO2 and particulate 

matter emissions are held at baseline levels and NOX emissions are reduced by 90%, 

there is very little change in the 98th percentile values for both boilers. The 98th

percentile deciview values for the No. 9 Boiler decrease by less than 0.10 deciview, thus 

there is no meaningful visibility improvement to controlling NOX emissions from the No. 

9 Boiler. For the No. 8 Boiler reducing NOX emissions by 90% results in a 0.29 deciview 

improvement in visibility at the 98th percentile value, which is also imperceptible. Also, 

comparing the existing actual NOX emission factors for both boilers with emission limits 

from recent BACT determinations, application of SCR would likely produce a 75-80% 

reduction in NOX emissions, not a 90% reduction and thus the visibility modeling that 

was performed in 2007 and 2008 for the SCR 90% control scenarios for both boilers 

over-states the possible visibility improvement. 

It is also noted that the baseline emission scenario evaluated for the No. 8 Boiler reflects 

a combination of peak SO2 emissions (due to peak oil firing rates) and peak NOX

emissions (due to peak natural gas firing rate). It is not physically possible to achieve 

this dual fuel, peak firing rates simultaneously. In fact a review of the No. 8 Boiler 

operating records conducted for the May 2008 response to Michigan DEQ shows that the 

peak firing of either natural gas or fuel oil occurs very infrequently. With respect to the 

peak No. 8 Boiler NOX emission rate of approximately 390 lbs/hr, the daily operating 

records indicated that the boiler emitted NOX at this rate on three days in 2005 and no 

days in 2004, 2006, 2007, and 2008. Thus the No. 8 Power Boiler never actually emitted 

EPC BART Response 3-22-2012.docx

ATTACHMENT A – 2006 CCA SCR BUDGET PROPOSAL
All4 UNIT #8 & 9 LOW NOx SCR 

BUDGET PROPOSAL 

For 

Marvin Gregory 

All4 Inc 

Jackson, OH 

EMAIL: mgregory@all4inc.com

Proposal No. ESS12162006 

December 16, 2006 

Prepared by: 

Edmund Schindler 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH 

203-261-7697 FAX 

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TABLE OF CONTENTS 

2.0 OBJECTIVES ............................................................................................................. 4

3.0 PROGRAM ACTION PLAN .................................................................................... 4

3.1 SCR System .............................................................................................................. 4 

3.2 Optimization, StartUp, Testing and Interim Report.................................................. 6 

4.0 COMMERCIAL TERMS .......................................................................................... 7

4.1 Program Budget ........................................................................................................ 7 

4.2 Program Schedule ..................................................................................................... 7 

4.3 Validity ..................................................................................................................... 8 

4.4 Terms of Payment..................................................................................................... 8 

4.5 Commercial Terms.................................................................................................... 8 

APPENDIX 

Appendix A – Experience Lists 

Appendix B– CCA Fees & Scope of Service Sheets 

 

Confidentiality and Proprietary Information 

Notice to Recipient of Proposal: 

In consideration of CCA preparation of this proposal and disclosure of certain proprietary information, its recipient agrees to treat as confidential all CCA proprietary information 

disclosed herein. Such proprietary information includes, but is not limited to, all technical requirements, specification(s), print(s), and information relating to the description and 

operation of the system, which is the subject of this proposal, its components, equipment, options and related services, designs, processes, techniques, documentation, pricing, 

installation, and safety. The recipient further acknowledges that CCA proprietary information is unique and valuable, was developed or acquired by CCA at substantial expense, 

and is the subject of efforts by CCA to maintain the secrecy thereof. The recipient agrees not to reverse engineer, to use or to disclose this proprietary information to any person or 

party without the prior written consent of CCA. This agreement is effective between the recipient and CCA regardless of whether the parties enter into a contract for sale of the 

goods and/or services that are the subject matter of this proposal. 

© Copyright 2006, CCA. An unpublished work. All rights reserved. This document may be reproduced as required only for the internal use of its recipient in evaluation of this 

proposal. 
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1.0 INTRODUCTION 

 

 

Boiler #8 at another location is a small natural gas/fuel oil-fired unit that does not have 

any add on PM controls. The heat input is 400 mmBtu/hr. 

 

Stack temp 300F - 320F 

Moisture 7% 

Flow rate 180,000 acfm 

SO2 115 tpy 

NOx 137 tpy 

O2 5% 

PM 7.6 lbs/MMCF when burning gas (AP-42) 

PM 12.4 lbs/MMCF when burning fuel oil (AP-42) 

Flue gas temp prior to air heater 600F 

CO and CO2 data are not available for this unit. 

 

 

Boiler #9 adjacent to boiler #8 burns wood waste and natural gas. The unit is equipped 

with multiclones and parallel wet scrubbers for PM control. The boiler is rated at 360 

mmBtu/hr heat input. 

 

Stack temp 140F to 150F 

Moisture 20% 

Flow rate 140,000 acfm 

SO2 43 tpy 

NOx 932 tpy 

O2 7 to 8.5% 

PM 0.119 lb/mmBtu after PM controls 

CO 800 ppm 

CO2 10 to 11% 

Flue gas temp prior to air heater 375F 
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2.0 OBJECTIVES 

The program objectives are as follows: 

1. Provide an SCR system for 90% NOx reduction for the worst fuel of each of the three 

boilers. 

2. Supply a urea supply and injection system to supply ammonia to the catalyst. 

3. Identify ID Fan upgrade requirements 

3.0 PROGRAM ACTION PLAN 

The program action plan consists of three (3) parts: 

1. Survey the units and locate space to install the catalyst bed and the urea tank. 

2. Design the system and the ductwork. 

3. Provide the system 

4. Provide installation supervision 

5. Provide startup, optimization and testing. 

 

3.1 SCR System 

 

CCA has provided SCR to mobile and stationary diesel engines ranging from a diesel engine in a 

pickup truck to a 2MW electric generation diesel system. We have supplied over 150 of these 

systems to date. All of these typically reduce the NOx 80 to 90% while moving down the road. 

Because we have focused on small mobile sources our SCR systems can be supplied for much 

less then the large OEM suppliers of SCR technology. Our patented injection and control system 

provides a compact and straightforward system that can easily be applied to small industrial 

boilers. In addition volume production of key components and pre-engineered systems has 

reduced the cost to provide a complete system. Our system uses no atomizing air or steam to 

atomize the urea or ammonia and the total power requirements is less then 100 watts for each 

complete system. 

The system is designed for 100% flow of flue gas through the catalyst bed at a temperature of 

600F. The SCR can maintain 90% reduction of NOx within a temperature range that is 

dependent on the catalyst used. Up stream of the catalyst the urea is injected into the duct and it 

converts to ammonia in the hot flue gas. The ammonia combines with the NOx at the catalyst 

surface and reduces the NOx to N2. After NOx reduction is achieved the Flue gas from the 
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catalyst is passed on to the ID fan and then to the ESP. Each of the two boilers will require a 

slightly different system. Boiler 9 will require a high dust catalyst, Boiler #8 can use a low 

dust catalyst used for oil and gas and boiler 9 will require a duct heater to bring the flue gas 

temperature up to 600F or to the minimum catalyst temperature. There are catalysts available that 

can operate down to 450F but they are more expensive and it may make sense to just bring the 

temperature up to 600F. For boiler #9 that burns wood waste, the trace gas 

constituents must be defined and limited to insure that no catalyst poisons are present. 

The Equipment and engineering supply is as follows: 

Boilers 1, 8&9 

SCR Component Unit #8 Unit #9 

Tank-6000 gallon polymer tank for inside storage 

of urea with urea pump and motor, inline filters 

and tank level sensor 

 One tank for Boiler #8 & 9 

Catalyst Type, Installed before the air heater. Oil and gas High dust 

wood and 

gas 

Catalyst Volume, CM 22.3 20.1 

Catalyst Shell-CS fabrication 1 1 

Transition Duct 20 feet of CS duct included per 

boiler 

 1 1 

Bypass Duct and two dampers to bypass 

minimum boiler load at 500F flue gas temperature 

and below. 

 1 1 

Additional ID fan requirements to be tested and 

proven or upgraded 

109,000 

a

180,000 

acfm at 4 

inwc 

140,000 at 6 

inwc 

Gas Duct burner to raise flue gas to 600F None 1 

Return Flow Injectors with SS hoses 4 4 

Electronic Control Units (ECU) 2 2 

Lot of instrumentation (flow sensor, temperature 

of gas) 

 1 1 

Urea pumps for each unit with auto backup 2 2 

Urea Day Tank for each boiler including urea 

pump and motor, inline filter, level sensor, ECU 

and wiring harness 

200 gallons 200 gallons 

CFD model to determine best injection point and 

mixing for each unit. 

 1 1 

Installation Supervision 4 days total 4 days total 

Note the Multiclone must be operating at its design condition to minimize the PM 

carryover to the SCR. 

Utilities Required for the System 

 Boilers8&9 

Electric 110 VAC 100 

Watts each 
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Air None 

Water None 

Urea Rate #8 #9 

Urea Average 

Rate, gph 

 6 43 

Control Voltage 0-5 VDC 

The ELIM-NOx pump system automatically starts when the boiler is started. Injection begins 

when the exhaust temperature at the catalyst reaches 500 degrees F or above. The system 

ECU takes in Boiler and load and sets the injection rate based upon a map that is 

programmed into the ECU at start-up. The bypass dampers switchover the flow to pass 

through the catalyst. The injection rate is set by modulation of the injector pulse width 

(injector % on time). If the exhaust temperature drops below 500 degrees F, such as during 

startup or shutdown, the injection will stop automatically and the bypass dampers will 

redirect the flow around the catalyst. When the boiler is turned off, the circulation pump 

through the injector continues for 10 minutes, until the exhaust pipe cools off. Then the pump 

shuts off. No compressed air is required for the ELIM-NOx system. A flow schematic of 

the system is shown below; 

There is no power or performance penalty associated with the ELIM-NOx system, other that 

the 100 watts of auxiliary power requirements and the urea consumption. The catalyst is 

guaranteed for 3 years or 12,000 hours, whichever comes first. The injection system is 

warranted for one year. 

CCA takes no responsibility for undisclosed trace elements in the wood waste that are 

catalyst poisons that may degrade catalyst performance prematurely. Known catalyst poisons 

will shorten the life of the catalyst. 

3.2 Optimization, StartUp, Testing and Interim Report 

Upon completion of the installation of the SCR system, CCA’s engineer will advise All4 on 

optimization of operational changes which will improve overall unit performance and reduce 

NOx emissions. The performance of the boiler will also be evaluated by operating the unit with 

bias firing. The performance testing will be conducted over the complete load range of the boiler. 

The SCR load range is limited by the catalyst inlet temperature. The unit will be operated and 

tested at various conditions, including: 

• Excess oxygen 

• Load 

• Fuel 

• Urea injection rate 

• Ammonia slip 

 

This performance and emission testing is expected not to exceed a total of 15 days for the two

boilers. All emission monitoring equipment and personnel to operate it are to be provided by 

CCA. Upon completion of testing, an interim report will be issued containing the following 
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information: 

1. Conclusions of the program and recommendations for future corrective actions, if any. 

2. Comprehensive report of the NOx reduction over the load range. 

3. Test Data Summary of the results of the optimization testing. 

If additional time is required through no fault of CCA, this will be charged at per diem rates. 

4.0 COMMERCIAL TERMS 

4.1 Program Budget 

CCA will perform the NOx Reduction Program outlined in this proposal in Section 3 for the 

Budget Price of $1,223,000 for unit #8&9 in accordance with our 

Commercial Terms and Conditions and Fees and Scope of Service schedules located in the 

Appendix. CCA is not responsible for incidental, consequential or special damages. 

I have included $50,000 for a duct burner allowance for unit #8. During a firm bid quote we can 

supply the duct burner or other means to raise the temperature of boiler #9. No provision has 

been included to upgrade the ID fans if that is required. 

The urea storage system is included in Boiler #8 price. Urea storage is designed 

for indoor location. If outdoor is required then heating and insulation must be added. 

All prices are quoted exclusive of state and local sales, excise, use or any other taxes. Such taxes, 

if applicable, will be in addition to the above prices and will be charged to your account. Any 

taxes assessed to CCA at a later date will be charged to your account. If the above items are tax 

exempt, the applicable tax exemption certificate is to be sent to CCA with your purchase order. 

The price is FOB the factory in Connecticut, with freight prepaid and included. 

4.2 Program Schedule 

CCA can complete the work outlined in Section 3 in approximately 10-12 weeks after the 

authorization to proceed and all required details. 

The actual schedule will vary depending upon manpower loading at the time the authorization to 

proceed is received. 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH 

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4.3 Validity 

This proposal is valid for acceptance for sixty (60) days. 

4.4 Terms of Payment 

Twenty percent (20%) of the contract price shall accompany your written purchase order. The 

remaining eighty percent (80%) shall be paid in progress payments upon completion of each 

phase or portion of phase as follows: 

With PO-------------------------------------------20% 

Engineering Complete--------------------------20% 

Purchase of Long Lead Items------------------20% 

Equipment ready for shipment----------------30% 

Completion of Startup--------------------------10% 

Note: Final payment is due 60 days after successful demonstration of contract performance or 

(when performance testing is delayed) 180 days from final shipment of equipment, whichever 

comes first. 

4.5 Commercial Terms 

CCA terms and conditions will be used for this project. They can be found in the appendix. 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH 

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Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH 

203-261-7697 FAX 

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Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH 

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Boiler 

Boiler 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH 

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Manpower Rate: 

Manpower charges shall be on an hourly, portal-to-portal basis at the following rates: Principal Consultant $200/hr 

Senior Engineer $160/hr 

Engineer $125/hr 

Designer $100/hr 

Draftsman $90/hr 

Technician $100/hr 

Secretary $50/hr 

The basic rates shall apply for work on Monday through Friday for an 8-hour period between the hours of 7 A.M. to 7 P.M. Work in excess of 8 hours, night work and Saturday work shall be at a rate of 1.5 times the basic rate. Sunday and holiday work shall be at 2 times the basic rate. Travel time charges shall be at the basic rate for hours actually spent in travel. 

Minimum Daily Charges: 

A minimum daily charge for personnel in the field shall apply of 8 hours per day per person at the basic manpower rate. The minimum daily charge shall apply to travel on weekends, but not weekdays. 

Expenses: 

Per-diem charges per person shall be actual cost plus 10% G&A. Vehicle travel charges shall be: 

 Automobile .48cts/mi 

Truck or Trailer .75cts/mi 

All other travel costs such as air fare, car rental, taxi, parking, tolls, etc., shall be charged at cost plus 10% G&A. 

CEM Van Rental: $750/Day 

Portable Gas Analyzer: $250/Day Coal Flow Testing Equipment: $600/Day LOI Testing: $600/Day 

Flow Laboratory Facility $1,300/Day Combustion Test Rig $2,500/Day 

Field Delays:

Delays imposed on CCA personnel in the field resulting from causes beyond CCA's direct control, such as partial or complete process shutdown or irregularity, strike, flood, fire, inclement weather, or failure of the client to meet herein stated responsibilities, shall be charged at the minimum daily rate plus per diem and applicable travel expenses, unless exceeded by actual time at the facility. Then, actual time will be charged. No 

delay time shall be charged for a delay directly caused by CCA, such as, malfunction of CCA test equipment. 

Quotations:

Unaccepted quotations shall expire 30 days from date of issuance. Requested changes in 

project work scope shall subject a price quotation to change. 

Acceptance:

A purchase order or a written commitment for a quoted amount shall be received prior to the rendering of any service. A purchase order with a "not to exceed" amount will result 

in the termination of services before the amount is exceeded. Issuance of a new purchase order, a written addition to the existing purchase order, or other written authorization 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH 

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from the client shall be received before rendering of services is resumed. Authorization 

by the client to proceed shall constitute the client's acceptance of these terms and conditions. 

Escalation:

Once yearly, the outstanding portion of a quotation or budget for a project conducted 

over a time span of more than one year shall be subject to escalation for any new 

manpower rates or expense schedules issued by CCA. 

Payments:

Invoiced payments shall be due in full within 30 days of the date of invoice. Invoices 30 days past due shall accrue interest charges at the rate of 1 1/2% per month, due and payable by the client. Reasonable attorney fees, collection fees and other expenses incurred in collecting overdue amounts may be charged. 

Extra Services:

Quotations for work do not include pre or post conferences or follow-up services, unless otherwise noted. CCA's standard charges for such extra services will apply unless 

provided at CCA's option. 

Research and Development Projects: 

Research and development programs are by nature subject to frequent changes in scope, direction, and budget. CCA Corporation undertakes such programs on a time-and- materials basis only. For each research and development program, a best-estimate budget 

shall be presented. Charges against is budget shall be made for time spent and costs 

incurred. Should a program require funding in excess of the budget, the client will be notified for written authorization of the new budget prior to initiating work, which would incur charges above the old budget. 

Combustion Optimization Programs: 

The performance requirements of combustion optimization programs necessitate that CCA Corporation charge such programs on a time-and-materials basis. However, for 

each program a budget will be presented to the client. Should a program require funding in excess of the budget, the client will be notified for written authorization of the new 

budget prior to initiating further work. 

Patents and Proprietary Technology: 

CCA reserves all proprietary rights, including patent rights, in and to all devices, 

concepts, processes, products, inventions or other technology conceived or developed by CCA personnel during work conducted for a client. The client may use such CCA proprietary technology, royalty free, solely for the specific installation for which CCA's 

work was provided, and client may negotiate terms with CCA for expanded use to other installations. 

Warranty - Services:

CCA represents and warrants that its procedures are generally accepted practices and methods and its personnel are qualified to affect such procedures. Tests are performed on a best-efforts basis and CCA assumes no liability for deviations required by existing conditions beyond its control or field of responsibility. No guarantee or warranty is issued, implied or intended and no responsibility is assumed for testing other than the accuracy of observed results. Should CCA’s testing be materially defective, the sole liability of CCA shall be to repeat said test run at no additional cost to Client, provided, however, that said test run was not defective because of a failure of Client to supply critical information or to fulfill responsibilities. 

Warranty – Products: 

CCA represents and warrants that (a) products manufactured by it shall be (i) free of defects in materials 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH 

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and workmanship for a period of sixty (60) days from date of shipment to client and (ii) shall conform in all 

material respects to the specifications for such product agreed upon in this contract. For products not 

manufactured by CCA the original manufacturers warranty, if any, shall be assigned to client to the extent 

permitted and such assigned warranty shall be in lieu of any other warranty express or implied. CCA’s sole 

liability hereunder shall be during the sixty (60) day product warranty period to repair or replace, at its 

option, products that are defective or non-conforming to agreed specifications. CCA shall have no liability 

for removal, transportation and replacement of such products. 

Limitation and Disclaimer of Warranties:

CCA shall not be liable under the warranties hereunder unless: 

(a) Client promptly notifies CCA in writing of the alleged deficiency in the product or service and offers 

CCA a reasonable opportunity to cure such deficiency, and (b) if a product deficiency in a CCA 

manufactured product, CCA inspection verifies the existence of the deficiency and determines it was not 

caused by damage or destruction, including any occurring while in shipment, improper installation, testing 

or repair (including any repair not by CCA agents or employees or otherwise not consented to in writing by 

CCA), misuse, neglect, or alteration. 

THESE WARRANTIES ARE IN LIEU OF AND CCA DISCLAIMS ALL OTHER WARRANTIES, 

EXPRESS OR IMPLIED, WRITTEN OR ORAL, INCLUDING THOSE MERCHANTABILITY, 

FITNESS FOR A PARTICULAR PURPOSE, OR OTHERWISE, AND MAY BE MODIFIED BY CCA 

ONLY IN A WRITING SIGNED BY CCA IN WHICH IT INTENDS TO BE FOUND. 

Limitation of Liability:

CCA SHALL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR 

CONSEQUENTIAL DAMAGES, WHETHER BASED ON BREACH OF CONTRACT 

OR WARRANTY, NEGLIGENCE, OR ANY OTHER MATTER RELATING TO THIS 

CONTRACT. CCA’S MAXIMUM LIABILITY SHALL IN NO CASE EXCEED THE 

AMOUNT THAT HAS BEEN PAID TO CCA FOR THE PRODUCT OR SERVICE 

PRIOR TO THE EVENT WHICH RESULTS IN SUCH LIABILITY OR, FOR 

INSURED MATTERS, THE AMOUNT OF SUCH INSURANCE. 

The prices quoted in this sale were determined in part on the basis that CCA’s liabilities and Client’s remedies are limited as provided in this Statement and the prices would have been substantially different had those limitations not been agreed. 

Choice of Law:

Any controversy between the parties shall be governed by the laws of the State of 

Connecticut, to the exclusion of the law of any other forum, without regard to the jurisdiction in which any action or special proceeding shall be instituted. 

Entire Agreement:

With respect to the subject matter herein, this document contains the entire agreement 

between the parties involved, and supersedes all other agreements between the parties except as noted in the Special Provisions section of this document. 

Special Provisions: 
ATTACHMENT B – 2012 REVISED CCA SCR BUDGET PROPOSAL 
All4 UNIT #8 & 9 LOW NOx SCR 

BUDGET PROPOSAL

For

Nicholas Leone

All4 Inc

2393 Kimberton Road 

P.O. Box 299 

Kimberton, PA 19442-0299 

EMAIL: nleone@ALL4INC.COM 

Proposal No. 12-528 

February 17, 2012 

Prepared by:

Edmund Schindler 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

203-261-7697 FAX

2

TABLE OF CONTENTS

1.0 INTRODUCTION ...................................................................................................... 3

2.0 OBJECTIVES ............................................................................................................. 3

3.0 PROGRAM ACTION PLAN .................................................................................... 4

3.1 SCR System .............................................................................................................. 4

3.2 Optimization, StartUp, Testing and Interim Report .................................................. 6

3.3 Long Term Costs....................................................................................................... 7

3.4 Heat Recovery ........................................................................................................... 7

3.4 By Others .................................................................................................................. 8

4.0 COMMERCIAL TERMS .......................................................................................... 9

4.1 Program Budget ........................................................................................................ 9

4.2 Program Schedule ..................................................................................................... 9

4.3 Validity ..................................................................................................................... 9

4.4 Terms of Payment ................................................................................................... 10

4.5 Commercial Terms.................................................................................................. 10

APPENDIX

Appendix A – Experience Lists

Appendix B Case Histories

Appendix C CCA Brochure

Appendix D– CCA Fees & Scope of Service Sheets 

 

Confidentiality and Proprietary Information

Notice to Recipient of Proposal:

In consideration of CCA preparation of this proposal and disclosure of certain proprietary information, its recipient agrees to treat as confidential all CCA proprietary information 

disclosed herein. Such proprietary information includes, but is not limited to, all technical requirements, specification(s), print(s), and information relating to the description and 

operation of the system, which is the subject of this proposal, its components, equipment, options and related services, designs, processes, techniques, documentation, pricing, 

installation, and safety. The recipient further acknowledges that CCA proprietary information is unique and valuable, was developed or acquired by CCA at substantial expense, 

and is the subject of efforts by CCA to maintain the secrecy thereof. The recipient agrees not to reverse engineer, to use or to disclose this proprietary information to any person or 

party without the prior written consent of CCA. This agreement is effective between the recipient and CCA regardless of whether the parties enter into a contract for sale of the 

goods and/or services that are the subject matter of this proposal. 

© Copyright 2012, CCA. An unpublished work. All rights reserved. This document may be reproduced as required only for the internal use of its recipient in evaluation of this 

proposal. 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

203-261-7697 FAX

3

1.0 INTRODUCTION 

Changes from previous proposal

1. Lessons learned on two wood fired boilers and the added equipment associated 

with the lessons. Primarily the reverse flow system to prevent the catalyst from 

plugging.

2. Changes in the controls and injections system

3. The duct burner is now included in the boiler 9 proposal.

4. Change to 50% urea to lower the cost of the reactant.

5. Added catalyst to Blr 9 for the duct burner NOx.

 

Boiler #8 at another location is a small natural gas/fuel oil-fired unit that does not have 

any add on PM controls. The heat input is 400 mmBtu/hr. 

 

Stack temp 300F - 320F 

Moisture 7% 

Flow rate 180,000 acfm 

SO2 115 tpy 

NOx 137 tpy 

O2 5% 

PM 7.6 lbs/MMCF when burning gas (AP-42) 

PM 12.4 lbs/MMCF when burning fuel oil (AP-42) 

Flue gas temp prior to air heater 600F 

CO and CO2 data are not available for this unit. 

 

Boiler #9 adjacent to boiler #8 burns wood waste and natural gas. The unit is equipped 

with multiclones and parallel wet scrubbers for PM control. The boiler is rated at 360 

mmBtu/hr heat input. 

 

Stack temp 140F to 150F 

Moisture 20% 

Flow rate 140,000 acfm 

SO2 43 tpy 

NOx 932 tpy 

O2 7 to 8.5% 

PM 0.119 lb/mmBtu after PM controls 

CO 800 ppm 

CO2 10 to 11% 

Flue gas temp prior to air heater 375F 

2.0 OBJECTIVES 

The program objectives are as follows: 

1. Provide an SCR system for 90% NOx reduction for the worst fuel of each of the two

boilers. 

2. Supply a urea supply and injection system to supply ammonia to the catalyst. 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

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3. Identify ID Fan upgrade requirements

3.0 PROGRAM ACTION PLAN 

The program action plan consists of three (3) or 5 parts: 

1. Survey the units and locate space to install the catalyst bed and the urea tank. 

2. Design the system and the ductwork.

3. Provide the system

4. Provide installation supervision 

5. Provide startup, optimization and testing.

Installation is not included.

3.1 SCR System

CCA has provided SCR systems to mobile and stationary diesel engines ranging from a diesel 

engine in a pickup truck to a 2.5 MW electric generation diesel system. We have supplied over 

150 of these systems to date, and supplied two SCR’s to green wood fired boilers, at which many 

lessons were learned. All of these typically reduce the NOx 80 to 90%. Because we have focused 

on small mobile sources our SCR systems can be supplied for much less then the large OEM 

suppliers of SCR technology. I have attached two Case Histories in the Appendix for similar 

projects.

The system is designed for 100% flow of flue gas through the catalyst bed at a temperature of

600F.The SCR can maintain 90% reduction of NOx within a temperature range that is dependent 

on the catalyst used. Up stream of the catalyst the urea is injected into the duct and it converts to 

ammonia in the hot flue gas. The ammonia combines with the NOx at the catalyst surface and 

reduces the NOx to N2. Each of the two boilers will require a slightly different system. Boiler 9 

will require a high dust catalyst a duct heater and a reverse flow system, Boiler #8 can use a low 

dust catalyst used for oil and gas. There are catalysts available that can operate down to 450F but 

they are more expensive and it may make sense to just bring the temperature up to 600F. For 

boiler #9 that burn wood waste, the trace gas constituents must be defined and limited to insure 

that no catalyst poisons are present. 

The Engineering Included is as follows: 

• Baseline Survey

• Baseline Test

• CFD Model of the flow path to insure good mixing 

• P&ID’s and GA Drawings

• Bill of Materials

• Specification Sheets

• Installation and Instruction Manuals 

• Training 

• Structural Engineering with State Stamp.
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

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5

• Installation Supervision

• Startup and Tuning Including Ammonia Slip Testing 

The Equipment Supply is as follows: 

Boilers 8&9

SCR Component Unit #8 Unit #9

Tank-14,000 gallon polymer tank for inside storage of urea 

with urea pump and motor, inline filters and tank level sensor

for 14 days supply.

One tank for Boiler #8 & 9

Catalyst Type, Installed before the air heater in 8 and after the 

duct burner in #9

Oil and gas High dust 

wood and gas

Catalyst Volume, M3 with space for an extra layer 15’ x 17’ x 2’ 21’ x 22’ x 5’

Catalyst Shell-CS fabrication 1 1

Transition Duct 200 feet of CS duct included per boiler 1 1

Reverse Flow Bypass Duct and four low leakage dampers to 

back flow catalyst every 12 hours.

None 1

Support and Stair Tower 2 per SCR required 2 2

Expansion Joints 2 8

Additional ID fan requirements to be tested and proven or 

upgraded

180,000 acfm 

at 4 in wc 

140,000 acfm

at 6 in wc 

Gas Duct burner to raise flue gas to 600F None 1-85 mmBtu/hr

Retractable Urea Flow Injectors with SS hoses 4 8

Compressor, receiver and filter 240 SCFM with backup 2 for both units

PLC based Control Units 1 1

Lot of instrumentation (flow sensor, temperature of gas) 1 1

Urea pumps for each unit with auto backup 2 2

CFD model to determine best injection point and mixing for 

each unit.

1 1

Installation Supervision 6 weeks total 6 weeks total

Note: 1. the Multiclone must be operating at its design condition to minimize the PM carryover to the 

SCR.

2. The NOx of the duct burner is included in the estimate of NOx reduction.

Utilities Required for the System

Boilers 8,9

Electric *10 HP pump 10 KW 

heaters

Air 240scfm

Water None

Boiler #8 #9

Gas Fuel 0 85000scfm

Urea Rate %50

Urea Full Load 

Rate, gph

5 32

Control Voltage 0-5 VDC

Notes: *excludes fan

Anhydrous Ammonia would be half the usage rate. 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

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The injection system automatically starts when the boiler is started. Injection begins when the 

exhaust temperature at the catalyst reaches 500 degrees F or above. The system controls takes 

in boiler and load and sets the injection rate based upon a map that is programmed into the 

controls at start-up. The bypass dampers will reverse the flow to pass through the catalyst in 

the opposite direction about every 12 hours on boiler #9; boiler #8 does not require a bypass. 

If the exhaust temperature on boiler #9 drops below 500 degrees F, such as during startup or 

shutdown, the injection will stop automatically and the bypass dampers will redirect the flow 

around the catalyst. When the boiler is turned off, the circulation pump through the tank and 

heaters continues to prevent crystallization of the 50% urea. 

The catalyst is guaranteed for 1 years or 8760 hours of operation or from installation date, 

time, whichever comes first. The injection system is warranted for one year. The expected 

life is for 25,000 hours or 3 years, whichever comes first. 

CCA takes no responsibility for undisclosed trace elements in the wood waste that are 

catalyst poisons that may degrade catalyst performance prematurely. Known catalyst poisons 

will shorten the life of the catalyst.

Ammonia Anhydrous Supply 

Anhydrous ammonia can be used as an alternate. Ammonia is typically less costly then urea 

but harder to site near suburban or urban settings. Ammonia also requires a vaporizer to heat 

the ammonia to a gas for injection. The overall capital cost would be approximately similar.

3.2 Optimization, StartUp, Testing and Interim Report 

Upon completion of the installation of the SCR system, CCA’s engineer will advise All4 on 

optimization of operational changes which will improve overall unit performance and reduce

NOx emissions. The performance of the boiler will also be evaluated by operating the unit 

with bias firing. The performance testing will be conducted over the complete load range of 

the boiler. The SCR load range is limited by the catalyst inlet temperature. The unit will be 

operated and tested at various conditions, including: 

• Excess oxygen

• Load 

• Fuel 

• Urea injection rate

• Ammonia slip

This performance and emission testing is expected not to exceed a total of 15 days for both 

boilers. All temporary emission monitoring equipment and personnel to operate it are to be 

provided by CCA. Upon completion of testing, an interim report will be issued containing the 

following information: 

1. Conclusions of the program and recommendations for future corrective actions, if any. 

2. Comprehensive report of the NOx reduction over the load range. 

3. Test Data Summary of the results of the optimization testing. 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

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If additional time is required through no fault of CCA, this will be charged at per diem rates. 

3.3 Long Term Costs

Long term costs are an important part of the overall cost of the project. I have attempted 

to provide in this section the cost or a way to estimate the cost for both of these projects. 

These costs include: 

• Catalyst replacement –After 1 years one layer per year is replaced $250,000/yr blr 

9 and $150,000 Blr 8. 

• Gas fuel for duct reheater to bring Blr #9 to 600F 

• Urea cost $1.75 gal 

• Annual operating cost 

o Annual stack testing/tuning $40,000 yr and/or CEM maintenance cost

o Truck Unloading 2 hours/wk. 

o Operating Manpower-2 hours/day 

o Training and safety- 40 hours yr. 

o Water

o Electric TBD 

o Depreciation TBD

o Project Management 5% for the first year.

3.4 Heat Recovery

The duct heater to bring the flue gas temperature up to 600F normal operating 

temperature is a substantial operating cost. There are a number of systems for heat 

recovery but all would likely have substantial cost. 70% recovery is unlikely since the 

boiler is probably that efficient.

1. Air heater to reheat air to the boiler: besides the cost of the system the duct cost 

back to the boiler FD fan system would be substantial. 

2. Organic Rankine Cycle recovery: this converts the waste heat to electricity and 

would be the most flexible but probably the most expensive. 

3. Economizer: I recently quoted an economizer for a boiler with 100mmBtu heat 

input and it was $450,000 installed. This is likely to reduce the heat into the 

boiler 5.5% at full load and 3.0% at half load, or the hot water could be used 

somewhere else. This would require an added boiler performance study to reduce 

the potential for boiling in the economizer if the boiler has an economizer already. 

4. Heat recovery steam generator: this would be expensive and the temperatures 

would normally be closer to 1400F to make sense. 

All the above would add pressure drop 3-5 inwc to the ID fan and almost assure a new 

fan is required besides the extra power required.
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

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8

3.4 By Others

The following is a partial list of items not included. 

1. Installation of equipment

2. Waste and hazardous waste identification and removal 

3. Site Safety Training as required

4. Site Drawings

5. Recent ultimate and proximate fuel analysis

6. Access to the unit for site survey

7. Test loads for the optimization in a timely manner

8. Freight to the job site
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

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9

4.0 COMMERCIAL TERMS 

4.1 Program Budget 

CCA will supply the NOx Reduction System outlined in this proposal in Section 3 for the Budget

Price of $5,800,000.00 for unit #9 and for unit #8 a budget price of $2,350,000.00 in 

accordance with our Commercial Terms and Conditions and Fees and Scope of Service schedules 

located in the Appendix. CCA is not responsible for incidental, consequential or special 

damages. 

Installation is not included in the above price but is likely to be equal to the supply price. 

I have included the duct burner in the above price. No provision has been included to upgrade the 

ID fans if that is required. 

The common systems such as the urea storage system and compressed air are included in the 

Boiler 9 price. Urea storage is designed for indoor location. If outdoor is required then heating 

and insulation must be added. 

All prices are quoted exclusive of state and local sales, excise, use or any other taxes. Such taxes, 

if applicable, will be in addition to the above prices and will be charged to your account. Any 

taxes assessed to CCA at a later date will be charged to your account. If the above items are tax 

exempt, the applicable tax exemption certificate is to be sent to CCA with your purchase order. 

The price is FOB the factory in Connecticut, with freight prepaid and included. 

4.2 Program Schedule 

CCA can complete the work outlined in Section 3 in approximately 20-26 weeks after the 

authorization to proceed and all required details. 

The actual schedule will vary depending upon manpower loading at the time the authorization to 

proceed is received. 

4.3 Validity 

This proposal is budgetary 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

203-261-7697 FAX

10

4.4 Terms of Payment

Twenty percent (20%) of the contract price shall accompany your written purchase order. The 

remaining eighty percent (80%) shall be paid in progress payments upon completion of each 

phase or portion of phase as follows: 

With PO-------------------------------------------20% 

Engineering Complete--------------------------20% 

Purchase of Long Lead Items------------------20% 

Equipment ready for shipment----------------30% 

Completion of Startup--------------------------10% 

Note: Final payment is due 60 days after successful demonstration of contract performance or 

(when performance testing is delayed) 180 days from final shipment of equipment, whichever 

comes first. 

4.5 Commercial Terms

CCA terms and conditions will be used for this project. They can be found in the appendix. 
Combustion Components Associates, Inc. 884 Main Street Monroe, CT 06468 203-268-3139 PH

203-261-7697 FAX

11

Appendix A – Experience Lists

Appendix B Case Histories

Appendix C CCA Brochure

Appendix D– CCA Fees & Scope of Service Sheets
No. Client/Station MW No. of Fuel Type of Firing

Burners

1 CIPCO - Fair Station #2 42 6 Coal Front

1 Intermountain Power Service #1 850 48 Coal Opposed

1 Intermountain Power Service #2 850 48 Coal Opposed

1 Champion International - #1 12 4 Coal/Oil Front

1 Champion International - #2 12 4 Coal/Oil Front

1 Madison Gas & Electric Co. - Blount #8 50 6 Coal/Gas Front

1 Madison Gas & Electric Co. - Blount #9 50 6 Coal/Gas Front

1 Rochester Public Service - Silver Lake #4 65 6 Coal/Gas Front

1 Mid American Energy - Neal #2* 300 16 Coal Front

1 Tucson Electric Power - Irvington #4 120 9 Coal Front

1 First Energy - Bayshore #3 * 150 12 PRB Coal Front

1 First Energy - Bayshore #4 * 230 18 Coal Front

1 Mirant - Chalk Point #1* 355 24 Coal/Gas Opposed

1 Mirant - Chalk Point #2* 355 24 Coal/Gas Opposed

1 PECO - Cromby #1* 160 16 Coal Front

1 Michigan South Central - Endicott #1 62 8 Coal Front

1 Northeast Utilities - PSNH Schiller #4 50 6 Coal/Oil Front

1 Northeast Utilities - PSNH Schiller #5 50 6 Coal/Oil Front

1 Northeast Utilities - PSNH Schiller #6 50 6 Coal/Oil Front

1 First Energy - Sammis #1 190 15 Coal Front

1 First Energy - Sammis #2 190 15 Coal Front

1 First Energy - Sammis #4 190 15 Coal Front

1 Ontario Power - Lakeview #5 300 18 Coal Front

1 Ontario Power - Lakeview #6 300 18 Coal Front

1 Ontario Power - Lakeview #1 300 24 Coal Front

1 Ontario Power - Lakeview #2 300 24 Coal Front

1 Orion Energy - New Castle #4 * 100 12 Coal Front

1 Orion Energy - New Castle #3 * 100 12 Coal Front

1 Orion Energy - New Castle #5 * 100 12 Coal Front

1 Detroit Edison - St. Clair #1* 163 12 Coal/Oil Front

1 Detroit Edison - St. Clair #2* 163 12 Coal/Oil Front

1 Detroit Edison - St. Clair #3* 163 12 Coal/Oil Front

1 Detroit Edison - St. Clair #4* 163 12 Coal/Oil Front

1 Otter Tail Power - Hoot Lake #3 100 8 Coal Front

1 Packaging Corp of America - Filer City #2 15 4 Coal Front

1 City of Hamilton - Ohio #9 55 12 Coal/Gas Tangential

1 Mirant Potomac River 3,4,5 100 16 Coal Tangential

1 Mirant Potomac River 1,2 80 16 Coal Tangential

1 Bayer Institute Plant 250 KPPH 4 Coal Front

* Has Overfire Air

Experience - Coal Fired Units

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
No. Client/Station MW No. of Fuel Description

Burners

1 Bayer CropScience - #10 250 KPPH 4 Coal/Gas Front

1 Bayer CropScience - #11 250 KPPH 4 Coal/Gas Front

1 Bayer CropScience - #12 250 KPPH 4 Coal/Gas Front

1 Customer Confidential 780 70 Coal Opposed

1 Detroit Edison - St. Clair #1 163 12 Coal/Oil Front

1 Detroit Edison - St. Clair #2 163 12 Coal/Oil Front

1 Detroit Edison - St. Clair #3 163 12 Coal/Oil Front

1 Detroit Edison - St. Clair #4 163 12 Coal/Oil Front

1 Exelon - Cromby #1 160 16 Coal Front

1 First Energy - Bayshore #3 150 12 PRB Coal Front

1 First Energy - Bayshore #4 230 18 PRB Coal Front

1 First Energy - Sammis #1 190 15 Coal Front

1 First Energy - Sammis #4 180 15 Coal Front

1 Orion Energy - New Castle #3 100 12 Coal Front

1 Orion Energy - New Castle #4 100 12 Coal Front

1 Orion Energy - New Castle #5 100 16 Coal Front

1 Upgrade OFA & Burner Mods

Work in Progress 860 32 Oil Tangential

1 Pulp and Paper Mill 390k pph 12 Wood/CoalStoker/T-Fired

1 Schenectady International 100k pph 0 Wood/Coal Stoker

1 Suez Energy Pinetree Power

Bethlehem 16 0 Wood Stoker

1 Suez Energy Pinetree Power

Bethlehem 18 0 Wood Stoker

Experience - Overfired Air Units

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
No. Client/Station MW No. of Fuel Description

Burners

1 Conectiv, B.L. England Unit #1 130 3 Coal Cyclone

1 Conectiv, B.L. England Unit #1

SNCR & RRI Demo 130 3 Coal Cyclone

1 Conectiv, B.L. England Unit #2 160 4 Coal Cyclone

1 Conectiv, B.L. England Unit #3 160 12 Oil Tangential

1 Exelon, Cromby Unit #1 160 16 Coal Front

1 Northeast Utilities, Schiller Unit #4 50 6 Coal/Oil Front

1 Northeast Utilities, Schiller Unit #5 50 6 Coal/Oil Front

1 Northeast Utilities, Schiller Unit #6 50 6 Coal/Oil Front

1 Suez Energy Pinetree Power

Bethelem 16 0 Wood Stoker

1 Suez Energy Pinetree Power

Tsamworth 18 0 Wood Stoker

1 Schenectady International 12 0 Wood Stoker

1 Utility 4 boilers 600 16 Coal Tangential

Experience - Tangential Fired Units

No. Client/Station MW No. of Fuel Description

Burners

1 City of Austin - Decker 1 320 16 Gas Burner Modifications Low NOx

1 City of Austin - Holly 4 185 16 Gas Burner Modifications Low NOx

1 City of Hamilton 55 12 Coal Burner Modifications

1 Conectiv [Atlantic Electric] 160 12 Oil Burner Modifications Low NOx

- B.L. England 3 & SNCR

1 MIRANT Potomac River 1 90 16 Coal Burner Modifications Low NOx

1 MIRANT Potomac River 2 90 16 Coal Burner Modifications Low NOx

1 MIRANT Potomac River 3 105 16 Coal Burner Modifications Low NOx

1 MIRANT Potomac River 4 105 16 Coal Burner Modifications Low NOx

1 MIRANT Potomac River 5 105 16 Coal Burner Modifications Low NOx

1 MIRANT Potomac River 5 105 16 Coal Burner Modifications Low NOx

Experience - SNCR Units

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
Experience - Tangential Fired Units - Gas, Oil, Gas-Oil Fired

No. Client/Station MW No. of Fuel Description

Burners

1 City of Austin - Decker 1 320 16 Gas Burner Modifications Low NOx

1 City of Austin - Holly 4 185 16 Gas Burner Modifications Low NOx

2 Duke - South Bay 4 220 12 Gas Burner Modifications &

Combustion Tempering

1 Entergy - Sabine 5 480 16 Gas Burner Modifications & OFA

1 Exelon Eddystone #3 600 32 Gas/Oil Burner Modifications Low NOx

1 Exelon Eddystone #4 600 32 Gas/Oil Burner Modifications Low NOx

1 Mirant [PEPCO] 640 32 Gas/Oil Burner Modifications Low NOx

- Chalk Point 3

1 Mirant [PEPCO] 640 32 Gas/Oil Burner Modifications Low NOx

- Chalk Point 4

1 Conectiv [Atlantic Electric] 160 12 Oil Burner Modifications Low NOx

- B.L. England 3 & SNCR

1 Customer Confidential 860 32 Oil Burner Modifications Low NOx

& OFA Upgrade

1 Exelon Mystic #4 135 24 Oil Burner Modifications Low NOx

1 Exelon Mystic #5 135 24 Oil Burner Modifications Low NOx

1 Exelon Mystic #6 135 24 Oil Burner Modifications Low NOx

1 EXELON MYSTIC #7 600 16 Oil Burner Modifications Low NOx

& SCOFA

1 FPL-WYMAN #3 125 12 Oil Burner Modifications Low NOx

& OFA

1 Northeast Utilities 84 16 Oil Atomizer Upgrade

- Montville 5

1 Northeast Utilities 165 24 Oil Burner Modifications Low NOx

- Norwalk Harbor 1 & SNCR

1 Northeast Utilities 175 24 Oil Burner Modifications Low NOx

- Norwalk Harbor 2 & SNCR

1 PP&L - Martins Creek 3 850 32 Oil Burner Modifications Low NOx

1 PP&L - Martins Creek 4 850 32 Oil Burner Modifications Low NOx

1 CSW/Swepco - Knox Lee 340 20 Oil/Gas NOx Tempering

3 Dynegy - Roseton 1 600 20 Oil/Gas Low NOx Atomizer

1 Dynegy - Roseton 2 600 20 Oil/Gas Low NOx Atomizer

1 Northeast Utilities 400 20 Oil/Gas Burner Modifications &

- Newington 1 Combustion Tempering

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
No. CLIENT/STATION MW No. of Fuel Boiler Type of Baseline Final

Burners Mfg. Firing NOX NOX

lb/mm lb/mm

Btu Btu

1 AEP (CSW/West

Texas Utilities)-

Paint Creek Unit 4 120 8 Gas Riley Front 0.55 0.24 (3)

1 AEP (CSW/West

Texas Utilities)-

Rio Pecos Unit 6 102 9 Gas/Oil Riley Front 0.7 0.315

1 AEP (SWEPCO) -

Wilkes Unit 2 348 18 Gas B&W Opposed 0.7 0.228

1 AEP (SWEPCO) -

Wilkes Unit 3 348 18 Gas B&W Opposed 0.37 0.228

1 AES Redondo Beach

Unit 5 170 12 Gas B&W Front 0.2 0.1

1 Austin Energy -

Decker Unit 1 320 16 Gas CE Tangential 0.23 0.14

1 Austin Energy -

Decker Unit 2 420 18 Gas B&W Front 0.11 0.055 (3)

1 Austin Energy -

Holly Unit 3 195 12 Gas/Oil B&W Opposed 0.24 0.125

1 Austin Energy -

Holly Unit 4 185 16 Gas CE Tangential N/A 0.147

1 Brazos Electric Power -

R.W. Miller Unit 3 220 9 Gas/Oil Riley Front 0.35 (1) 0.23 (1)

1 City of Bryan -

Dansby Plant 110 6 Gas B&W Front 0.18 0.08

1 City of Dover (DE) -

McKee Run Unit 1 18 4 Gas/Oil B&W Front 0.57 (2) 0.37 (2)

1 City of Dover (DE) -

McKee Run Unit 2 18 4 Gas/Oil B&W Front 0.57 (2) 0.37 (2)

1 City of Dover (DE) -

McKee Run Unit 3 95 9 Gas/Oil Riley Front 0.42 (2) 0.27 (2)

Conectiv Edge Moor #5 440 28 Oil B&W Opposed 0.35 0.2

1 Conectiv (Atlantic Electric) -

B.L. England Unit 3 160 12 Oil CE Tangential 0.43 0.28

1 ConEd-60 1.4M KPPH 12 Oil FW Opposed 0.31/ 0.22/

0.33 0.17

1 ConEd-70 w/wo FGR 180 18 Oil/Gas FW Rear 0.31/ wo/0.2/

0.33 0.17

w/na/0.11

1 Customer Confidntial 860 32 Oil CE Tangential 0.21 0.174

Experience - Gas, Oil or Gas/Oil Installations

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
No. CLIENT/STATION MW No. of Fuel Boiler Type of Baseline Final

Burners Mfg. Firing NOX NOX

lb/mm lb/mm

Btu Btu

1 Duke - South Bay Unit 4 220 12 Gas CE Tangential 0.18 0.11

1 Dynegy - Roseton Unit 1 600 20 Oil CE Tangential 0.25 0.2 (3)

1 Dynegy - Roseton Unit 2 600 20 Oil CE Tangential 0.25 0.2 (3)

1 Eastern Fine Paper -

Boiler 1 12 4 Oil B&W Front N/A 0.22

1 Eastern Fine Paper -

Boiler 2 12 4 Oil B&W Front N/A 0.23

1 El Paso Electric -

Newman Unit 2 80 12 Gas/Oil B&W Front 0.52 0.22

1 El Paso Electric -

Newman Unit 3 105 9 Gas/Oil B&W Front 0.72 (1) 0.32 (1)

1 El Paso Electric -

Rio Grande Unit 7 50 8 Gas/Oil B&W Front 0.52 0.26

1 El Paso Electric -

Rio Grande Unit 8 163 12 Gas B&W Front 0.3 0.25

1 El Paso Electric -

Newman Unit 1 80 12 Gas/Oil B&W Front 0.54 0.267

1 Entergy -

Lousiana Unit 10 42 6 Gas C&E Front 0.17 0.10

1 Entergy -

Lousiana Unit 11 42 6 Gas C&E Front 0.13 0.085

1 Entergy -

Lousiana Unit 12 62 12 Gas C&E Front 0.14 0.10

1 Entergy -

Monroe Unit 12 74 6 Gas C&E Front 0.53 0.091

1 Entergy - Sabine Unit 5 480 16 Gas CE Tangential 0.15 0.094 (3)

1 Entergy -

Willow Glen Unit 3 485 24 Gas FW Opposed 0.20 0.20 (4)

1 Exelon (PECO) -

Fairless Hills Unit 1 40 6 Gas/Oil Riley Front 0.15 (1) 0.10 (1)

1 Exelon (PECO) -

Fairless Hills Unit 2 40 6 Gas/Oil Riley Front 0.15 (1) 0.10 (1)

1 Exelon (PECO) -

Fairless Hills Unit 3 40 6 Gas/Oil Riley Front 0.15 (1) 0.10 (1)

1 Exelon (PECO) -

Fairless Hills Unit 4 40 6 Gas/Oil Riley Front 0.15 0.10

1 Exelon (PECO) -

Fairless Hills Unit 5 40 6 Gas/Oil Riley Front 0.15 0.10

1 Exelon (TXU) -

Mountain Creek Unit 6 115 15 Gas/Oil Riley Front 0.56 (1) 0.23 (1)

Experience - Gas, Oil or Gas/Oil Installations

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
No. CLIENT/STATION MW No. of Fuel Boiler Type of Baseline Final

Burners Mfg. Firing NOX NOX

lb/mm lb/mm

Btu Btu

1 Exelon (TXU) -

Mountain Creek Unit 7 125 12 Gas/Oil B&W Front 0.73 (1) 0.48

1 Exelon-Mystic #7 600 16 Oil CE Tangential 0.29 .2

2 FPLPort Everglades #3 & 4 400 18 Oil FW Rear 0.65 .45

1 FPL- Wyman #1 55 6 Oil FW Front 0.41 0.27

1 FPL- Wyman #2 55 6 Oil FW Front 0.41 0.27

1 FPL-Manatee #1 800 32 Oil FW Front 0.38 .32

1 FPL-Manatee #2 800 32 Oil FW Front

1 FPL-Wyman #3 125 12 Oil CE Tangential 0.26 .145

1 FPL-Wyman #4 630 30 Oil FW Front 0.24 .167

1 Huntsman Corporation -

Port Neches Boiler 5 12 6 Gas Vogt Front 0.12 0.05

1 Huntsman Corporation -

Port Neches Boiler 6 12 6 Gas Vogt Front 0.12 0.06

1 Huntsman Corporation -

Port Neches Boiler 7 20 4 Gas Vogt Front 0.14 0.08

1 Huntsman Corporation -

Port Neches Boiler 7@C4 65 12 Gas Vogt Front 0.20 0.02

1 Huntsman Corporation -

Port Neches Boiler 8 20 4 Gas Vogt Front 0.14 0.08

1 International Paper -

Boiler 1 43 6 Oil B&W Front 0.43 0.25

1 International Paper -

Boiler 2 43 6 Oil B&W Front 0.43 0.25

1 JEA - Northside Unit 3 500 24 Gas/oil Riley Front 0.5 0.375 (3)

1 Kimberly Clark

(Scott Paper Co) -

Boiler 2 18 4 Oil Riley Front 0.54 0.23

1 Kimberly Clark

(Scott Paper Co) -

Boiler 3 18 4 Oil Riley Front 0.29 0.22

1 Massport 10 3 Oil Keeler Front 0.35 0.20

1 Mirant (Potomac Electric) -

Chalk Point Unit 3 640 32 Gas/Oil CE Tangential 0.48 (2) 0.24 (2)

1 Mirant (Potomac Electric) -

Chalk Point Unit 4 640 32 Gas/Oil CE Tangential 0.48 (2) 0.24 (2)

1 NRG (NU) -

Middletown Unit 2 122 12 Oil Riley Front 0.38 0.29

Experience - Gas, Oil or Gas/Oil Installations

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
No. CLIENT/STATION MW No. of Fuel Boiler Type of Baseline Final

Burners Mfg. Firing NOX NOX

lb/mm lb/mm

Btu Btu

1 NRG (NU) -

Norwalk Harbor Unit 1 165 24 Oil CE Tangential 0.4 0.25

1 NRG (NU) -

Norwalk Harbor Unit 2 175 24 Oil CE Tangential 0.4 0.25

1 NRG Cabrillo -

Encina Unit 1 110 10 Gas/Oil B&W Front 0.13 0.075

1 NRG Cabrillo -

Encina Unit 2 110 10 Gas/Oil B&W Front 0.13 0.085

1 NRG Cabrillo -

Encina Unit 3 115 10 Gas/Oil B&W Front 0.13 0.08

1 Packaging Corporation

of America

(Tenneco Packaging) -

Filer City Boiler 2 15 4 Gas/Coal B&W Front 0.20 (1) 0.15 (1)

1 PG&E -

Hunters Point Unit 4 170 15 Gas C&E Front 0.11 0.03

1 PP&L Martins Creek #3 850 32 oil CE Tangential 0.4 0.27

1 PP&L Martins Creek #4 850 32 oil CE Tangential 0.36 0.29

1 Reliant -

WA Parish Unit 2 180 20 Gas CE Front 0.35 0.20 (3)

1 Rhode Island Prison

Authority - Unit 7 10 4 Oil Riley Front 0.29 0.091

1 Texas Utilities (TXU) -

Eagle Mountain Unit 2 175 24 Gas/Oil Riley Front 0.43 (1) 0.19 (1)

1 Texas Utilities (TXU) -

Eagle Mountain Unit 3 400 16 Gas FW Opposed 0.31 0.15

1 Texas Utilities (TXU) -

Lake Hubbard Unit 2 540 32 Gas/Oil B&W Opposed 0.36 (1) 0.18 (1)

1 Texas Utilities (TXU) -

Parkdale Unit 2 115 15 Gas/Oil B&W Front 0.81 (1) 0.29 (1)

1 Texas Utilities (TXU) -

Parkdale Unit 3 134 12 Gas/Oil B&W Front 0.76 (1) 0.42 (1)

1 Texas Utilities (TXU) -

Stryker Creek Unit 1 175 18 Gas/Oil B&W Front 0.72 0.45 (3)

1 Texas Utilities (TXU) -

Valley Unit 1 175 9 Gas/Oil B&W Front 0.46 0.20

1 U.S Gen Salem

Harbor #4 450 24 Oil Riley Rear 0.55 0.28

1 US Pharmaceuticals -

Boiler 1 12 4 Oil CE Front 0.38 0.23

Experience - Gas, Oil or Gas/Oil Installations

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
No. CLIENT/STATION MW No. of Fuel Boiler Type of Baseline Final

Burners Mfg. Firing NOX NOX

lb/mm lb/mm

Btu Btu

1 US Pharmaceuticals -

Boiler 2 12 4 Oil CE Front 0.38 0.23

1 US Pharmaceuticals -

Boiler 3 12 4 Oil CE Front 0.38 0.23

1 Western Farmers

Electric Coop -

Mooreland Unit 2 138 9 Gas Riley Front 0.45 0.30

1 Western Farmers

Electric Coop -

Mooreland Unit 3 153 9 Gas Riley Front 0.6 0.30

88 Totals 18,725 1173

** Does not include coal-fired expertise

Overfire Air - Gas, Oil, Oil-Gas

No. CLIENT/STATION MW No. of Fuel Boiler Type of Baseline Final

Burners Mfg. Firing NOX NOX

lb/mm lb/mm

Btu Btu

1 Entergy-Sabine #5 480 20 Gas CE Tangential 0.15 0.094 (4) (5)

1 PG&E Hunters Point #4

BOOS w/FGR 175 15 GAS CE Front 0.11 0.03 (4)

1 Conectiv Edge Moor 5 440 28 Oil B&W Opposed 0.35 0.2 (5) (4)

1 FPL-Wyman 3 125 12 Oil CE Tangential 0.29 0.16

1 FPL-Wyman 4 630 30 Oil FW Rear 0.3 0.21

1 Customer Confidential 860 32 Oil CE Tangential 0.21 0.174 (5)

1 Con Ed-Unit 60 1.4M KPPH 12 Oil/Gas FW Opposed 0.31/ 0.22/

0.33 0.17 (2) (4)

1 Con Ed-Unit 70

w/wo FGR 180 18 Oil/Gas FW Rear .31/.33 wo/

0.20/0.17

w/na/0.11

1 Exelon-Mystic #7 BOOS 600 16 Oil/Gas CE Opposed 0.29 0.2 (3)

Experience - Gas, Oil or Gas/Oil Installations

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
No. CLIENT/STATION MW No. of Fuel Boiler Type of

Burners Mfg. Firing

1 NRG - Northeast Utilities -

Middletown - # 3 245 5 Gas/Oil Babcock & Wilcox Cyclone

1 Northeast Utilities -

Newington Station #1 406 16 Gas/Oil Combustion Engineering Tangential

1 Western Farmers Elec. -

Mooreland #3 153 9 Gas Riley Front

1 CSW/Swepco - Knox Lee #5 350 16 Gas Combustion Engineering Tangential

1 PG&E - Hunters Point #4 170 15 Gas Combustion Engineering Front

1 Entergy - Monroe #12 74 6 Gas Combustion Engineering Front

1 CSW - Sweeny #8 & 9 65 16 Gas Babcock & Wilcox Front

1 Lowe Paper 7 2 Gas Bieglo Front

1 Duke Power - South Bay #4 220 12 Gas Combustion Engineering Tangential

3 NRG - Cabrillo -

Encina #1, 2 & 3 110 30 Gas Babcock & Wilcox Front

1 Austin Energy - Holly #3 165 12 Gas/Oil Babcock & Wilcox Opposed

2 Entergy -

Louisianna #10 & 11 40 6 Gas Combustion Engineering Front

1 Entergy - Louisianna #12 60 12 Gas Combustion Engineering Front

1 Conectiv - B.L. England #2 160 4 Coal Babcock & Wilcox Cyclone

1 Austin Energy - Decker #1 321 16 Gas/Oil Combustion Engineering Tangential

1 Austin Energy - Holly #4 180 12 Gas Combustion Engineering Tangential

1 Austin Energy - Decker #2 410 18 Gas/Oil Babcock & Wilcox Opposed

1 El Paso Electric -

Rio Grande #8 163 12 Gas Babcock & Wilcox Front

1 Exelon-Mystic #7 600 16 OIL Combustion Engineering Tangential

4 Lucent Bell Labs - 1 Gas B&W ‘D’ Package

NOx Tempering Installation List

(T-Fired, Front, Opposed, Cyclone Boilers)

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
Company Plant Combustion Upgrade &

Nox Reduction Scope

International Paper Jay Maine – Boilers 1 & 2 425k pph Oil Fired

Burner Modifications

International Paper Riegelwood North Carolina – 300k pph Bark & Oil Fired

Boiler 2 Burner Modifications

International Paper Riegelwood North Carolina– Site Survey for Combustion

Boiler 1 Upgrade

International Paper Bucksport Maine Atomizer Upgrade

International Paper Pensacola Florida – CFD Modeling for NOx Reduction

Thermal Oxidizer Burner Modifications

International Paper Pensacola Florida – Boiler 4 420k pph Steam Bark &

Coal fired boiler

Coal burner modifications

International Paper Mansfield Louisiana - 500k pph Steam Bark &

Power Boiler #1&2 Coal fired boiler

Coal burner modifications

International Paper Georgetown South Carolina – 450k pph steam Bark &

Power Boilers 1 & 2 Coal fired boilers

Coal Burner Modifications

International Paper Prattville Alabama – 450k pph steam Bark,

Power Boiler 2 Coal & Oil Boiler

OFA System

International Paper Augusta Georgia 1-400kpph Bark, Coal Gas

and Oil Boiler

Coal and Gas Burner Modifications

Schenectady Intl. New York PH wood Boiler for Electric Gen.

OFA, FGR & SNCR for NOx Reduction

Suez New Hampshire 160 and 250 KPPH Wood Boiler

for Electric Gen. - OFA, FGR, SNCR

& SCR for NOx Reduction

Champion Paper Deferiet, NY Low NOx Coal

Warsau Paper New York Low NOx Oil

Garden State Paper New Jersey Low NOx Oil

PCA Filer City, MI Low NOx Gas & Coal

Huhtamachi Paper Watertown, ME Low NOx Oil

Lincoln Paper Lincoln, ME Low NOx Oil

Eastern Fine Paper Lincoln, ME Low NOx Oil

Finch Pruyn Glens Falls, NY Low NOx Oil

Simkins Conn. and New Jersey Low NOx Oil

Experience - Pulp & Paper Units

CCA - Combustion Components Associates, Inc.

www.cca-inc.net • info@cca-inc.net • Tel: 203-268-3139 • Fax: 203-261-7697
Confidential Proposal

CCA firm Proposal 10‐282r1 17 May 14, 2010

CASE HISTORY

CLIENT 

Pinetree Power Tamworth New Hampshire

PLANT NAME Pinetree Power Tamworth Station (GDF Suez NA)

APPLICATION Biomass fired stoker boiler burning clean wood chips requiring low NOx

emissions for renewable fuel credits.

PROJECT SCOPE Engineer, supply, install and commission OFA modifications, installation of a FGR

system, SNCR and SCR systems to the existing Zurn boiler.

Manufacturer Zurn

Type Wood Fired Stoker Boiler

Capacity 220,0001blhr

Steam Conditions 700 PSIG @ 900F  SH

Fuels Clean Wood Chips

Burners 5 Zurn Feeders

Firing Arrangement Traveling Grate Stoker

Combustion Air Temperature 450 F

Furnace Plan 18 feet x 22 feet

Overfire Air 6 Ports on the side walls

FOR 5 Ports Undergrate

SNCR 6 Tilting Injectors

SCR 2 Layers

BOILER DATA

Baseline NOx 0.212 Ib/MMbtu

CONTACT PERSON Russ Dowd Plant Manager Tel: 1‐603‐323‐8187

DESCRIPTION The plant desired to reduce NOx emissions to less than 0.065 lb/MMBtu to apply

for renewable energy credits through the sale of power to the States of

Connecticut and Massachusetts.

This project was executed on a very tight schedule with 5 months from order to

outage. The scope of work was to modify the existing OFA system to reduce the

undergrate air to provide improved combustion for a reduction in LOI and CO

emissions. The FGR system was installed to maintain the bed fluidity with the

reduction of the undergrate air and provide NOx reduction.

The SNCR system was installed to provide significant NOx reduction to reduce

the size of the SCR catalyst volume. The SCR was installed after the ESP and the

flue gases of the boiler were relatively low at 375 F. A by‐pass was installed

around the air heater to reheat the flue gas at the SCR to 420 F. The SCR was

installed to achieve the remainder of the NOx reduction to the 0.065 lb/MMBtu

goal. The outage duration was 8 days.

PERFORMANCE

The NOx was reduced to 0.05 lb/MMBtu. The LOI was reduced by 60% from 28%

to 11%. The CO emissions were unchanged at 200 ppm. NOx emissions

decreased 76% from 0.212lb/MMBtu to 0.05 lb/MMBtu. The control of ash

fouling of the SCR catalyst was effectively achieved with the installation of a

forward‐reverse duct arrangement. A new booster ID fan was installed to help

overcome limited existing ID fan capacity.  
Confidential Proposal

CCA firm Proposal 10‐282r1 18 May 14, 2010

CASE HISTORY 

CLIENT 

Pinetree Power Bethlehem New Hampshire

PLANT NAME Pinetree Power Bethlehem Station (GDF Suez NA)

APPLICATION Biomass fired stoker boiler burning clean wood chips requiring low NOx

emissions for renewable fuel credits.

PROJECT SCOPE Engineer, supply, install and commission OFA modifications, installation of a

FGR system, SNCR and SCR systems to the existing Zurn boiler.

Manufacturer Zurn

Type Wood Fired Stoker Boiler

Capacity 165,0001blhr

Steam Conditions 635 PSIG @ 825F  SH

Fuels Clean Wood Chips

Burners 4 Zurn Feeders

Firing Arrangement Traveling Grate Stoker

Combustion Air Temperature 450 F

Furnace Plan 18 feet x 20 feet

Overfire Air 6 Ports on the side walls

FOR 4 Ports Undergrate

SNCR 6 Tilting Injectors

SCR 2 Layers

BOILER DATA

Baseline NOx 0.212 Ib/MMbtu

CONTACT PERSON Mark Driscoll Plant Manager Tel: 1‐603‐444‐9993

DESCRIPTION The plant desired to reduce NOx emissions to less than 0.065 lb/MMBtu to

apply for renewable energy credits through the sale of power to the States of

Connecticut and Massachusetts.

This project was executed on a very tight schedule with 5 months from order

to outage. The scope of work was to modify the existing OFA system to

reduce the undergrate air to provide improved combustion for a reduction in

LOI and CO emissions. The FGR system was installed to maintain the bed

fluidity with the reduction of the undergrate air and provide NOx reduction.

The SNCR system was installed to provide significant NOx reduction to reduce

the size of the SCR catalyst volume. The SCR was installed after the ESP and

the flue gases of the boiler were relatively low at 375 F. A by‐pass was

installed around the air heater to reheat the flue gas at the SCR to 420 F. The

SCR was installed to achieve the remainder of the NOx reduction to the 0.065

lb/MMBtu goal. The outage duration was 8 days.

PERFORMANCE

The NOx was reduced to 0.05 lb/MMBtu. The L01 was reduced by 25% from

20% to 15%. The CO emissions decreased from 360 to 232 ppm. NOx

emissions decreased 76% from 0.212lb/MMBtu to 0.05 lb/MMBtu. The

control of ash fouling of the SCR catalyst was effectively achieved with the

installation of a forward‐reverse duct arrangement.
C C A

Combustion

Components

Associates, Inc.

www.cca-inc.net
CCA is a global provider of combustion control technologies to reduce NOx, particulate matter (PM), unburned carbon and CO emissions at various types of combustion facilities including utility power plants, paper & pulp mills, chemical plants, oil refineries, ethanol plants,

marine vessels, and diesel engines.

CCA specializes in supplying in-furnace and post

combustion emission control technologies. CCA’s

technologies have been installed in over 100 steam

generators worldwide ranging in size from 10 MW to

800 MW (50,000 to 5,500,000 lb/hr steam flow) on

coal, natural gas, fuel oil, refinery gas, and biofuel

fired units. CCA technologies also have been installed on thermal oxidizers and dryers.

CCA’s in-furnace combustion control technologies

achieve up to 70% reduction in NOx emissions

through patented and proprietary modifications on

wall-fired, tangential-fired, cyclone-fired, circulating

fluid bed (CFB), and stoker-fired boilers, in addition

to heaters and dryers. NOx reductions up to 95%

can be achieved with the addition of post combustion systems such as SNCR and SCR. The combination of combustion system modifications with post

combustion technologies provides the most cost effective approach to minimize NOx emissions.

About CCA

CCA’s core expertise is emissions technologies for gaseous, liquids, and solid fuels, including combustion and post combustion

NOx controls. CCA offers burner upgrades

for coal, oil, and gas-fired systems, new

burners, overfire air (OFA), flue gas recirculation (FGR), targeted water tempering,

SNCR, and SCR. Technologies can be implemented alone or in combination to

achieve high levels of NOx control.

Flue Gas Recirculation

SCR

Furnace and Stack

Emissions Testing

Urea or NH3

Injection

ESP

Air Heater

Rich Reagent

Injection

Overfire Air

System

Urea Injection

SNCR

Burners:

- Flame

Stabilizers

- Atomizers

- Coal

Nozzles

- Gas

Injectors

- Combustion

Tempering

Computer Modeling and Simulation

Combustion Products & Services
Overfire Air (OFA)

CCA’s Overfire Air (OFA) system typically diverts 20-30%

of the combustion air from the burners to the upper furnace to

stage the combustion process beyond what can be achieved with low-NOx

burners. CCA’s OFA technology has been applied to wall, cyclone,

tangential, and stoker-fired boilers burning oil, gas, coal, and biofuels. CCA’s

unique OFA port design ensures good air/fuel mixing and carbon burnout

at all boiler loads.

CCA offers patented technologies that can be retrofit to existing

coal, oil, and gas burners to achieve NOx emissions comparable to

new low-NOx burners at a fraction of the cost. CCA has performed upgrades on over 3,000 OEM burners on wall-fired

and tangential-fired boilers, package boilers, heaters,

and dryers. CCA also supplies new burners that incorporate our low-NOx technologies for applications where burner upgrades are not practical.

The basis of CCA’s NOx reduction technology is

fuel and air staging. Fuel staging is accomplished using fuel injectors that produce fuel

rich and fuel lean zones immediately downstream of the burner. Similarly, the combustion

air is staged into air lean and air rich zones by a

multi-zone flame stabilizer. The end result is fuel

rich and fuel lean zones that can reduce NOx emissions by up to 50% with extremely stable flames.

Low-NOx Burners

Standard Oil Fired Burner Oil/Gas Burner

Low-NOx

Flame Stabilizer
The unique ports are designed to inject air at the

proper velocity and direction to complete combustion prior to the furnace exit at all boiler loads. If

required to improve burnout, tilting (vertical) and

yawing (horizontal) port designs are available. CCA

uses CFD modeling to locate the OFA ports on the

furnace walls and to design the geometry of the OFA

port. NOx reductions achieved with a CCA OFA system range from 25-40% depending on the fuel and

initial NOx level.

Flue Gas Recirculation (FGR)

Flue Gas Recirculation (FGR) is a powerful NOx control technique where flue gases from the

boiler exhaust duct are mixed with the combustion air stream and enter the furnace through

the windbox and burners. FGR reduces peak flame temperature and therefore reduces thermal NOx formation. Consequently, FGR is most effective on gaseous fuels where NOx emissions are almost always 100% thermal NOx. FGR is less effective on liquid fuels because a

portion of the NOx emissions can be generated from fuel bound nitrogen compounds.

Two approaches are commonly used to inject the FGR into the combustion air. Forced FGR

uses a separate fan (FGR fan) to inject the flue gas into the combustion air downstream of the

FD fan. The second approach uses the suction of the FD fan to induce flue gas from the exhaust duct, through the FD fan, and into the windbox (induced FGR). Induced FGR is lower

in cost, but has the disadvantage of reduced effectiveness at high load as FD fan suction diminishes. CCA offers both forced and induced FGR, which are compatible with CCA’s other

NOx control technologies.

Combustion Tempering

Combustion tempering is a patented NOx reduction process by which micronized water, steam,

or flue gas is target injected into the flame. Typically water is used because of low capital cost.

The water is injected just upstream of the flame which reduces the temperature at the point of

initial combustion. CFD modeling is used to determine the injection droplet size, velocity,

spray pattern and direction to insure that the water is injected into the most effective NOx reduction zone. Research has shown that NOx production decreases about 50% for every 190°F

reduction in flame temperature in the NOx production zone of a flame. CFD modeling effectively identifies the optimum zone to minimize the water and maximize the NOx reduction

when compared to conventional bulk water injection. Laser doppler spray testing is used to

confirm that the water spray is consistent with the design requirements. CCA also provides skid

mounted pumps and control skids to control the water usage and to integrate our systems with

the boiler controls.

CCA’s Overfire Air Ports
Selective Non-Catalytic Reduction (SNCR)

CCA’s SNCR system provides a low

cost technique to reduce NOx emissions by 30%-60%. The SNCR

process involves injecting a reagent

(urea or ammonia) into the flue gas

in the appropriate temperature window. The reagent reacts with NOx

to form harmless nitrogen and

water. The optimum temperature

window for efficient SNCR operation typically occurs between

1,620°F and 2,010°F (900°-1,100°C)

and is usually located in the upper furnace and convective areas. The design, arrangement,

and location of the reagent injectors is critical to the performance of the SNCR system.

CCA uses CFD modeling to optimally locate the injectors on the boiler to provide for complete mixing of the reagent with the flue gas across the injection plane. Depending on the

application, multiple levels of injectors, along with other proprietary techniques, are used to

ensure that the reagent is injected in the optimal temperature window across the operating

range of the boiler. The modeling results also provide

design information related to reagent flow requirements

and design aspects to minimize ammonia slip.

CCA’s SNCR systems include reagent storage tanks, pumping and flow control, reagent injection systems, and a

boiler control interface. CCA also provides experienced

field engineers for optimizing the SNCR in conjunction

with the combustion system and overall operations.

SNCR Temperature Window

Optimal SNCR

Temperature

Window

Temperature oF

Chemical Utilization

80%

60%

40%

20%

0%

1290 1470 1830 2010 2190 2370 1650

CCA SNCR Injector

CCA’s SCR System on a stoker-fired unit in New Hampshire
Rich Reagent Injection (RRI)

CCA is a licensed implementer of the Rich Reagent

Injection (RRI) technology. RRI was jointly developed by Reaction Engineering International

(REI) in collaboration with EPRI and DOE.

RRI is similar to SNCR in that a reducing reagent

is injected into the furnace to chemically reduce

NOx formed by the combustion process. RRI,

however, is injected into a fuel rich zone of the

combustion process to react with NOx. Overfire

air is used to complete combustion above the RRI

zone. RRI is useful in many applications, since it

generates very little ammonia slip.

Selective Catalytic Reduction

CCA supplies Selective Catalytic Reduction (SCR)

systems which convert NOx into nitrogen and

water with the aid of a catalyst and an injected

reagent such as ammonia or urea. The reagent is

injected prior to the catalyst chamber and mixes

with the flue gas. NOx reduction takes place as

flue gas passes through the catalyst chamber.

SCR systems can provide any level of NOx reduction required depending on the size of the

catalyst chamber and the type of catalyst used.

CCA supplies complete SCR systems using ammonia (aqueous NH3, anhydrous NH3, or the

urea-to-NH3 process) to suit customer and regulatory requirements. Our system includes the

reagent storage tank, pumping and flow control,

reagent injection system, boiler control interface,

and the SCR catalyst chamber.

The SCR catalyst chamber is designed as a complete unit to provide for proper flow patterns

through the catalyst and easy access for maintenance. Our catalysts chambers are equipped

with sootblowers or sonic horns as necessary and

can accommodate layer additions. Experienced

CCA field engineers provide technical support in

the start-up and operation of the CCA SCR system.

Contact Information

Corporate & Engineering Offices

CCA

884 Main Steet

Monroe, CT 06468

Tel: 203-268-3139

Fax: 203-261-7697

Manufacturing Plant

Holmes Tools & Engineering Inc.

1019 N. Waukesha St

Bonifay, FL 32425

Tel: 850-547-4417

Fax: 850-547-9329

Web: www.cca-inc.net

Email: info@cca-inc.net
CCA PROJECT LOCATIONS
CCA CORPORATION 

FEES, TERMS, AND CONDITIONS 

JANUARY 2012 

PAGE 1 OF 3 

 

Manpower Rate: 

Manpower charges shall be on an hourly, portal-to-portal basis at the following rates: Principal Consultant $240/hr 

Senior Engineer $195/hr 

Engineer $155/hr 

Designer $130/hr 

Draftsman $120/hr 

Technician $130/hr 

Secretary $65/hr 

The basic rates shall apply for work on Monday through Friday for an 8-hour period between the hours of 7 A.M. to 7 

P.M. Work in excess of 8 hours, night work and Saturday work shall be at a rate of 1.5 times the basic rate. Sunday and 

holiday work shall be at 2 times the basic rate. Travel time charges shall be at the basic rate for hours actually spent in 

travel. 

Minimum Daily Charges: 

A minimum daily charge for personnel in the field shall apply of 8 hours per day per person at the basic manpower rate. 

The minimum daily charge shall apply to travel on weekends, but not weekdays. 

Expenses: 

Per-diem and shipping charges shall be actual cost plus 10% G & A. 

 

All travel costs shall be charged at cost plus 10% G & A. 

 Automobile 55.5 cts/mi 

Truck or Trailer 90 cts/mi 

CEM Van Rental: $850/Day 

Portable Gas Analyzer: $270/Day 

NH3 Test Equipment $270/Day 

Coal Flow Testing Equipment: $630/Day 

LOI Testing: $630/Day 

Flow Laboratory Facility $1600/Day 

 Combustion Test Rig $2650/Day 

Diesel Engine Test Rig $2650/Day 

Diesel Engine and Combustion Test rig costs do not include the cost of the set-up & dismantling, fuel, SNCR or SCR 

reagent, or freight, which shall be billed at cost plus 10%. 

Field Delays:

Delays imposed on CCA personnel in the field resulting from causes beyond CCA's direct control, such as partial or 

complete process shutdown or irregularity, strike, flood, fire, inclement weather, or failure of the client to meet herein 

stated responsibilities, shall be charged at the minimum daily rate plus per diem and applicable travel expenses, unless 

exceeded by actual time at the facility. Then, actual time will be charged. No delay time shall be charged for a delay 

directly caused by CCA, such as, malfunction of CCA test equipment. 

Quotations:

Unaccepted quotations shall expire 30 days from date of issuance. Requested changes in project work scope shall subject 

a price quotation to change. Projected schedules in quotations are based upon manpower loadings at the time a quotation 

is provided. Actual schedules are subject to change based upon manpower loading at the time the order is received. 
CCA CORPORATION 

FEES, TERMS, AND CONDITIONS 

JANUARY 2012 

PAGE 2 OF 3 

Acceptance:

A purchase order or a written commitment for a quoted amount shall be received prior to the rendering of any service. A 

purchase order with a "not to exceed" amount will result in the termination of services before the amount is exceeded. 

Issuance of a new purchase order, a written addition to the existing purchase order, or other written authorization from 

the client shall be received before rendering of services is resumed. Authorization by the client to proceed shall 

constitute the client's acceptance of these terms and conditions. 

Escalation:

Once yearly, the outstanding portion of a quotation or budget for a project conducted over a time span of more than one 

year shall be subject to escalation for any new manpower rates or expense schedules issued by CCA. 

Payments:

Invoiced payments shall be due in full within 30 days of the date of invoice. Invoices past due shall accrue interest 

charges at the rate of 1 1/2% per month, due and payable by the client. Reasonable attorney fees, collection fees and 

other expenses incurred in collecting overdue amounts may be charged. 

Extra Services:

Quotations for work do not include pre or post conferences or follow-up services, unless otherwise noted. CCA's 

standard charges for such extra services will apply unless provided at CCA's option. 

Research and Development Projects: 

Research and development programs are by nature subject to frequent changes in scope, direction, and budget. CCA 

Corporation undertakes such programs on a time-and-materials basis only. For each research and development program, 

a best-estimate budget shall be presented. Charges against is budget shall be made for time spent and costs incurred. 

Should a program require funding in excess of the budget, the client will be notified for written authorization of the new 

budget prior to initiating work, which would incur charges above the old budget. 

Combustion Optimization Programs: 

The performance requirements of combustion optimization programs necessitate that CCA Corporation charge such 

programs on a time-and-materials basis. However, for each program a budget will be presented to the client. Should a 

program require funding in excess of the budget, the client will be notified for written authorization of the new budget 

prior to initiating further work. 

Patents and Proprietary Technology: 

CCA reserves all proprietary rights, including patent rights, in and to all devices, concepts, processes, products, 

inventions or other technology conceived or developed by CCA personnel during work conducted for a client. The client 

may use such CCA proprietary technology, royalty free, solely for the specific installation for which CCA's work was 

provided, and client may negotiate terms with CCA for expanded use to other installations. 

Warranty - Services:

CCA represents and warrants that its procedures are generally accepted practices and methods and its personnel are 

qualified to affect such procedures. Tests are performed on a best-efforts basis and CCA assumes no liability for 

deviations required by existing conditions beyond its control or field of responsibility. No guarantee or warranty is 

issued, implied or intended and no responsibility is assumed for testing other than the accuracy of observed results. 

Should CCA’s testing be materially defective, the sole liability of CCA shall be to repeat said test run at no additional 

cost to Client, provided, however, that said test run was not defective because of a failure of Client to supply critical 

information or to fulfill responsibilities. 

Warranty – Products: 

CCA represents and warrants that (a) products manufactured by it shall be (i) free of defects in materials and 

workmanship for a period of one year from date of shipment to client and (ii) shall conform in all material respects to the 
CCA CORPORATION 

FEES, TERMS, AND CONDITIONS 

JANUARY 2012 

PAGE 3 OF 3 

specifications for such product agreed upon in this contract. For products not manufactured by CCA the original 

manufacturers warranty, if any, shall be assigned to client to the extent permitted and such assigned warranty shall be in 

lieu of any other warranty express or implied. CCA’s sole liability hereunder shall be during the one year product 

warranty period to repair or replace, at its option, products that are defective or non-conforming to agreed specifications. 

 CCA shall have no liability for on-site diagnostics, removal, transportation and reinstallation of such products.

Limitation and Disclaimer of Warranties:

CCA shall not be liable under the warranties hereunder unless: 

(a) Client promptly notifies CCA in writing of the alleged deficiency in the product or service and offers CCA a 

reasonable opportunity to cure such deficiency, and (b) if a product deficiency in a CCA manufactured product, CCA 

inspection verifies the existence of the deficiency and determines it was not caused by damage or destruction, including 

any occurring while in shipment, improper installation, testing, operation or repair (including any repair not by CCA 

agents or employees or otherwise not consented to in writing by CCA), misuse, neglect, or alteration. 

THESE WARRANTIES ARE IN LIEU OF AND CCA DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR 

IMPLIED, WRITTEN OR ORAL, INCLUDING THOSE MERCHANTABILITY, FITNESS FOR A PARTICULAR 

PURPOSE, OR OTHERWISE, AND MAY BE MODIFIED BY CCA ONLY IN A WRITING SIGNED BY CCA IN 

WHICH IT INTENDS TO BE FOUND. 

Limitation of Liability:

CCA SHALL NOT BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES, 

WHETHER BASED ON BREACH OF CONTRACT OR WARRANTY, NEGLIGENCE, OR ANY OTHER MATTER 

RELATING TO THIS CONTRACT. CCA’S MAXIMUM LIABILITY SHALL IN NO CASE EXCEED THE 

AMOUNT THAT HAS BEEN PAID TO CCA FOR THE PRODUCT OR SERVICE PRIOR TO THE EVENT WHICH 

RESULTS IN SUCH LIABILITY OR, FOR INSURED MATTERS, THE AMOUNT OF SUCH INSURANCE. 

The prices quoted in this sale were determined in part on the basis that CCA’s liabilities and Client’s remedies are limited 

as provided in this Statement and the prices would have been substantially different had those limitations not been 

agreed. 

Choice of Law:

Any controversy between the parties shall be governed by the laws of the State of Connecticut, to the exclusion of the 

law of any other forum, without regard to the jurisdiction in which any action or special proceeding shall be instituted. 

Entire Agreement:

With respect to the subject matter herein, this document contains the entire agreement between the parties involved, and 

supersedes all other agreements between the parties except as noted in the Special Provisions section of this document. 

Special Provisions: 
ATTACHMENT C – REVISED CONTROL COST TABLES 
CAPITAL COSTS ANNUALIZED COSTS

NO. 8 BOILER 

COST ITEM FACTOR COST ($) COST ITEM 

Costs to Purchase and Install Equipment Annual Operating Costs

Purchased Equipment Costs Direct Annual Costs

(a)

SCR system including urea storage and delivery system, and catalyst $1,991,525 Operating Labor 

(d) Platform materials to support the new equipment $0 (c) Labor, one employee (d) New fan $0(d) New stack $0(d) Electrical for the fan $0 Maintenance 

Purchased Equipment Costs Subtotal A $1 991 525 (b) Maintenance Labor and Materials 

TABLE C-1 (REVISED 3/21/2012)

ESCANABA PAPER COMPANY

BART EVALUATION CAPITAL AND ANNUALIZED COSTS

NO. 8 BOILER NOx CONTROL

SELECTIVE CATALYTIC REDUCTION (SCR)

Purchased Equipment Costs Subtotal A $1,991,525 (b) Maintenance Labor and Materials 

(b) Instrumentation 0.100 A $199,153 Utilities(b) Sales taxes 0.030 A $59,746 (a),(c) Reagent (b) Freight 0.050 A $99,576 (a),(c) Electricity 

Total Purchased Equipment Cost B $2,350,000 (a)

Catalyst replacement (1/3 of total peyear) 

Direct Installation Costs Total Direct Annual Costs 

(c)

Installation of SCR system including urea storage and delivery system, platform, demolition of old stack, demo of old fan, installation of new fan, new stack, foundations and supports, electrical, piping, insulation, and painting 0.85 B $1,997,500Direct Installation Cost C $1,997,500

Indirect Annual Costs

(b) Overhead 

Total Direct Cost D $4,347,500 (b) Administrative Charges 

(b) Property Taxes 

Indirect Costs (Installation) (b) Insurance 

(b) General Facilities 0.05 D $217,375

(b) Engineering and Home Office Fees 0.10 D $434,750 Total Indirect Annual Costs 

(b) Process Contingency 0.05 D $217,375

(b) Project Contingency 0.15 (D+Gen Fac+Eng+Proc Cont) $782,550 Total Annual O&M Costs 

(b) Total Plant Cost (D+Gen Fac+Eng+Proc Cont+Proj Cont) $5,999,550(b) Preproduction Cost 0.02 Total Plant Cost $119,991 Cost Effectiveness

Expected lifetime of equipment, yea

Interest rate, %/yr 

Total Capital Investment (TCI)............................................................................. (Tot Plt Cost+Preprod Cost) $6,119,541 Capital recovery factor 

Total capital investment cost Annualized capital investment co

Total Annualized Cost (Including O&M) 

Cost EffectivenessAnnual Cost/Ton Removed 

Incremental Cost Effectiveness

Uncontrolled Emissions (Worst-Case Scena

current FGR control is decommissioned and N

Controlled Emissions if the Mill were to U

Annual Cost/Ton Removed 

current FGR on a Year-Round Basis and Also In

Notes:(a) Cost information obtained from Mr. Ed Schindler at Combustion Components Associates (CCA) on December 16, 2006 and revised February 2012.(b) Cost information estimated using the U.S. EPA Air Pollution Control Cost Manual (6th edition) published in January 2002 by the OAQPS. The website for the manual is available at http://www.epa.gov/ttn/catc/dir1/c_allchs(c) Cost information estimated by the Mill. Direct installation costs were approximated using a combination of Mill historical information and experience with multiple capital equipment installations. This experience indicates tof the complexity of the installation that would need to occur at high elevations. Operating labor and maintenance costs were estimated using an assumption of one employee per shift, 3 shifts per day, and 90% utilization.d) EPC has identified additional retrofitting costs that have not been included in the quotation provided by CCA. EPC has not included specific cost for the additional retrofitting that would be required. Given that additional cocurrent levels.

No. 8 PB Cost Effectiveness Calcs 2_22_12.xls, 8PB SCR 
CAPITAL COSTS ANNUALIZED COSTS

NO. 9 BOILER 

COST ITEM FACTOR COST ($) COST ITEM 

Costs to Purchase and Install Equipment Annual Operating Costs

Purchased Equipment Costs Direct Annual Costs

(a)

SCR system including urea storage and delivery system, catalyst, and air heater $4,915,254 Operating Labor 

(d) Platform materials to support the new equipment $0 (c) Labor, one employee 

(d) New fan $0(d) New stack $0

(d) Electrical for the fan $0 Maintenance 

Purchased Equipment Costs Subtotal A $4,915,254 (b) Maintenance Labor and Materials 

TABLE C-10 (REVISED 3/21/2012)

ESCANABA PAPER COMPANY

BART EVALUATION CAPITAL AND ANNUALIZED COSTS

NO. 9 BOILER NOx CONTROL

SELECTIVE CATALYTIC REDUCTION (SCR) WITH AIR HEATER

q p , , ( )

(b) Instrumentation 0.100 A $491,525 Utilities(b) Sales taxes 0.030 A $147,458 (a),(c) Reagent 

(b) Freight 0.050 A $245,763 (a),(c)

Natural gas for air heater system (350F 600F) 

Total Purchased Equipment Cost B $5,800,000 (a),(c) Electricity 

(a),(c) Catalyst replacement 

Direct Installation Costs

(c)

Installation of SCR system including air heater, urea storage and delivery system, platform, demolition of old stack, installation of new fan, new stack, foundations and supports, electrical, piping, insulation, and painting 0.85 B $4,930,000 Total Direct Annual Costs 

Direct Installation Cost C $4,930,000

Indirect Annual Costs Indirect Annual Costs

Total Direct Cost D $10,730,000 (b) Overhead 

(b) Administrative Charges 

Indirect Costs (Installation) (b) Property Taxes 

(b) General Facilities 0.05 D $536,500 (b) Insurance 

(b) Engineering and Home Office Fees 0.10 D $1,073,000(b) Process Contingency 0.05 D $536,500 Total Indirect Annual Costs 

(b) Project Contingency 0.15 (D+Gen Fac+Eng+Proc Cont) $1,931,400

(b) Total Plant Cost (D+Gen Fac+Eng+Proc Cont+Proj Cont) $14,807,400 Total Annual O&M Costs 

(b) Preproduction Cost 0.02 Total Plant Cost $296,148

Cost Effectiveness

Expected lifetime of equipment, years 

Total Capital Investment (TCI)...................................................................................(Tot Plt Cost+Pre Prod Cost) $15,103,548 Interest rate, %/yr 

Capital recovery factor Total capital investment cost Annualized capital investment cost 

Total Annualized Cost (Including O&M) 

Annual Cost/Ton Removed 

Uncontrolled Emissions (Updated Estimate of Emiss

Notes:(a) Cost information obtained from Mr. Ed Schindler at Combustion Components Associates (CCA) on December 16, 2006 and revised February 2012. (b) Cost information estimated using the U.S. EPA Air Pollution Control Cost Manual (6th edition) published in January 2002 by the OAQPS. The website for the manual is available at http://www.epa.gov/ttn/catc/dir1/c_allchs.pdf. (c) Cost information estimated by the Mill. Direct installation costs were approximated using a combination of Mill historical information and experience with multiple capital equipment installations. This experience indicates that the tota

of the installation that would need to occur at high elevations. Operating labor and maintenance costs were estimated using an assumption of one employee per shift, 3 shifts per day, and 90% utilization.d) EPC has identified additional retrofitting costs that have not been included in the quotation provided by CCA. EPC has not included specific cost for the additional retrofitting that would be required. Given that additional cost for these 

No. 9 PB Cost Effectiveness Calcs 2_22_12.xls, 9PB SCR