SNCR Capital Costs

Description Formula1Value

Boiler Size (MMBtu/hr) QB 1941

NOx Removal Efficiency (%) ηNOx 25%

Cost Year 2010

Total Direct Capital Costs ($)2

A $4,573,993

Indirect Installation Costs

 General Facilities ($) 0.05 x A $228,700

 Engineering and Home Office Fees ($) 0.10 x A $457,399

 Process Contingency ($) 0.05 x A $228,700

Total Indirect Installation Costs ($) B = A × (0.05 + 0.10 + 0.05) $914,799

Project Contingency ($) C = (A + B)× 0.15 $823,319

Total Plant Costs ($) D = A + B+ C $6,312,111

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

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

Preproduction Cost ($) G = 0.02 × (D + E) $126,242

Inventory Capital* ($) H = Vol reagent (gal) × Cost reagent ($/gal) $26,338

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

T otal Capital Investment (TCI) ($) TCI = D + E + F + G + H + I $6,464,691

T otal Capital Investment (TCI) ($) Per kW $19

SNCR Annual Costs

Direct Annnual Costs

 Maintenance Cost $96,970

 Reagent Cost $476,657

 Electricity Cost $7,226

 Water Cost $2,031

 Annual ∆Coal Cost $54,911

 Annual ∆Ash Cost -

Total Direct Annual Costs DAC $637,795

Indirect Annual Costs IDAC = TCI x CRF $610,267

Total Annual Costs TAC = DAC + IAC $1,248,062

SOFA Captial Costs

Total Captial Investment for SOFA ($)3

TCI $3,350,365

Total Capital Investment for SOFA ($/kW) Per kW $20,681

SOFA Annual Costs

Total Direct Annual Costs4

DAC $315,754

Indirect Annual Costs IDAC = TCI x CRF $330,375

Total Annual Costs TAC = DAC + IAC $646,129

Cost Effectivness

SOFA NOx Removed (tons/yr) 435

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

SNCR NOx Removed (tons/yr) 295

SNCR Cost Effectiveness ($/ton removed) $4,230

SNCR+SOFA NOx Removed (tons/yr) 730

SNCR+SOFA Cost Effectiveness ($/ton removed) $2,596

1

Taken from "EPA Control Cost Manual", Section 4.2, Chapter 1, October 2000.

Corette Unit 1 BART Cost Analysis - SNCR+SOFA

(2010 Dollars)

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

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

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

TRC for PPL, June 2008. Direct capital costs were escalated to 2010 using the CEPCI.
SNCR Capital Cost Estimate Worksheet

Variable Designation Units Value Calculation

Boiler Type BT Tangential InputUnit Size A (MW) 162 InputRetrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Heat Rate C (Btu/kWh) 11982 InputNOx Rate D (lb/MMBtu) 0.200 Input

SO2 Rate E (lb/MMBtu) 0.6 Input

Type of Coal F PRB InputCoal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate Factor H 1.20 C/10000Heat Input I (Btu/hr) 1.94E+09 A*C*1000Capacity Factor J (%) 69.4 InputNOx Removal Efficiency K (%) 25.0 Input

NOx Removed L (lb/hr) 97.1 D*I/106*K/100

Urea Rate (100%) M (lb/hr) 422 L/UF/46*30; IF Boiler type = CFB OR D> 0.3 then UF =0.25; else UF 0.15Steam Required N (lb/hr) 3798 M*9Aux Power O (%) 0.05 Auxilliary power Dilution Water Rate P (1000 gph) 0.46 N*0.12/1000Urea Cost 50% wt sol. Q ($/ton) 450 InputAux Power Cost R ($/kWh) 0.045 InputDilution Water Cost S ($/klb) 1 InputOperating Labor Rate T ($/hr) 60 Labor cost including all benefitsCosts are all based on 2009 dollarsCapital Cost Calculation Include: equipment, installation, buildings, foundations, electrical, and retrofit difficulty. BMS ($) = BT*B*G/1.05*200000*(A*H)0.42; (If CFB then BT=0.75, else BT=1) $1,828,000 SNCR (injectors, blowers, DCS, reagent system) cost

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

 BMB ($) = BT*270000*(A)0.33*(L)0.12; (If CFB then BT=0.75, else BT=1) $2,506,000 Balance of plant cost (piping, including site upgrades)

 BM ($) = BMS + BMA + BMB $4,334,000 Total bare module cost including retrofit factor BM ($/kW) $27 Base cost per kWTotal Project Cost A1 = 10% of BM $433,000 Engineering and construction management costs A2 = 10% of BM $433,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $433,000 Contractor profit and fees CECC($) = BM+A1+A2+A3 $5,633,000 Capital, engineering and construction cost subtotal CECC($/kW) = $35 Capital, engineering and construction cost subtotal per kW B1 = 5% of CECC $282,000 Owners costs including "home office" costs (owner engineering, management, a TPC ($) = CECC + B1 $5,915,000 Total project cost TPC ($/kW) = $37 Total project cost per kW
PPL Corette

Modified from OAQPS Control Cost Manual Section 4.2, SCR

Given/AssumptionsGeneration Capacity (MW Gross) 162 SourceFuel High Heating Value (Btu/lb) 8,458 From EIA for 1999Maximum Fuel Consumption Rate (lb/hr) 229,487 Calculated from 1,941 MMBtu/hAverage Annual Fuel Consumption (lb) 1.40E+09 Calcuated from 11,802,864 MMBtu/yNumber of SNCR Operating Days 365 AssumedPlant Capacity Factor 69.4%Uncontrolled NOx Concentration (lb/mmBtu) 0.274 Average for 2008-2010 from CAMD

SOFA Total Capital Cost $ 3,350,365 TRC BART Report for PPl (6/25/2008) adjusted using 2010 CEPCISOFA Total Annual Cost $ 632,028 TRC BART Report for PPl (6/25/2008) adjusted using 2010 CEPCI

NOx concentration after combustion controls 0.200 NOx Control Update Report by TRC for PPL (September 2011)SNCR Controlled NOx Concentration (lb/mmBtu) 0.150 NOx Control Update Report by TRC for PPL (September 2011)ash product (Btu/mmBtu) 7.7E+04 OAQPS Control Cost Manual

Stored Urea Concentration 50% OAQPS Control Cost ManualInjected Urea Concentration 10% OAQPS Control Cost ManualReagent Heat of vaporization Hv (lb/Btu) 900 OAQPS Control Cost ManualReagent Molecular Weight (g/mole) 60.06 OAQPS Control Cost Manual

SRT 2 OAQPS Control Cost ManualReagent Density (lb/ft3 @ 60F) 71.0 OAQPS Control Cost Manual

Reagent Specific Volume (gal/ft3) 7.481 OAQPS Control Cost ManualNOx Molecular Weight (g/mole) 46.01 OAQPS Control Cost Manual

Number of Days of Storage for Urea 14 OAQPS Control Cost ManualEquipment Life (years) 20 OAQPS Control Cost ManualAnnual Interest Rate 7% OAQPS Control Cost ManualInflation Since 1998 1.34 CEPCI 2009/CEPCI 1998 Inflation Since 2006 1.04 CEPCI 2009/CEPCI 2006Water Consumption Cost ($/gal) 0.001 OAQPS Control Cost ManualElectrical Power Cost ($/kWh) $ 0.045 Ref50% Urea Solution Cost ($/gal) $ 1.07 calculated from $ 450 /ton

Coal Cost ($/mmBtu) $ 1.60

Ash Disposal Cost ($/ton) $ 10.00 Meeting with PPL

Lost ash sales ($/yr) $0Additional Ash Disposal Cost ($/ton) $0
Boiler Calculations

1.3 QB = HVm-dotfuel

QB = 8458 Btu/lb * 229,487 lb/hr

QB = 1941 mmBtu/hr

1.7 CFPlant = actual heat input/maximum heat input

CFPlant = 69.4%

1.8 CFSNCR = tSCR/365 days

CFSCR = 365 days/ 365 daysCFSCR = 100%

1.6 CFTotal = CFPlant x CFSNCR

CFTotal = 69% * 100%CFTotal = 69%

1.9 ηNOx = (NOxin – NOxout) / NOxin

ηNOx = ( 0.200 lb/mmBtu - 0.15 lb/mmBtu)/ 0.2 lb/mmBtuηNOx = 25%Uncontrolled NOx emissions (tpy) 1,615
Reagent Calculations

1.14 NSR = [2NOxin + 0.7] ηNOx/ NOxin

NSR = ( 2 * 0.2 + 0.7 ) * 25% / 0.2NSR = 1.38

1.13 Utilization = ηNOx/NSR

Utilization = 18%

1.15 m-dotreagent = NOxinQBηNOxNSR Mreagent/MNOx/SRT

m-dotreagent = 0.200 * 1941 * 1.00 * 1.38 * 60.06 / 2 / 46.01m-dotreagent = 348 lb/hr

1.16 m-dotsol = m-dotreagent/Csol

m-dotsol = 348 / 0.50m-dotsol = 697 lb/hr

1.17 qsol = m-dotvol/ρsol

qsol = 697 * 7.481 / 71qsol = 73 gph

2.35 Tank Volume = qsolt

Tank Volume = 73 * 14 * 24Tank Volume = 24,668 gal
Annual Costs

2.45 DAC = Annual Maintenance Cost + Annual Reagent Cost + Annual Electricity Cost + Annual Water Cost + 

2.46 Annual Maintenance Cost = 0.015 TCI

Annual Maintenance Cost = 0.015 * $ 6,464,691Annual Maintenance Cost = $ 96,970

1.22 Annual Reagent Cost = qsolCostreagenttop

1.22.a top = CFtotal8760hr/yr

top = 69% * 8760top = 6081

Annual Reagent Cost = 73 * 1.067704852 * 6081Annual Reagent Cost = $ 476,657

1.24 Annual Electricity Cost = Power (Costelect)top1.23 Power = 0.47NOxinNSRQB/9.5

Power = 0.47 * 0.2 * 1.38 * 1941 / 9.5Power = 26 kW

Annual Electricity Cost = 26 * 6081 * 0.045Annual Electricity Cost = $ 7,226

1.27 Annual Water Cost = qwaterCostwater top1.25 qwater = m-dotsol/ρwater[Cureastored/Curea sol inj -1]

qwater = 697 / 8.345 *( 50% / 10% - 1 )

qwater = 334

Annual Water Cost = 334 * 0.0010 * 6081

Annual Water Cost = $ 2,031

1.31 Annual ∆Coal cost = ∆Coal costcoal top1.28 ∆Coal(Btu/hr) = Hv(Btu/lb)* m-dotreagent(lb/hr)[1/ Curea sol inj -1]

∆Coal(Btu/hr) = 900 * 697 *( 1 / 10% - 1 )∆Coal(Btu/hr) = 5,643,861

Annual ∆Coal cost = 5.6 * 1.60 $ * 6081 

Annual ∆Coal cost = 54,911 $ 

1.32 Annual ∆Ash cost = ∆Ash costash top

1.30 ∆Ash = ∆Coal ash product/HHV

∆Ash = 5.64 * 77000 / 8458
∆Ash = 51

Annual ∆Ash cost = 51 * 10.00 $ * 6081 / 2000Annual ∆Ash cost = 1,562 $ 

Additional Ash Disposal Cost ($/ton) = - $ 

Lost ash sales ($/yr) = - $ 

Total Variable Cost = $ 542,387

Total Direct Annual Cost = $ 96,970 + $ 542,387Total Direct Annual Cost = $ 639,357

1.34 CRF = i(1+i)n/[(1+i)n-1]

CRF = 0.07 *( 1 + 0.07 )^ 20 /(( 1 + 0.07 CRF = 0.0944

1.33 IDAC = CRF*TCI

Indirect Annual Cost = 0.0944 * $ 6,464,691Indirect Annual Cost = $ 610,221

1.35 Total Annual Cost = Direct Annual Cost + Indirect Annual Cost

Total Annual Cost = $ 639,357 + 610,221Total Annual Cost = $ 1,249,578

1.36 NOx Removed SOFA = NOxinηNOxQBtop

NOx Removed = 0.274 * 27% * 1941 * 6081 / 2000NOx Removed = 435

1.36 NOx Removed SNCR = NOxinηNOxQBtop

NOx Removed = 0.200 * 25% * 1941 * 6081 / 2000NOx Removed = 295

1.37 Cost effectiveness = TAC/NOx removed

Cost effectiveness = $ 4,235
STATE

FACILITY_

NAME

ORISPL 

CODE UNIT ID OP YEAR

SUM OP 

TIME

NUM 

MONTHS 

REPORTE

D

GROSS 

LOAD 

(MWh) SO2 MASS SO2 RATE NOX RATE

NO

MA

MT J E Corette 2187 2 2008 7,314 12 1,086,477 2,817 0.472 0.278 1MT J E Corette 2187 2 2009 7,824 12 1,141,292 2,832 0.455 0.261 1MT J E Corette 2187 2 2010 7,401 12 1,025,597 2,519 0.457 0.282 1

Averages 7,513 1,084,455 2,723 0.461 0.274 1