# SNCR Capital Costs

Description Formula 1 

# Value

Boiler Size (MMBtu/hr) Q B 

# 1941

NOx Removal Efficiency (%) **η** NOx 

# 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 (A ssumed 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 fo r 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 Costs 4 

# 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)

2 

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

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

3,4 

# Direct capital costs and direct annual costs for SO FA were taken from "Addendum to PPL Montana's Coret te BART Report,"

TRC for PPL, June 2008. Direct capital costs were escalated to 2010 using the CEPCI.SNCR Capital Cost Estimate WorksheetVariableDesignationUnitsValueCalculationBoiler TypeBTTangentialInputUnit SizeA(MW)162InputRetrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Heat RateC(Btu/kWh)11982InputNOxRateD (lb/MMBtu) 0.200 InputSO2RateE (lb/MMBtu) 0.6 InputType of CoalFPRBInputCoal FactorG1.05Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate FactorH1.20C/10000Heat InputI(Btu/hr)1.94E+09A*C*1000Capacity FactorJ(%)69.4InputNOxRemoval EfficiencyK (%) 25.0 InputNOxRemovedL (lb/hr) 97.1D*I/106*K/100Urea Rate (100%)M(lb/hr)422L/UF/46*30; IF Boiler type = CFB OR D> 0.3 then UF =0.25; else UF 0.15Steam RequiredN(lb/hr)3798M*9Aux PowerO(%)0.05Auxilliary powerDilution Water RateP(1000 gph)0.46N*0.12/1000Urea Cost 50% wt sol.Q($/ton)450InputAux Power CostR($/kWh)0.045InputDilution Water CostS($/klb)1InputOperating Labor RateT($/hr)60Labor cost including all benefitsCosts are all based on 2009 dollarsCapital Cost CalculationInclude: 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)$1,828,000 SNCR (injectors, blowers, DCS, reagent system) costBMA ($) = If E >= 3 and F = Bituminous then 65000*(B)*(A*G*H)^0.78; else 0 $0Air heater modification / SO3control (bituminous only & > 3 lb/MMbtu)BMB ($) = 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$4,334,000Total bare module cost including retrofit factorBM ($/kW)$27Base cost per kWTotal Project CostA1 = 10% of BM$433,000Engineering and construction management costsA2 = 10% of BM$433,000Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 10% of BM$433,000Contractor profit and feesCECC($) = BM+A1+A2+A3$5,633,000Capital, engineering and construction cost subtotalCECC($/kW) =$35Capital, engineering and construction cost subtotal per kWB1 = 5% of CECC$282,000Owners costs including "home office" costs (owner engineering, management, and procurement activities)TPC ($) = CECC + B1$5,915,000Total project costTPC ($/kW) =$37Total project cost per kWPPL CoretteModified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsGeneration Capacity (MW Gross)162SourceFuel High Heating Value (Btu/lb)8,458From EIA for 1999Maximum Fuel Consumption Rate (lb/hr)229,487Calculated from1,941MMBtu/hr from TRC Report for PPL (6/25/2008)Average Annual Fuel Consumption (lb)1.40E+09Calcuated from11,802,864MMBtu/yr average for 2008-2010 from CAMDNumber of SNCR Operating Days365AssumedPlant Capacity Factor69.4%Uncontrolled NOx Concentration (lb/mmBtu)0.274Average for 2008-2010 from CAMDSOFA Total Capital Cost3,350,365$TRC BART Report for PPl (6/25/2008) adjusted using 2010 CEPCISOFA Total Annual Cost632,028$TRC BART Report for PPl (6/25/2008) adjusted using 2010 CEPCINOx concentration after combustion controls 0.200NOx Control Update Report by TRC for PPL (September 2011)SNCR Controlled NOx Concentration (lb/mmBtu) 0.150NOx Control Update Report by TRC for PPL (September 2011)ash product (Btu/mmBtu)7.7E+04OAQPS Control Cost ManualStored Urea Concentration50%OAQPS Control Cost ManualInjected Urea Concentration10%OAQPS Control Cost ManualReagent Heat of vaporization Hv (lb/Btu)900OAQPS Control Cost ManualReagent Molecular Weight (g/mole)60.06OAQPS Control Cost ManualSRT2OAQPS Control Cost ManualReagent Density (lb/ft3 @ 60F)71.0OAQPS Control Cost ManualReagent Specific Volume (gal/ft3)7.481OAQPS Control Cost ManualNOx Molecular Weight (g/mole)46.01OAQPS Control Cost ManualNumber of Days of Storage for Urea14OAQPS Control Cost ManualEquipment Life (years)20OAQPS Control Cost ManualAnnual Interest Rate7%OAQPS Control Cost ManualInflation Since 19981.34CEPCI 2009/CEPCI 1998Inflation Since 20061.04CEPCI 2009/CEPCI 2006Water Consumption Cost ($/gal)0.001OAQPS Control Cost ManualElectrical Power Cost ($/kWh)0.045$Ref50% Urea Solution Cost ($/gal)1.07$calculated from450$/tonCoal Cost ($/mmBtu)1.60$Ash Disposal Cost ($/ton)10.00$Meeting with PPLLost ash sales ($/yr)$0Additional Ash Disposal Cost ($/ton)$0Boiler Calculations1.3QB= HVm-dotfuelQB = 8458 Btu/lb *229,487lb/hrQB = 1941 mmBtu/hr1.7CFPlant= actual heat input/maximum heat inputCFPlant =69.4%1.8CFSNCR= tSCR/365 daysCFSCR = 365 days/ 365 daysCFSCR =100%1.6CFTotal= CFPlantx CFSNCRCFTotal = 69% * 100%CFTotal =69%1.9ηNOx= (NOxin– NOxout) / NOxin**η**NOx = ( 0.200 lb/mmBtu - 0.15 lb/mmBtu)/ 0.2 lb/mmBtu**η**NOx =25%Uncontrolled NOx emissions (tpy)1,615Reagent Calculations1.14NSR = [2NOxin+ 0.7]ηNOx/ NOxinNSR = ( 2 * 0.2 + 0.7 ) * 25% / 0.2NSR = 1.381.13Utilization =ηNOx/NSRUtilization =18%1.15m-dotreagent= NOxinQBηNOxNSR Mreagent/MNOx/SRTm-dotreagent = 0.200 * 1941 * 1.00 * 1.38 * 60.06 / 2 / 46.01m-dotreagent = 348 lb/hr1.16m-dotsol= m-dotreagent/Csolm-dotsol = 348 / 0.50m-dotsol = 697 lb/hr1.17qsol= m-dotvol/ρsolqsol = 697 * 7.481 / 71qsol = 73 gph2.35Tank Volume = qsoltTank Volume = 73 * 14 * 24Tank Volume =24,668galAnnual Costs2.45 DAC = Annual Maintenance Cost + Annual ReagentCost + Annual Electricity Cost + Annual Water Cost+ Annual Catalyst Cost2.46 Annual Maintenance Cost = 0.015 TCIAnnual Maintenance Cost = 0.015 *6,464,691$Annual Maintenance Cost =96,970$1.22Annual Reagent Cost = qsolCostreagenttop1.22.atop= CFtotal8760hr/yrtop =69%*8760top =6081Annual Reagent Cost =73*1.067704852*6081Annual Reagent Cost =476,657$1.24Annual Electricity Cost = Power (Costelect)top1.23Power = 0.47NOxinNSRQB/9.5Power =0.47*0.2*1.38*1941/9.5Power =26kWAnnual Electricity Cost =26*6081*0.045Annual Electricity Cost =7,226$1.27Annual Water Cost = qwaterCostwatertop1.25qwater= m-dotsol/ρwater[Cureastored/Cureasol inj-1]qwater = 697/ 8.345 *( 50% / 10% - 1 )qwater = 334Annual Water Cost = 334 *0.0010* 6081Annual Water Cost =2,031$1.31Annual∆Coal cost =∆Coal costcoaltop1.28∆Coal(Btu/hr) = Hv(Btu/lb)* m-dotreagent(lb/hr)[1/ Cureasol inj-1]∆Coal(Btu/hr) = 900* 697 *( 1 / 10% - 1 )∆Coal(Btu/hr) = 5,643,861Annual∆Coal cost = 5.6* 1.60$ * 608134319.28406Annual∆Coal cost = 54,911$1.32Annual∆Ash cost =∆Ash costashtop1.30∆Ash =∆Coal ash product/HHV∆Ash = 5.64* 77000 / 8458∆Ash =51Annual∆Ash cost = 51* 10.00$ * 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$+542,387$Total Direct Annual Cost =639,357$1.34CRF = i(1+i)n/[(1+i)n-1]CRF =0.07*(1+0.07)^20/((1+0.07)^20-1CRF =0.09441.33 IDAC = CRF*TCIIndirect Annual Cost = 0.0944 *6,464,691$Indirect Annual Cost =610,221$1.35 Total Annual Cost = Direct Annual Cost + Indirect Annual CostTotal Annual Cost =639,357$+610,221Total Annual Cost =1,249,578$1.36NOx Removed SOFA = NOxinηNOxQBtopNOx Removed =0.274*27%*1941*6081/2000NOx Removed =4351.36NOx Removed SNCR = NOxinηNOxQBtopNOx Removed =0.200*25%*1941*6081/2000NOx Removed =2951.37Cost effectiveness = TAC/NOxremovedCost effectiveness =4,235$STATEFACILITY_NAMEORISPLCODE UNIT ID OP YEARSUM OPTIMENUMMONTHSREPORTEDGROSSLOAD(MWh)SO2 MASS SO2 RATE NOX RATENOXMASSHEAT INPUT(MMBtu)HEATINPUT(MMBtu/hr)MTJ E Corette2187220087,314121,086,4772,8170.4720.2781,65811,925,734993,811MTJ E Corette2187220097,824121,141,2922,8320.4550.2611,64112,445,1521,037,096MTJ E Corette2187220107,401121,025,5972,5190.4570.2821,57511,037,706919,809Averages7,5131,084,4552,7230.4610.2741,62511,802,864983,572