UTAC Line 1 GSA

Given/Assumed

Flow rate (acfm) 578,225 Barr 9/28/12 Table 6

Flue Gas Temperature (degrees F) 280 Barr 9/28/12 Table 6

Pellet production (LT/hr) 208 calculated from Barr Table 6

SO2 emission factor (lb/LT) 0.88 calculated from Barr Table 6

Safety factor

Uncontrolled SO2 emissions (lb/hr) 182.4 calculated

Uncontrolled SO2 emissions (TPY) 729 Cliffs 11/9/12 response

Savings from shutdown of exsiting emission controls $ (639,933) Barr 9/28/12 Table 6

SO2 molar weight 64

ESP $ 2,528,500 vendor quote

GSA $ 4,299,800 vendor quote

Baghouse $ 6,199,800 vendor quote

Auxiliary equipment Barr 9/28/12 Table 11

Sales taxes Barr 9/28/12 Table 2

Site preparation Barr 9/28/12 Table 11

Buildings Barr 9/28/12 Table 11

Lost production costs $ 3,850,000 Barr 9/28/12 Table 6

Total Capital Investment $ 46,257,943 Barr 9/28/12 Table 6

Controlled SO2 emissions (lb/hr) 19.7 calculated from Barr 9/28/12 Table 6 for 5 ppm 

SO2 Control efficiency 89.2% calculated

Operating Hours per Year 7,992 Barr 9/28/12 Table 2

Operating Hours per Shift 8 assumed

Operating Shifts per Year 999 calculated

Utilization 100% Barr 9/28/12 Table 6

Operating Labor Cost ($/hr) $31.75 Barr 9/28/12 Table 4

Maintenance Labor Cost ($/hr) $32.50 Barr 9/28/12 Table 4

Hydrated Lime molar weight 74

Chemical usage molar ratio 1.3 Barr 9/28/12 Table 4

Chemical cost ($/ton) $ 145.00 Barr 9/28/12 Table 4

Solvent usage (gpm) 0 Barr 9/28/12 Table 4

Solvent cost ($/kgal) $2.07 Barr 9/28/12 Table 4

CaSO4 molar weight 172 dihydrate

Waste disposal ($/ton) $ 50.00 Barr 9/28/12 Table 4

Compressed air cost ($/kscf) $ 0.38 Barr 9/28/12 Table 4

Compressed air use (scfm/kacfm) 2 Barr 9/28/12 Table 4

Electricity cost ($/kWh) $ 0.064 Barr 9/28/12 Table 4

Electricity use (kW/hr) 3,224 Barr 9/28/12 Table 4

Equipment Life (yr) 30 EPA R10

PM10 emissions (lb/day) 426.40 8/30/06 BART report

Number of filter bags 2244 Barr 9/28/12 Table 4

Bag/cage cost $ 180 Barr 9/28/12 Table 4

Bag life 3 Barr 9/28/12 Table 4

Bag replacement (min/bag) 10 OAQPS Control Cost Manual for pulse jet

Interest Rate (%) 7.00% Barr 9/28/12 Table 6
UTAC Line 1 GSA

Capital Cost factors for ESPs--OAQPS Control Cost Manual, Chap 6.2

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

ESP + auxiliary equipment, EC A $2,528,500

Instrumentation 0.10 A $252,850

Sales taxes 0.00 A $0

Freight 0.05 A $126,425

Purchased equipment cost, PEC B= 1.15 A $2,907,775

Direct installation costs

Foundations & supports 0.04 B $116,311

Handling & erection 0.50 B $1,453,888

Electrical 0.08 B $232,622

Piping 0.01 B $29,078

Insulation 0.02 B $58,156

Painting 0.02 B $58,156

Direct installation costs x x 0.67 B $1,948,209

Site preparation As required, SP

Buildings As required, Bldg.

Total Direct Costs, DC 1.85 B+SP+Bldg $4,855,984

Indirect Costs (installation)

Engineering 0.20 B $581,555

Construction and field expenses 0.20 B $581,555

Contractor fees 0.10 B $290,778

Start-up 0.01 B $29,078

Performance test 0.01 B $29,078

Model Study 0.02 B $58,156

Contingencies 0.03 B $87,233

Total Indirect Costs, IC 0.57 B $1,657,432

Total Capital Investment = DC + IC 2.24 B+SP+Bldg $6,513,416
UTAC Line 1 GSA

Annual Cost factors for ESPs--OAQPS Control Cost Manual, Chap 6.2

Cost Item Cost

Direct Annual Costs, DC

Operating labor

Operator 3 hr/day $ 31,718

Supervisor 15% of operator $ 4,758

Operating materials

Maintenance

Labor for collector area < 50,000 sq ft $ 4,125

Material 1.00% of ESP PEC $ 29,078

Utilities

Electricity-fan kW/hr * 7,992 hr/yr * $ 0.064 /kWh = $ -

Electricity-operating

Waste Disposal 71 ton PM removed/yr * $ 50.00 /ton = $ 3,550

Total Direct Costs (DC) = $ 69,679

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs $ 41,807

Administrative charges 2% of Total Capital Investment

Property tax 1% of Total Capital Investment exempt in MN

Insurance 1% of Total Capital Investment

Capital recovery 0.0806 * Total Capital Investment

Total Indirect Costs (IC) = $ 41,807

Total Annual Cost DC + IC $ 111,486
UTAC Line 1 GSA

Capital Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 5.2

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

Absorber + auxiliary equipment, EC A $4,299,800

Instrumentation 0.10 A $429,980

Sales taxes 0.00 A $0

Freight 0.05 A $214,990

Purchased equipment cost, PEC B= 1.15 A $4,944,770

Direct installation costs

Foundations & supports 0.12 B $593,372

Handling & erection 0.40 B $1,977,908

Electrical 0.01 B $49,448

Piping 0.30 B $1,483,431

Insulation 0.01 B $49,448

Painting 0.01 B $49,448

Direct installation costs x x 0.85 B $4,203,055

Site preparation As required, SP $0

Buildings As required, Bldg. $0

Total Direct Costs, DC 1.85 $9,147,825

Indirect Costs (installation)

Engineering 0.10 B $494,477

Construction and field expenses 0.10 B $494,477

Contractor fees 0.10 B $494,477

Start-up 0.01 B $49,448

Performance test 0.01 B $49,448

Contingencies 0.03 B $148,343

Total Indirect Costs, IC 0.35 B $1,730,670

Lost production costs $3,850,000

Total Capital Investment = DC + IC 2.20 B+SP+Bldg $50,107,943
UTAC Line 1 GSA

Annual Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 5.2

Cost Item Cost

Direct Annual Costs, DC

Operating labor

Operator 0.5 hr/shift $ 15,859

Supervisor 15% of operator $ 2,379

Operating materials

Solvent 0 gpm * $ 2.07 /kgal = $ -

Chemicals 182.43 lb SO2/hr = 729.0 tpy SO2

1.3 lb-mole CaO/lb-mole SO2 * 22,781 lb-moles SO2/yr = 29,616 lb-mole CaO/yr

 29,616 lb-mole CaO/yr * 74 lb/lb-mole = 2,194,222 lb CaO/yr

 2,194,222 lb CaO/yr/ 2,000 lb/ton * $ 145.00 / ton = $ 159,081

Waste Disposal 650 ton SO2 removed/yr = 20,321 mole SO2 removed/yr = 20,321 mole CaSO4-2H2O produced/yr =

 20,321 mole CaSO4-2H2O produced/yr * 172 lb/lb-mole = 1,748 tpy CaSO4-2H2O

 1,748 tpy CaSO4-2H2O * $ 50.00 /ton = $ 87,382

23% of CaO is wasted = 253 tpy * $ 50.00 /ton = $ 12,659

Maintenance

Labor 1 hr/shift $ 32,468

Material 100.00% of maintenance $ 32,468

Electricity kW/hr * 7,992 hr/yr * $ 0.064 /kWh = $ -

Savings from shutdown of exsiting emission controls $ (639,933)

Total Direct Costs (DC) = $ (297,638)

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs $ 49,904

Administrative charges 2% of Total Capital Investment

Property tax 1% of Total Capital Investment exempt in MN

Insurance 1% of Total Capital Investment

Capital recovery 0.0806 * Total Capital Investment

Total Indirect Costs (IC) = $ 49,904

Total Annual Cost DC + IC $ (247,735)
UTAC Line 1 GSA

Capital Cost factors for Fabric Filters--OAQPS Control Cost Manual, Chap 6.1

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

ESP + auxiliary equipment, EC A $2,528,500

Instrumentation 0.10 A $252,850

Sales taxes 0.00 A $0

Freight 0.05 A $126,425

Purchased equipment cost, PEC B= 1.15 A $2,907,775

Direct installation costs

Foundations & supports 0.04 B $116,311

Handling & erection 0.50 B $1,453,888

Electrical 0.08 B $232,622

Piping 0.01 B $29,078

Insulation 0.07 B $203,544

Painting 0.04 B $116,311

Direct installation costs x x 0.74 B $2,151,754

Site preparation As required, SP

Buildings As required, Bldg.

Total Direct Costs, DC 1.85 B+SP+Bldg $5,059,529

Indirect Costs (installation)

Engineering 0.10 B $290,778

Construction and field expenses 0.20 B $581,555

Contractor fees 0.10 B $290,778

Start-up 0.01 B $29,078

Performance test 0.01 B $29,078

Contingencies 0.03 B $87,233

Total Indirect Costs, IC 0.45 B $1,308,499

Total Capital Investment = DC + IC 2.19 B+SP+Bldg $6,368,027
UTAC Line 1 GSA

Annual Cost factors for Fabric Filter Systems--OAQPS Control Cost Manual, Chap 6.1

Cost Item Cost

Direct Annual Costs, DC

Operating labor

Operator 2 hr/shift $ 63,437

Supervisor 15% of operator $ 9,515

Operating materials

Maintenance

Labor 0.5 hr/shift $ 16,234

Material 100.00% of maintenance $ 16,234

Replacement parts, bags

 2,244 bags * 0.17 hr/bag * $33 /hr = $12,155

 2,244 bags/cages * $ 180 /bag/cage = $ 403,920

CRF = 0.3811 0% sales tax 5% freight

$12,155 labor + $ 424,116 bags & cages * 0.3811 CRF = $ 166,242

Utilities

Electricity 3,224 kW/hr * 7,992 hr/yr * $ 0.064 /kWh = $ 1,649,037

Compressed air 2 scfm/kacfm * 578,225 acfm * $ 0.38 /kscf = $ 210,726

Waste Disposal 71 ton PM removed/yr * $ 50.00 /ton = $ 3,550

Total Direct Costs (DC) = $ 1,920,699

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs $ 63,252

Administrative charges 2% of Total Capital Investment

Property tax 1% of Total Capital Investment exempt in MN

Insurance 1% of Total Capital Investment

Capital recovery 0.0806 * Total Capital Investment

Total Indirect Costs (IC) = $ 63,252

Total Annual Cost DC + IC $ 1,983,950
UTAC Line 1 GSA SO2

Uncontrolled emissions (TPY) 729.0

Control efficiency (%) 89%

Emission reduction (TPY) 650

Controlled emissions (TPY) 79

UTAC Line 1 GSA PM10

Uncontrolled emissions (TPY) 71

Control efficiency (%) 100%

Emission reduction (TPY) 71

Controlled emissions (TPY) 0

Total Capital Investment $50,107,943 Barr 9/28/12 Table 6

Total Direct Annual Cost $ 1,692,739 sum of ESP+ABS+FF

Total Indirect Annual Cost $ 5,696,220 sum of (Overhead for ESP+ABS+FF)+(3% of TCI for Administrative Charges + Insurance) + Capital Recovery Cost

Total annualized cost ($/yr) $ 7,388,959

Cost/ton removed ($/T) $ 10,244