# MEMORANDUM

TO: Steam Electric Effluent Guideline Rulemaking Record

FROM: Debra Falatko , ERG

Kavya Kasturi, ERG

Elizabeth Sabol, ERG

Danielle Lewis, ERG

DATE: April 19

, 201 3

SUBJECT: Supplemental Costs and Loadings Documentation (DCN SE01825 )

EPA ’s report “Incremental Costs and Pollutant Removals for the Proposed Effluent Limitations

Guidelines and Standards for the Steam Electric Power Generating Point Source Category”

(DCN SE01957) describes the methodologies used to estimate engineering complia nce costs

associated with installing and operating the various technologies and practices that make up the

regulatory options considered by EPA. That report also presents the methodologies used to

estimate baseline and post

- compliance pollutant loadings an d the corresponding pollutant

removals for each regulatory option.

ERG prepared this document as a complement to that report, providing addition al detailed

information and data regarding the steam electric costs and loadings. This documen t , consisting

of a compilation of appendices to this cover memorandum, includes the following types of

additional detailed information and data :

**•** Spreadsheets documenting development of input tables, cost factors, chemical dosage

rates, and other cost elements;

**•** Telephone contact reports and other detailed cost information provided by vendors;

**•** Equipment specifications provided by vendors; and

**•** Calculations performed using the cost information, including the generation of cost

curves.

Table 1 lists the document appendices a nd describes the information and data contained in each.

## Memorandum

April 19 , 201 3

Page 2

Table 1. List of Supplemental Cost Document Appendices

DCN Relevant Cost Element Topic Description

Chemical Precipitation Treatment System

SE01825.A1 Purchased equipment costs Dry cargo van frei ght costs E quipment freight costs by full dry cargo van provided by vendor

SE01825.A2 Purchased equipment costs Pump purchase costs Development of cost equations for pump purchase costs

SE01825.A3 Purchased equipment costs Pump purchase costs FGD wastewa ter forwarding pump purchase costs provided by a vendor

SE01825.A4 Purchased equipment costs Pump purchase costs Treated FGD wastewater discharge pump purchase costs provided by a vendor

SE01825.A5 Purchased equipment costs Pump purchase costs Sump pump purchase costs provided by a vendor

SE01825.A6 Purchased equipment costs Pump purchase costs Lime slurry transfer pump purchase costs provided by a vendor

SE01825.A7 Purchased equipment costs Pump purchase costs Online freight costs by weight for shippin g pumps approximately 500 miles

SE01825.A8 1 Purchased equipment costs Tank purchase costs Assessment of materials of construction for wastewater treatment tanks

SE01825.A8 Purchased equipment costs Tank purchase costs Development of cost equations for ca rbon steel and fiberglass reinforced plastic

(FRP) tank purchase costs and development of a cost algorithm to select

between these tank types

SE01825.A9 Purchased equipment costs Tank purchase costs Development of the design basis for chemical precipitati on storage and reaction

tanks expressed by hydraulic residence time

SE01825.A85 Purchased equipment costs Tank purchase costs Development of the design basis for the biological and vapor

- compression

treatment system feed tank expressed by hydraulic reside nce time

SE01825.A10 Purchased equipment costs Tank purchase costs FRP tank purchase costs provided by a vendor

SE01825.A11 Purchased equipment costs Tank purchase costs Development of a cost equation for freight costs for shipping FRP tanks

SE01825.A1 2 Purchased equipment costs Tank purchase costs FRP tank freight costs provided by a vendor

SE01825.A13 Purchased equipment costs Tank purchase costs Carbon steel tank information provided by a vendor

SE01825.A14 Purchased equipment costs Tank and clari fier purchase costs Carbon steel tank purchase and freight costs provided by a vendor

SE01825.A15 Purchased equipment costs Tank purchase costs Carbon steel tank information provided by a vendor

SE01825.A16 Purchased equipment costs Tank and clarifier pu rchase costs Carbon steel tank information and specifications provided by a vendor

SE01825.A17 Purchased equipment costs Tank and clarifier purchase costs Carbon steel tank purchase costs and specifications provided by a vendor

SE01825.A18 Purchased equi pment costs Tank and clarifier purchase costs Carbon steel tank liner purchase costs and specifications provided by a vendor

SE01825.A19 Purchased equipment costs Tank and clarifier purchase costs Carbon steel tank liner specifications provided by a vendo r

SE01825.A86 Purchased equipment costs Tank purchase costs Totes information and costs provided by a vendor

SE01825.A 20 Purchased equipment costs Chemical feed system purchase costs Chemical feed system information and purchase costs provided by a vendo r

SE01825.A 21 Purchased equipment costs Chemical feed system purchase costs Chemical feed system information and purchase costs provided by a vendor

SE01825.A 22 Purchased equipment costs Chemical feed system purchase costs Chemical feed system specificat ions provided by a vendor

SE01825.A 23 Purchased equipment costs Chemical storage tank purchase costs Development of an algorithm to determine whether chemical storage tanks are

required (as opposed to onsite storage in chemical totes), and if so, the tank size

requirements

SE01825.A 24 Purchased equipment costs Chemical feed system purchase costs Development of an algorithm to estimate lime storage requirements and lime

storage silo size. Development of a cost equation for lime feed system purchase

costs

## Memorandum

April 19 , 201 3

Page 3

Table 1. List of Supplemental Cost Document Appendices

DCN Relevant Cost Element Topic Description

SE01825.A 25 Purchased equipment costs Chemical feed system purchase costs Chemical feed system specifications provided by a vendor

SE01825.A 26 Purchased equipment costs Mixer purchase costs Mixer information and purchase costs provided by a vendor

SE0182 5.A 27 Purchased equipment costs Mixer purchase costs Mixer freight costs provided by a vendor

SE01825.A 28 Purchased equipment costs Mixer purchase costs Mixer specifications provided by a vendor

SE01825.A 29 Purchased equipment costs Mixer purchase costs Development of cost factors used to estimate mixer purchase costs as a function

of tank volume and mixer torque

SE01825.A84 Purchased equipment costs Mixer purchase costs Development of a filtrate sump sizing factor used to calculate the filtrate sump

mi xer cost

SE01825.A 30 Purchased equipment costs Clarifier purchase costs Solids contact clarifier costs and specifications provided by a vendor

SE01825.A 31 Purchased equipment costs Clarifier purchase costs Clarifier freight costs provided by a vendor

S E01825.A 32 Purchased equipment costs Clarifier purchase costs Solids contact clarifier costs and specifications provided by a vendor

SE01825.A 83 Purchased equipment costs Clarifier purchase costs Development of the design basis and treatment in place meth odology for

clarifiers

SE01825.A 33 Purchased equipment costs Clarifier purchase costs Development of an equation to estimate clarifier tank volume as a function of

FGD wastewater flow

SE01825.A 34 Purchased equipment costs Pump, tank, and filter press pur chase costs Development of factor used to determine the flow rate of sludge generated by

chemical precipitation as a function of FGD wastewater flow

SE01825.A 35 Purchased equipment costs Filter press purchase costs Filter press information and purchase co sts provided by a vendor

SE01825.A 36 Purchased equipment costs Filter press purchase costs Filter press information and purchase costs provided by a vendor

SE01825.A 37 Purchased equipment costs Filter press purchase costs Filter press specifications prov ided by a vendor

SE01825.A 38 Purchased equipment costs Filter press purchase costs Development of a cost equation for filter press units as a function of required

filter press size. Development of algorithms to determine required number and

sizes of filte r presses as a function of the flow rate of sludge generated by

chemical precipitation

SE01825.A 39 Purchased equipment costs Sand filter purchase costs Sand filter information provided by a vendor

SE01825.A 40 Purchased equipment costs Sand filter purchas e costs Sand filter information and purchase costs provided by a vendor

SE01825.A 41 Purchased equipment costs Sand filter purchase costs Sand filter freight costs and specifications provided by a vendor

SE01825.A 42 Purchased equipment costs Sand filter p urchase costs Carbon steel tank information and specifications provided by a vendor

SE01825.A 43 Capital costs (except for purchased

equipment costs) Equipment installation costs

Building costs

Land costs

Site preparation costs

Engineering costs

Constructi on expenses

Other contractor’s fees

Contingency fees Development of cost factors used to estimate certain capital costs as a function

of purchased equipment costs

SE01825.A 44 Operating and maintenance costs Operating labor costs Development of a cost equa tion for operating labor costs

SE01825.A 45 Operating and maintenance costs Operating and maintenance costs Development of annual FGD wastewater treatment flows for plant operating

chemical precipitation; development of capacity factor used to size FGD

## Memorandum

April 19 , 201 3

Page 4

Table 1. List of Supplemental Cost Document Appendices

DCN Relevant Cost Element Topic Description

was tewater treatment systems

SE01825.A 46 Operating and maintenance costs Maintenance labor costs

Maintenance materials costs Development of cost factors used to estimate maintenance labor and materials

costs as a function of annual FGD wastewater flow

SE018 25.A 47 Operating and maintenance costs Chemical purchase costs Development of chemical dosage rates

SE01825.A 48 Operating and maintenance costs Chemical purchase costs Chemical purchase costs provided by vendors

SE01825.A 49 Operating and maintenance cost s Chemical purchase costs Derivation for an overall shipping rate for chemical precipitation chemicals

SE01825.A 50 Operating and maintenance costs Energy costs Development of an equation to estimate pump and clarifier mixer horsepower as

a function of FGD wastewater flow

SE01825.A 51 Operating and maintenance costs Energy costs Development of an equation to estimate filter press horsepower as a function of

chemical precipitation sludge flow

SE01825.A 52 Operating and maintenance costs Sludge disposal costs Development of an equation to estimate chemical precipitation dewatered

sludge generation as a function of FGD wastewater flow. Estimation of density

of dewatered chemical precipitation dewatered sludge

SE01825.A53 Current FGD Wastewater Flows Cost Input s Development of methodology to estimate missing FGD wastewater flow rates

for plants currently operating wet FGD scrubbers.

SE01825.A54 Planned FGD Wastewater Flows Cost Inputs Development of methodology to estimate missing FGD wastewater flow rates

for plants planning to install a wet FGD scrubber between 2009 and January 1,

2014.

SE01825.A55 FGD High Flow and Recycle Analysis Cost Inputs Analysis of plants with high FGD wastewater flow rates, greater than or equal to

1,000 gpm, to determine if recyclin g FGD wastewater is feasible.

SE01825.A82 Chemical Precipitation Treatment in

Place Cost Inputs Plant

- specific assessments and determinations of FGD wastewater treatment in

place.

SE01825.A56 Equalization Tank Cost Analysis Equalization Tank Costs Cost c omparison of equalization tanks and pond operating costs for high flow

FGD plants. Analysis to determine which option, equalization tanks or existing

segregated ponds, is more cost effective for achieving wastewater equalization

at plants with FGD wastewa ter flow of 1,000 gpm or greater.

Biological Treatment System

SE01825.A57 Capital and O&M Costs for GE’s

ABMet System Purchased Equipment Costs

Installation Costs

Energy Costs

Labor Costs

Chemical Costs Correspondence with General Electric (GE) regarding costing information for

their ABMet biological treatment system.

SE01825.A58 Capital Costs for Heat Exchanger Purchased Equipment Costs

Freight Costs Development of costing equations for purchase and freight associated with heat

exchanger and cooling w ater pumps.

SE01825.A59 Indirect Capital Costs Overhead Engineering Cost Development of factor used to calculate the overhead engineering cost

associated with the biological treatment system.

SE01825.A60 Operating and Maintenance Cost Maintenance Materia ls Cost Development of factor used to calculate costs associated with purchasing

materials used for maintaining the biological treatment system.

Vapor Compression Evaporation Treatment System

## Memorandum

April 19 , 201 3

Page 5

Table 1. List of Supplemental Cost Document Appendices

DCN Relevant Cost Element Topic Description

SE01825.A61 Capital and O&M costs for Vapor

Compression Evapor ation System Purchased Equipment Cost

Installation Cost

Energy Cost

Chemical Cost

Sludge Generation Compilation of data from GE and HPD regarding costing information for the

vapor compression evaporation system. Cost curves and equations developed

from ve ndor data were used to estimate system level costs for installing and

operating a vapor compression evaporation system.

Landfill Leachate Treatment

SE01825.A62 Landfill Leachate Flows Cost Inputs Development of methodology to estimate landfill leachate f low rate.

SE01825.A63 Landfill Leachate and FGD Treatment

In Place Analysis Cost Inputs Analysis of plants with treatment in place for FGD wastewater to determine if

treatment units contain the capacity to also treat landfill leachate.

SE01825.A64 Leacha te Conveyance Cost Analysis Cost Methodology Cost comparison of leachate conveyance options. Analysis compares the cost of

transporting leachate by truck from the landfill site back to the main plant area

to the cost of pumping the leachate from the landf ill back to the main plant area.

Transportation Costs

SE01825.A65 O&M Costs for Solids Transportation Annual Costs Development of methodology to estimate dollar per ton costs to transport

treatment solids to an on

- site or off

- site landfill.

Disposal Cos ts

SE01825.A66 O&M Costs for Off

- Site Disposal Annual Costs Development of dollar per ton cost to deposit treatment solids in an off

- site

landfill.

Mercury Analyzer Costs

SE01825.A67 Capital and O&M Costs for Mercury

Analyzer Purchased Equipment Cost

Re curring Cost Development of methodology to estimate capital and O&M costs associated

with installing and operating a mercury analyzer and feed

- back system on the

FGD wastewater treatment effluent.

Pond Operation Costs

SE01825.A68 Pond Operation Costs Pla nt Specific MW Factor Development of an equation to create a specific unitized cost value for pond

operation costs based on plant size (in MW).

Fly Ash

SE01825.A69 Fly Ash Handling Conversion Specifications of the Fly Ash Dry Vacuum

System Telecon and su bmitted data from fly ash handling vendor discussing the

specifications of the fly ash dry vacuum system and other assumptions about the

conversion. File also includes the conveyance pump energy requirements for

different sized systems used in the fly ash handling cost methodology.

SE01825.A70 Fly Ash Conveyance Cost Equations and Factors Developed for

Fly Ash Conveyance Capital and O&M

Costs Development of factors and equations for the fly ash handling conveyance

capital and O&M costs. These equations and factors include the conveyance

equipment capital cost equation, installation factor, engineering overhead cost

factor, operating and maintenance labor rates, operating and maintenance hours,

and maintenance materials cost factor.

SE01825.A71 Fly Ash Int ermediate Storage Cost Equations and Factors Developed for

Fly Ash intermediate Storage Capital and

O&M Costs Development of factors and equations for the fly ash handling intermediate

capital and O&M costs. These equations and factors include the intermed iate

storage equipment capital cost equation (for concrete and steel silos),

installation factor, engineering overhead cost factor, water truck labor and

## Memorandum

April 19 , 201 3

Page 6

Table 1. List of Supplemental Cost Document Appendices

DCN Relevant Cost Element Topic Description

operating hours, water truck fuel costs (maintenance materials), operating and

maintenance labor rates , operating and maintenance hours, maintenance

materials cost factor, and pugmill energy requirements.

SE01825.A72 Fly Ash Disposal Fly Ash Typical Moisture Content Development of the typical moisture content used to calculate the amount of

moisture cond itioned fly ash to be transported to a landfill.

Bottom Ash

SE01825.A73 Bottom Ash Handling Conversion Bottom Ash Handling Conversion Costs Email correspondence and attached bottom ash cost data from bottom ash

handling vendor discussing several operatin g characteristics and capital cost

relationships for bottom ash handling conversions. File also contains

information on the conveyance energy requirements for the MDS and Remote

MDS pumps.

SE01825.A74 Bottom Ash MDS Capital Costs Cost Equations and Factor s Developed for

the Bottom Ash MDS Capital Costs Development of factors and equations for the bottom ash handling MDS capital

costs. These equations and factors include the MDS conveyance and

intermediate storage e quipment capital cost equation (includes i nstallation) and

engineering overhead cost factor.

SE01825.A75 Bottom Ash Conveyance Cost Equations and Factors Developed for

Bottom Ash Conveyance O&M Costs Development of factors for the bottom ash MDS conveyance O&M costs. These

factors include the con veyance operating and maintenance labor rates, operating

and maintenance labor hours, maintenance materials cost factor.

SE01825.A76 Bottom Ash Intermediate Storage Cost Equations and Factors Developed for

Bottom Ash Intermediate Storage O&M

Costs Develop ment of factors for the bottom ash intermediate storage O&M costs.

These factors include the intermediate storage operating and maintenance labor

rates, operating and maintenance labor hours, maintenance materials cost factor,

and pugmill energy requiremen ts.

SE01825.A77 Bottom Ash Wet Sluicing Cost Equations and Factors Developed for

Bottom Ash Wet Sluicing O&M Costs Development of factors for the bottom ash wet sluicing O&M costs. These

factors include the wet sluicing operating and maintenance labor rat es, operating

and maintenance labor hours, and maintenance materials cost factor.

SE01825.A78 Bottom Ash Remote MDS Capital

Costs Cost Equations and Factors Developed for

the Bottom Ash Remote MDS Capital Costs Development of factors and equations for the bottom ash handling remote MDS

capital costs. These equations and factors include the remote MDS conveyance

and intermediate storage quipment capital cost equation (includes installation)

and engineering overhead cost factor.

SE01825.A79 Bottom Ash Dispo sal Bottom Ash Typical Moisture Content Development of the typical moisture content used to calculate the amount of

moisture conditioned bottom ash to be transported to a landfill.

SE01825.A80 Bottom Ash Recurring Costs MDS/Remote MDS Drag Chain

Replaceme nt Frequency and Cost Telecon and email correspondence with bottom ash handling vendor containing

information on bottom ash handling conversions and specific costs for bottom

ash conversions, drag chain replacement costs, and drag chain replacement

frequen cy.