**UTA C 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

### UTA**C Line 1 GSA**

**Capital Cost factors for ESPs--OA QPS 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 $** 

### UTA**C Line 1 GSA**

**Capital Cost factors for Gas A bsorbers--OA** **QPS 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--OA QPS 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 $** 

### UTA**C Line 1 GSA SO2**  Uncontrolled emissions (TPY) 729.0 Control efficiency (%) 89% Emission reduction (TPY) 650 Controlled emissions (TPY) 79 **UTA C 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 $