Development of Bottom Ash Handling MDS Methodologies - 

Conveyance Capital Cost Equations and Factors for MDS

This Excel file contains the following worksheets:

MDS Capital Cost

Engineering Cost Factor

This Excel workbook documents EPA's analyses to calculate equations and factors used in the bottom ash conveyance cost 

methodology for a mechanical drag system (MDS).

Contains data from Clyde Bergemann Power Group (CBPG) used to develop a cost 

curve to estimate equipment capital costs associated with the conveyance and 

intermediate storage portions of the bottom ash handling systems, based on unit cap

(in MW). Contains data from the Steam Electric Survey (Question C3-39) to evaluate the 

percentage of total capital costs represented by engineering overhead costs. The val

used (the calculated median percentage) is highlighted orange.
tom ash conveyance cost 

PG) used to develop a cost 

h the conveyance and 

g systems, based on unit capacity

 C3-39) to evaluate the 

ng overhead costs. The value 
Mechanical Drag System - Development of the Capital Cost Equation

EPA used data provided by Clyde Bergemann Power Group (nonCBI), previously Delta Ducon, (below) to generate a 

As shown in the footnote, this includes the intermediate storage for the system (Conveyance + Intermediate cap cost)

Based on the information provided in the table above, EPA used the upper MW bounds to plot MW vs. Capital Cost 

Unit MW Capital Cost

150 7,000,000

300 9,000,000

500 13,000,000

700 17,000,000

20,000,000

25,000,000
900 22,000,000

EPA plotted the points above to generate a cost equation to estimate

capital costs based on unit MW. EPA selected the linear equation 

based on the best r-squared value. EPA used the following equation:

Unit Cost (2010$) = 20,083 × Capacity, MW + 3,000,000

0

5,000,000

10,000,000

15,000,000

20,000,000

0
elta Ducon, (below) to generate a cost curve for a mechanical drag system (SSC) based on MW. 

veyance + Intermediate cap cost).

nds to plot MW vs. Capital Cost for the mechanical drag system.

y = 20083x + 3E+06

R2 = 0.9919

Unit MW vs. Capital Cost
R2 = 0.9919

200 400 600 800 1000
EPA's Methodology for Developing the Bottom Ash Handling MDS Engineering Factor

Responses from C3-39:

Plant ID

SE Unit 

ID CBI Flag Project Cost

Year 

Basis Plant ID

SE Unit 

ID CBI Flag

3831 SE Unit-2 TRUE[Redacted][Redacted][Redacted] 3831 SE Unit-2 TRUE

3433 SE Unit-4 FALSE Engineering Overhead 279767 2003 3433 SE Unit-4 FALSE

1245 SE Unit-1 FALSE Engineering Overhead 250000 2009 1245 SE Unit-1 FALSE

1245 SE Unit-2 FALSE Engineering Overhead 250000 2009 1245 SE Unit-2 FALSE

1634 SE Unit-1 TRUE[Redacted][Redacted][Redacted] 1634 SE Unit-1 TRUE

3831 SE Unit-1 TRUE[Redacted][Redacted][Redacted] 3831 SE Unit-1 TRUE

1695 SE Unit-3 TRUE[Redacted][Redacted][Redacted] 1695 SE Unit-3 TRUE

9534 SE Unit-7 FALSE Engineering Overhead 75000 2002 9534 SE Unit-7 FALSE

4781 SE Unit-2 FALSE Engineering Overhead 73242 2008 4781 SE Unit-2 FALSE

8437 SE Unit-1 TRUE[Redacted][Redacted][Redacted] 8437 SE Unit-1 TRUE

249 SE Unit-1 TRUE[Redacted][Redacted][Redacted] 249 SE Unit-1 TRUE

8233 SE Unit-1 FALSE Engineering Overhead 15000 2007 8233 SE Unit-1 FALSE

6118 SE Unit-2 TRUE[Redacted][Redacted][Redacted] 6118 SE Unit-2 TRUE

2766 SE Unit-1 FALSE Engineering Overhead 9000 2003 2766 SE Unit-1 FALSE

6118 SE Unit-1 TRUE[Redacted][Redacted][Redacted] 6118 SE Unit-1 TRUE

8075 SE Unit-1 TRUE[Redacted][Redacted][Redacted] 8075 SE Unit-1 TRUE

2548 SE Unit-1 FALSE Engineering Overhead0 -555 2548 SE Unit-1 FALSE

2548 SE Unit-2 FALSE Engineering Overhead0 -555 2548 SE Unit-2 FALSE

8750 SE Unit-1 TRUE[Redacted][Redacted][Redacted] 8750 SE Unit-1 TRUE

3235 SE Unit-3 FALSE Engineering Overhead0 -999 3235 SE Unit-3 FALSE

3235 SE Unit-4 FALSE Engineering Overhead0 -999 3235 SE Unit-4 FALSE

6672 SE Unit-1 TRUE[Redacted][Redacted][Redacted] 6672 SE Unit-1 TRUE

2548 SE Unit-3 FALSE Engineering Overhead0 -555 2548 SE Unit-3 FALSE

9526 SE Unit-4 FALSE Engineering Overhead0 -999 9526 SE Unit-4 FALSE

3146 SE Unit-1, SE Unit-2 FALSE Engineering Overhead0 2009 3146 SE Unit-1, SE Unit-2 FALSE

1258 SE Units -1,2,3,4 (see comments) FALSE Engineering Overhead0 -999 1258 SE Units -1,2,3,4 (see comments) FALSE

3097 SE Unit-4 FALSE Engineering Overhead0 -999 3097 SE Unit-4 FALSE

EPA used data from the Steam Electric Survey (Questions C3-39 (conveyance) and C3-47 (intermediate storagae)) to 

compare engineering overhead costs to total capital costs. Using this comparison, EPA calculated a factor for estimat

engineering overhead costs. EPA excluded any responses that were marked as blank or missing, and total capital cost

listed as zero.
Responses from C3-47:

Plant ID

SE Unit 

ID CBI Flag Project Cost

Year 

Basis Plant ID

SE Unit 

ID CBI Flag

1245 Outdoor Pile 1FALSE Engineering Overhead 30000 2009 1245 Outdoor Pile 1FALSE

1245 Outdoor Pile 2FALSE Engineering Overhead 30000 2009 1245 Outdoor Pile 2FALSE

9534 Silo 2 FALSE Engineering Overhead 3200 2002 9534 Silo 2 FALSE

6245 30 yard roll offFALSE Engineering Overhead0 -555 6245 30 yard roll offFALSE

2548 1, 2, 3 FALSE Engineering Overhead0 -555 2548 1, 2, 3 FALSE

9526 Other FALSE Engineering Overhead0 -999 9526 Other FALSE

6616 Other_Enclosed Buildings FALSE Engineering Overhead0 2009 6616 Other_Enclosed Buildings FALSE

3097 Silo 4 FALSE Engineering Overhead0 -999 3097 Silo 4 FALSE
Project Cost

Year 

Basis

Total 

Capital 

minus 

Overhead

Overhead 

% of 

Capital 

(excludin

g 

[Redacted][Redacted][Redacted] [Redacted][Redacted]

Total Capital3448808 NA 3169041 9%

Total Capital10250000 NA 10000000 3%

Total Capital10250000 NA 10000000 3%

[Redacted][Redacted][Redacted] [Redacted][Redacted]

[Redacted][Redacted][Redacted] [Redacted][Redacted]

[Redacted][Redacted][Redacted] [Redacted][Redacted]

Total Capital 580166 NA 505166 15%

Total Capital4223311 NA 4150069 2%

[Redacted][Redacted][Redacted] [Redacted][Redacted]

[Redacted][Redacted][Redacted] [Redacted][Redacted]

Total Capital 497000 NA 482000 3%

[Redacted][Redacted][Redacted] [Redacted][Redacted]

Total Capital 313000 NA 304000 3%

[Redacted][Redacted][Redacted] [Redacted][Redacted]

[Redacted][Redacted][Redacted] [Redacted][Redacted]

Total Capital 82500 NA 82500 0%

Total Capital 82500 NA 82500 0%

[Redacted][Redacted][Redacted] [Redacted][Redacted]

Total Capital17462901 NA 17462901 0%

Total Capital10365146 NA 10365146 0%

[Redacted][Redacted][Redacted] [Redacted][Redacted]

Total Capital 82500 NA 82500 0%

Total Capital 82500 NA 82500 0%

Total Capital8512055 NA 8512055 0%

Total Capital4552907 NA 4552907 0%

Total Capital2022218 NA 2022218 0%

Conveyance: min 0%

max 15%

average 2.276%

 (intermediate storagae)) to 

culated a factor for estimating 

ssing, and total capital costs 
median 1.765%

** Because median for Int Storage = 0, used the value for conveyance

Project Cost

Year 

Basis

Total 

Capital 

minus 

Overhead

Overhead 

% of 

Capital 

(excludin

g 

Total Capital 250000 NA 220000 14%

Total Capital 250000 NA 220000 14%

Total Capital 26253 NA 23053 14%

Total Capital 3922 NA 3922 0%

Total Capital 1000 NA 1000 0%

Total Capital 1000 NA 1000 0%

Total Capital 466732 NA 466732 0%

Total Capital 98201 NA 98201 0%

Int Storage: min 0%

max 14%

average 5.144%

median 0.000%

the value for conveyance