### 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 capacity (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 value used (the calculated median percentage) is highlighted orange.This Excel workbook documents EPA's analyses to calculate equations and factors used in the bottom ash conveyance cost

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 capacity Contains data from the Steam Electric Survey (Question C3-39) to evaluate the percentage of total capital costs represented by engineering overhead costs. The valueMechanical 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 cost curve for a mechanical drag system (SSC) based on MW. 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 for the mechanical drag system.

**Unit MW Capital Cost**  150 7,000,000 300 9,000,000 500 13,000,000 700 17,000,000 20,000,000 25,000,000900 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

0EPA used data provided by Clyde Bergemann Power Group (nonCBI), previously Delta Ducon, (below) to generate a cost curve for a mechanical drag system (SSC) based on MW. 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 for the mechanical drag system.

y = 20083x + 3E+06 R2 = 0.9919 

## Unit MW vs. Capital CostR2 = 0.9919

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

Responses from C3-39:

Plant ID SE Unit

ID CBIFlag Project Cost Year Basis Plant ID SE Unit

ID CBIFlag 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 Overhead 0 -555 2548 SE Unit-1 FALSE 2548 SE Unit-2 FALSE Engineering Overhead 0 -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 Overhead 0 -999 3235 SE Unit-3 FALSE 3235 SE Unit-4 FALSE Engineering Overhead 0 -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 Overhead 0 -555 2548 SE Unit-3 FALSE 9526 SE Unit-4 FALSE Engineering Overhead 0 -999 9526 SE Unit-4 FALSE 3146 SE Unit-1, SE Unit-2

FALSE Engineering Overhead 0 2009 3146 SE Unit-1, SE Unit-2 FALSE 1258 SE Units -1,2,3,4 (see comments)

FALSE Engineering Overhead 0 -999 1258 SE Units -1,2,3,4 (see comments) FALSE 3097 SE Unit-4 FALSE Engineering Overhead 0 -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 estimating engineering overhead costs. EPA excluded any responses that were marked as blank or missing, and total capital costs listed as zero.Responses from C3-47:

Plant ID SE Unit

ID CBIFlag Project Cost Year Basis Plant ID SE Unit

ID CBIFlag 1245 Outdoor Pile 1

FALSE Engineering Overhead

30000 2009 1245 Outdoor Pile 1 FALSE 1245 Outdoor Pile 2

FALSE Engineering Overhead

30000 2009 1245 Outdoor Pile 2 FALSE 9534 Silo 2 FALSE Engineering Overhead 3200 2002 9534 Silo 2 FALSE 6245 30 yard roll off

FALSE Engineering Overhead 0 -555 6245 30 yard roll off FALSE 2548 1, 2, 3 FALSE Engineering Overhead 0 -555 2548 1, 2, 3 FALSE 9526 Other FALSE Engineering Overhead 0 -999 9526 Other FALSE 6616 Other_Enclosed Buildings

FALSE Engineering Overhead 0 2009 6616 Other_Enclosed Buildings FALSE 3097 Silo 4 FALSE Engineering Overhead 0 -999 3097 Silo 4 FALSEProject Cost Year Basis Total

Capital minus Overhead Overhead

% of Capital (excludin g [Redacted] [Redacted] [Redacted] [Redacted] [Redacted] Total Capital

3448808 NA 3169041 9% Total Capital

10250000 NA 10000000 3% Total Capital

10250000 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 Capital

4223311 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 Capital

17462901 NA 17462901 0% Total Capital

10365146 NA 10365146 0% [Redacted] [Redacted] [Redacted] [Redacted] [Redacted] Total Capital 82500 NA 82500 0% Total Capital 82500 NA 82500 0% Total Capital

8512055 NA 8512055 0% Total Capital

4552907 NA 4552907 0% Total Capital

2022218 NA 2022218 0%

Conveyance: min 0%

max 15% average 2.276% 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 estimating engineering overhead costs. EPA excluded any responses that were marked as blank or missing, and total capital costsmedian 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%** Because median for Int Storage = 0, used the value for conveyance