US Steel - Minntac 9/6/2006

BART Report - Attachment A: Emission Control Cost Analysis

Table A.1: Furnaces Cost Summary

NOx Control Cost Summary 

Control Technology Control 

Eff %

Controlled 

Emissions T/y

Emission 

Reduction T/yr

Installed Capital 

Cost $

Annualized 

Operating Cost $/yr

Pollution Control 

Cost $/ton

Incremental 

Control Cost 

$/ton

Selective Catalytic Reduction with Reheat (SCR)

Line 3 80% 269.0 1076.0 $69,222,423 $19,513,772 $18,135 n/a

Line 4 80% 362.4 1449.6 $58,874,795 $28,169,433 $19,433 n/a

Line 5 80% 364.0 1456.0 $58,874,795 $28,169,433 $19,347 n/a

Line 6 80% 355.2 1420.8 $56,748,729 $26,419,264 $18,595 n/a

Line 7 80% 385.6 1542.4 $56,748,729 $26,419,264 $17,129 n/a

Low NOX Burners + Ported Kilns

Line 3 n/a n/a n/a n/a n/a n/a n/a

Line 4 15% 2908.6 248.5 $5,091,356 $480,588 $5,844 $5,076

Line 5 15% 3359.4 272.6 $6,474,892 $611,184 $5,974 $5,209

Line 6 n/a n/a n/a n/a n/a n/a n/a

Line 7 n/a n/a n/a n/a n/a n/a n/a

Low NOX Burners

Line 3 n/a n/a n/a n/a n/a n/a n/a

Line 4 10% 1630.8 181.2 $1,474,892 $139,219 $768 -$3,673

Line 5 10% 1638.0 182.0 $1,474,892 $139,219 $765 -$3,657

Line 6 n/a n/a n/a n/a n/a n/a n/a

Line 7 10% 1735.2 192.8 $1,200,000 $113,272 $588 n/a

Ported Kilns

Line 3 5% 1277.8 67.3 $3,616,464 $341,369 $5,076 n/a

Line 4 5% 1721.4 90.6 $5,000,000 $471,965 $5,209 n/a

Line 5 5% 1729.0 91.0 $5,000,000 $471,965 $5,186 n/a

Line 6 n/a n/a n/a n/a n/a n/a n/a

Line 7 n/a n/a n/a n/a n/a n/a n/a

SO2 Control Cost Summary 

Control Technology Control 

Eff %

Controlled 

Emissions T/y

Emission 

Reduction T/yr

Installed Capital 

Cost $

Annualized 

Operating Cost $/yr

Pollution Control 

Cost $/ton

Incremental 

Control Cost 

$/ton

Line 3 80% 65.9 263.5 $27,948,027 $5,322,323 $20,201 n/a

Line 4 80% 89.5 358.0 $39,347,773 $8,448,332 $23,597 n/a

Line 5 80% 89.5 358.0 $39,347,773 $8,448,332 $23,597 n/a

Line 6 80% 109.0 435.9 $36,370,821 $7,939,628 $18,216 n/a

Line 7 80% 109.0 435.9 $37,793,453 $8,123,761 $18,638 n/a

Line 3 60% 131.7 197.6 $19,626,314 $2,816,433 $14,253 n/a

Line 4 60% 179.0 268.5 $26,664,036 $4,123,939 $15,358 n/a

Line 5 60% 179.0 268.5 $26,664,036 $4,123,939 $15,358 n/a

Line 6 60% 217.9 326.9 $25,704,464 $3,953,025 $12,093 n/a

Line 7 60% 217.9 326.9 $25,704,464 $3,953,025 $12,093 n/a

Secondary Wet Scrubber

(after existing scrubber)

Wet Walled Electrostatic Precipitator (WWESP)

(after existing scrubber)

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Cost Summary 9/7/2006 Page 1 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost AnalysisTable A.2 - Summary of Utility, Chemical and Supply Costs

Operating Unit: Line 3 waste gas Study Year 2006

Emission Unit Number EU 223Stack/Vent Number SV 103

Operating Unit: Line 4 waste gas

Emission Unit Number EU 259Stack/Vent Number SV 118

Operating Unit: Line 5 waste gas

Emission Unit Number EU 280Stack/Vent Number SV 127

Operating Unit: Line 6 waste gas

Emission Unit Number EU 313Stack/Vent Number SV 144

Operating Unit: Line 7 waste gas

Emission Unit Number EU 332Stack/Vent Number SV 151

Reference

Item Unit Cost Units Cost Year Data Source NotesOperating Labor 61 $/hr Per Chrissy Bartovich e-mailMaintenance Labor 61 $/hr Per Chrissy Bartovich e-mailElectricity 0.051 $/kwh 2006

Expected annual average industrial price of electricity in the West North Central Division for 2007 - DOE http://tonto.eia.doe.gov/steo_query/app/elecpage.htm

Natural Gas 9.2575 $/mscf 2005

Energy Information Administration. Average US Industrial Natural Gas Prices. July '05 to June '06. http://tonto.eia.doe.gov/dnav/ng/hist/n3035us3m.htm

Water 0.08 $/mgal 2006 Per Chrissy Bartovich e-mail

Cooling Water 0.08 $/mgal 2006 Per Chrissy Bartovich e-mailCompressed Air 0.32 $/mscf 0.25 1998

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 1 

Example problem; Dried & Filtered, Ch 1.6 '98 cost adjusinflation

Wastewater Disposal Neutralization 1.69 $/mgal 1.50 2002

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 2 Chapter 2.5.5.5

Section 2 lists $1- $2/1000 gal. Cost adjusted for 3% infl3 lists $1.30 - $2.15/1,000 gal

Chemicals & SuppliesLime 91.40 $/ton 91.40 2006 Estimate from Cutler-Magney CompanyOxygen 40.00 $/ton 2006 BOC estimate.Ammonia (29% aqua.) 0.12 $/lb 0.101 2000

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4 Chapter 2, page 2-50

Annual costs for a retrofit SCR system example problem. adjusted for 3% inflation.

Caustic 305.96 $/ton 280 2003 Hawkins Chemical 50% solution (50 Deg Be); includes delivery. '03 cost adju

SCR Catalyst 141.00 $/ft3 Cormetech, Inc.

OtherSales Tax 6.5% %Interest Rate 7.00% %

EPA Air Pollution Control Cost Manual Introduction, Chapter 2, section 2.4.2. Social (discount) rate used as a default.

Operating InformationAnnual Op. Hrs 7946 Hours Engineering EstimateUtilization Rate 93%Equipment Life 20 yrs Engineering Estimate

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control CostsUtility Chem$ Data 
Standardized Flow Rate

SV 103 268,515 scfm @ 32o F Calculated.

SV 118 556,174 scfm @ 32o F Calculated.

SV 127 556,174 scfm @ 32o F Calculated.

SV 144 518,805 scfm @ 32o F Calculated.

SV 151 518,805 scfm @ 32o F Calculated.

TemperatureSV 103 130 Deg F BART spreadsheet.

SV 118 115 Deg F BART spreadsheet.

SV 127 115 Deg F BART spreadsheet.

SV 144 109 Deg F BART spreadsheet.

SV 151 109 Deg F BART spreadsheet.

Moisture ContentSV 103 10.5% Assumed value.SV 118 10.5% Assumed value.SV 127 10.5% Assumed value.SV 144 10.5% Assumed value.SV 151 10.5% Assumed value.Actual Flow RateSV 103 322,000 acfm BART spreadsheet.

SV 118 650,000 acfm BART spreadsheet.

SV 127 650,000 acfm BART spreadsheet.

SV 144 600,000 acfm Same as line 7

SV 151 600,000 acfm BART spreadsheet.

Standardized Flow RateSV 103 288,163 scfm @ 68o F Calculated.

SV 118 596,870 scfm @ 68o F Calculated.

SV 127 596,870 scfm @ 68o F Calculated.

SV 144 556,766 scfm @ 68o F Calculated.

SV 151 556,766 scfm @ 68o F Calculated.

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control CostsUtility Chem$ Data 
Dry Std Flow Rate

SV 103 257,906 dscfm @ 68o F Calculated.

SV 118 534,198 dscfm @ 68o F Calculated.

SV 127 534,198 dscfm @ 68o F Calculated.

SV 144 498,306 dscfm @ 68o F Calculated.

SV 151 498,306 dscfm @ 68o F Calculated.

24-hour

Max Emis Projected future actual lb/hr ton/year

Pollutant Lb/Hr emissions (tpy) ppmv ppmv Max 24 hour emissions source Projected future actual emissions source

Nitrous Oxides (NOx)SV 103 876.9 1,345.0 474 166.1 Based on max stack test plus 10% Based on 2005 AEI plus 10%.

SV 118 1353.0 1,812.0 353 108.0 Based on max stack test plus 10% Based on 2005 AEI plus 10%.

SV 127 1353.0 1,820.0 353 108.5 Based on max stack test plus 10% Based on 2005 AEI plus 10%.

SV 144 1202.3 1,776.0 336 113.5 Based on max stack test plus 10% Based on 2005 AEI plus 10%.

SV 151 1202.3 1,928.0 336 123.2 Based on max stack test plus 10% Based on 2005 AEI plus 10%.

Sulfur Dioxides (SO2)SV 103 98.6 329.3 38 29.2

Based on max stack test plus 10%, minus 30% to account for new scrubber.

Based on AEI avg 2004/2005 plus 10%., minus 30% to a

scrubber.

SV 118 146.3 447.5 27 19.2 Based on max stack test plus 10%. Based on AEI avg 2004/2005 plus 10%.

SV 127 146.3 447.5 27 19.2 Based on max stack test plus 10%. Based on AEI avg 2004/2005 plus 10%.

SV 144 184.8 544.8 37 25.0 Based on max stack test plus 10%. Based on AEI avg 2004/2005 plus 10%.

SV 151 184.8 544.8 37 25.0 Based on max stack test plus 10%. Based on AEI avg 2004/2005 plus 10%.

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control CostsUtility Chem$ Data 
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.a - NOx Control - Selective Catalytic Reduction with Reheat

Operating Unit: Line 3 waste gas

Emission Unit Number EU 223 Stack/Vent Number SV 103 Chemical Engineering

Design Capacity 200 mmbtu/hr Standardized Flow Rate 268,515 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 130 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 322,000 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 288,163 scfm @ 68o F

Dry Std Flow Rate 257,906 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs EPRI Correlation

 Purchased Equipment 28,387,757

 Purchased Equipment Total SCR Only 30,232,961

SCR + Reheat 30,950,318

Total Capital Investment (TCI) = DC + IC SCR + Reheat 69,222,423

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. SCR + Reheat 11,235,240

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost SCR + Reheat 8,288,440

Total Annual Cost (Annualized Capital Cost + Operating Cost) SCR + Reheat 19,513,772

Emission Control Cost Calculation

Max Emis Annual Cont Eff Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 876.9 1,345.0 80% 269.0 1,076.0 18,135 

Notes & Assumptions

1 Estimated Equipment Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2.

2 For Calculation purposes, duty reflects increased flow rate, not actual duty.

3 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2

4 Capital Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.36 -2.43

5 Reagent Use per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.32 - 2.35

6 SCR Catalyst Volume per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.18 - 2.24

7 SCR Reactor Size per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.25 - 2.31

8 SCR Catalyst Replacement per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.50 - 2.53

9 SCR Electrical Demand per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.48

10 SCR Maintenance Costs EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.46

11 Control Efficiency = 80% reduction

12 Site specific electricity costs

13 Catalyst replacement every 3 years.

14 CUECost Workbook Version 1.0, USEPA Document Page 2

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line3 SCR Line3 SCR 5 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.a - NOx Control - Selective Catalytic Reduction with Reheat

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (1)

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 28,387,757

Instrumentation 10% of control device cost (A) NA

MN Sales Taxes 6.5% of control device cost (A) 1,845,204

Freight 5% of control device cost (A) NA

Purchased Equipment Total 30,232,961

Indirect Installation

General Facilities 0% of purchased equip cost (A) 0

Engineering & Home Office 0% of purchased equip cost (A) 0

Process Contingency 0% of purchased equip cost (A) 0

Site Specific-Other 9% Replacement Power, two weeks 2,643,899

Total Indirect Installation Costs (B) 9% of purchased equip cost (A) 2,643,899

Project Contingeny (C) 15% of (A + B) 4,931,529

Total Plant Cost (D) A + B + C 37,808,389

Allowance for Funds During Construction (E) 0 for SCR 0

Royalty Allowance (F) 0 for SCR 0

Pre Production Costs (G) 2% of (D+E)) 756,168

Inventory Capital Reagent Vol * $/gal 102,618

Total Capital Investment (TCI) = DC + IC D + E + F + G +H + I 38,667,175

Retrofit Factor (14) 60% of TCI 23,200,305

Sitework and foundations 1,400,000

Structural steel 4,800,000

Total Capital Investment Retrofit Installed 68,067,479

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Total 1.50 % of Total Capital Investment 580,008

Maintenance Materials NA % of Maintenance Labor - 

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 652 kW-hr, 7946 hr/yr, 93% utilization 245,543

SCR Catalyst 64.71 Catalyst Replacement 193,359

Ammonia (29% aqua.) 0.12 $/lb, 3,024 lb/hr, 7946 hr/yr, 93% utilization 2,694,872

Total Annual Direct Operating Costs 3,853,135

Indirect Operating Costs

Overhead 60% of total labor and material costs 94,284

Administration (2% total capital costs) 2% of total capital costs (TCI) 773,343

Property tax (1% total capital costs) 1% of total capital costs (TCI) 386,672

Insurance (1% total capital costs) 1% of total capital costs (TCI) 386,672

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 6,425,089 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 8,066,059

Total Annual Cost (Annualized Capital Cost + Operating Cost) 11,919,195

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line3 SCR Line3 SCR 6 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.a - NOx Control - Selective Catalytic Reduction with Reheat

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catayst Estimate amount of catalyst required 

Equipment Life 24,000 hours Vol. #1 2708 ft3

Cormetech, Inc.

FCW 0.3111 Flow #1 177,000 scfm Cormetech, Inc.

Rep part cost per unit $141 Flow #2 288,163 scfm

Vol #2 4408.7 ft3

Amount Required 4,409 ft3

Catalyst Cost 621,630

Y catalyst life factor 3 Years

Annualized Cost 193,359

Equivalent Duty 1,547 Plant Cap kW A 158,727

Est power platn eff 35% Unc Nox lb/mmBtu B 0.62 D=75*(300,000)*((B/1.5)^0.05*(C/100)^0.04)A)^0.35

Watt per Btu/hr 0.29307 Nox Red. Eff. C 80% E=D*A*0.0066

Equivalent power plant kW 158,727 Capital Cost $/kW D $150.00 $23,809,086.67 Total SCR Equipment

Uncontrolled Nox t/y 3,840.9 Fixed O&M E $157,139.97

Annual Operating Hrs 7,946 Variable O&M F $394,208.98

Uncontrolled Nox lb/mmBtu 0.625 Ann Cap Factor G 0.82

Heat Input mmBtu/hr H 1,547

Electrical Use

Equivalent Duty 1,547 MMBtu/hr kW

NOx Cont Eff 80% Power 651.5

NOx in 0.62 lb/MMBtu

n catalyst layers 4 layers

Press drop catalyst 1 in H2O per layer

Press drop duct 3 in H2O 

Total 651.5

Reagent Use & Other Operating Costs

Ammonia Use 56.0 lb/ft3 Density

877 lb/hr Neat 404.0 gal/hr

29% solution Volume 14 day inventory 135,729 gal $102,618 Inventory Cost

3024 lb/hr

Design Basis Max Emis Control Eff (%)

lb/MMBtu 80%

Nitrous Oxides (NOx) 0.625

Actual 77,372 dscf/MMBtu

Method 19 Factor 10,000 dscf/MMBtu

Adjusted Duty 1,547 MMBtu/hr

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maintenance Total 1.5 % of Total Capital Investment 580,008 % of Total Capital Investment

Maint Mtls 0 % of Maintenance Labor NA 0 0% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 651.5 kW-hr 4,814,574 245,543 $/kwh, 652 kW-hr, 7946 hr/yr, 93% utilization

SCR Catalyst 141 $/ft3 193,359 Catalyst Replacement

Ammonia (29% aqua.) 0.12 $/lb 3024 lb/hr 22,345,675 2,694,872 $/lb, 3,024 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line3 SCR Line3 SCR 7 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.a: NOx

 Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Operating Unit: Line 3 waste gas

Emission Unit Number EU 223 Stack/Vent Number SV 103 Chemical Engineering

Design Capacity 200 mmbtu/hr Standardized Flow Rate 268,515 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 130 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 322,000 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 288,163 scfm @ 68o F

Dry Std Flow Rate 257,906 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 590,417

 Purchased Equipment Total (B) 22% of control device cost (A) 717,356

 Installation - Standard Costs 30% of purchased equip cost (B) 215,207

 Installation - Site Specific Costs NA

 Installation Total 215,207

 Total Direct Capital Cost, DC 932,563

 Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 222,380

Total Capital Investment (TCI) = DC + IC 1,154,944

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 7,382,105

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 212,472

Total Annual Cost (Annualized Capital Cost + Operating Cost) 7,594,577

Notes & Assumptions

1 Equipment cost estimate EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2.5.1 

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2 

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line3 Reheat Line3 Reheat 8 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.a: NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 590,417

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 

Instrumentation 10% of control device cost (A) 59,042

MN Sales Taxes 6.5% of control device cost (A) 38,377

Freight 5% of control device cost (A) 29,521

Purchased Equipment Total (B) 22% 717,356

Installation

Foundations & supports 8% of purchased equip cost (B) 57,389

Handling & erection 14% of purchased equip cost (B) 100,430

Electrical 4% of purchased equip cost (B) 28,694

Piping 2% of purchased equip cost (B) 14,347

Insulation 1% of purchased equip cost (B) 7,174

Painting 1% of purchased equip cost (B) 7,174

Installation Subtotal Standard Expenses 30% 215,207

Site Preparation, as required Site Specific NA

Buildings, as required Site Specific NA

Site Specific - Other Site Specific NA

Total Site Specific Costs NA

Installation Total 215,207

Total Direct Capital Cost, DC 932,563

Indirect Capital Costs

Engineering, supervision 10% of purchased equip cost (B) 71,736

Construction & field expenses 5% of purchased equip cost (B) 35,868

Contractor fees 10% of purchased equip cost (B) 71,736

Start-up 2% of purchased equip cost (B) 14,347

Performance test 1% of purchased equip cost (B) 7,174

Model Studies of purchased equip cost (B) 0

Contingencies 3% of purchased equip cost (B) 21,521

Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 222,380

Total Capital Investment (TCI) = DC + IC 1,154,944

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 1,154,944

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,193 kW-hr, 7946 hr/yr, 93% utilization 449,620

Natural Gas 9.26 $/mscf, 1,666 scfm, 7946 hr/yr, 93% utilization 6,837,058

Total Annual Direct Operating Costs 7,382,105

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 23,099

Property tax (1% total capital costs) 1% of total capital costs (TCI) 11,549

Insurance (1% total capital costs) 1% of total capital costs (TCI) 11,549

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 109,019 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 212,472

Total Annual Cost (Annualized Capital Cost + Operating Cost) 7,594,577

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line3 Reheat Line3 Reheat 9 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.a: NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst: Catalyst

Equipment Life 3 years

CRF 0.3811

Rep part cost per unit 0 $/ft3

Amount Required 39 ft3

Catalyst Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Thermal 322,000 19 0.6 1,193.0 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Blower, Catalytic 322,000 23 0.6 1,444.2 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Oxidizer Type thermal (catalytic or thermal) 1193.0

Reagent Use & Other Operating Costs Oxidizers - NA

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1193.0 kW-hr 8,816,081 449,620 $/kwh, 1,193 kW-hr, 7946 hr/yr, 93% utilization

Natural Gas 9.26 $/mscf 1,666 scfm 738,543 6,837,058 $/mscf, 1,666 scfm, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line3 Reheat Line3 Reheat 10 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.a: NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Flue Gas Re-Heat Equipment Cost Estimate Basis Thermal Oxidizer with 70% Heat Recovery

Auxiliary Fuel Use Equation 3.19 

Twi 130 Deg F - Temperature of waste gas into heat recovery

Tfi 750 Deg F - Temperature of Flue gas into of heat recovery

Tref 77 Deg F - Reference temperature for fuel combustion calculations

FER 70% Factional Heat Recovery % Heat recovery section efficiency

Two 564 Deg F - Temperature of waste gas out of heat recovery

Tfo 316 Deg F - Temperature of flue gas into of heat recovery 

-hcaf 21502 Btu/lb Heat of combustion auxiliary fuel (methane)

-hwg 0 Btu/lb Heat of combustion waste gas

Cp wg 0.2684 Btu/lb - Deg F Heat Capacity of waste gas (air)

p wg 0.0739 lb/scf - Density of waste gas (air) at 77 Deg F

p af 0.0408 lb/scf - Density of auxiliary fuel (methane) at 77 Deg F

Qwg 288,163 scfm - Flow of waste gas 

Qaf 1,666 scfm - Flow of auxiliary fuel

Year 2005 Inflation Rate 3.0%

Cost Calculations 289,828 scfm Flue Gas Cost in 1989 $'s $495,188

Current Cost Using CHE Plant Cost Index $590,417

Heat Rec % A B

0 10,294 0.2355 Exponents per equation 3.24

0.3 13,149 0.2609 Exponents per equation 3.25

0.5 17,056 0.2502 Exponents per equation 3.26

0.7 21,342 0.2500 Exponents per equation 3.27

Indurator Flue Gas Heat Capacity - Basis Typical Composition

100 scfm 359 scf/lbmole

Gas Composition lb/hr f wt % Cp Gas Cp Flue

28 mw CO 0 v % 0

44 mw CO2 15 v % 184 22.0% 0.24 0.0528

18 mw H2O 10 v % 50 6.0% 0.46 0.0276

28 mw N2 60 v % 468 56.0% 0.27 0.1512

32 mw O2 15 v % 134 16.0% 0.23 0.0368

Cp Flue Gas 100 v % 836 100.0% 0.2684

Reference: OAQPS Control Cost Manual 5th Ed Feb 1996 - Chapter 3 Thermal & Catalytic Incinerators

 (EPA 453/B-96-001)

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line3 Reheat Line3 Reheat 11 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.b - NOx Control - Selective Catalytic Reduction with Reheat

Operating Unit: Line 4 waste gas

Emission Unit Number EU 259 Stack/Vent Number SV 118

Design Capacity 300 mmbtu/hr Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs EPRI Correlation

 Purchased Equipment 23,050,831

 Purchased Equipment Total SCR Only 24,549,135

SCR + Reheat 25,409,745

Total Capital Investment (TCI) = DC + IC SCR + Reheat 58,874,795

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. SCR + Reheat 21,125,878

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost SCR + Reheat 7,066,876

Total Annual Cost (Annualized Capital Cost + Operating Cost) SCR + Reheat 28,169,433

Emission Control Cost Calculation

Max Emis Annual Cont Eff Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,353.0 1,812.0 80% 362.4 1,449.6 19,433 

Notes & Assumptions

1 Estimated Equipment Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2.

2 For Calculation purposes, duty reflects increased flow rate, not actual duty.

3 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2

4 Capital Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.36 -2.43

5 Reagent Use per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.32 - 2.35

6 SCR Catalyst Volume per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.18 - 2.24

7 SCR Reactor Size per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.25 - 2.31

8 SCR Catalyst Replacement per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.50 - 2.53

9 SCR Electrical Demand per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.48

10 SCR Maintenance Costs EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.46

11 Control Efficiency = 80% reduction

12 Site specific electricity costs

13 Catalyst replacement every 3 years.

14 CUECost Workbook Version 1.0, USEPA Document Page 2

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 SCR Line4 SCR 12 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.b - NOx Control - Selective Catalytic Reduction with Reheat

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (1)

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 23,050,831

Instrumentation 10% of control device cost (A) NA

MN Sales Taxes 6.5% of control device cost (A) 1,498,304

Freight 5% of control device cost (A) NA

Purchased Equipment Total 24,549,135

Indirect Installation

General Facilities 0% of purchased equip cost (A) 0

Engineering & Home Office 0% of purchased equip cost (A) 0

Process Contingency 0% of purchased equip cost (A) 0

Site Specific-Other 11% Replacement Power, two weeks 2,643,899

Total Indirect Installation Costs (B) 11% of purchased equip cost (A) 2,643,899

Project Contingeny (C) 15% of (A + B) 4,078,955

Total Plant Cost (D) A + B + C 31,271,989

Allowance for Funds During Construction (E) 0 for SCR 0

Royalty Allowance (F) 0 for SCR 0

Pre Production Costs (G) 2% of (D+E)) 625,440

Inventory Capital Reagent Vol * $/gal 158,329

Total Capital Investment (TCI) = DC + IC D + E + F + G +H + I 32,055,758

Retrofit Factor (14) 60% of TCI 19,233,455

Sitework and foundations 1,400,000

Structural steel 4,800,000

Total Capital Investment Retrofit Installed 57,489,212

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Total 1.50 % of Total Capital Investment 480,836

Maintenance Materials NA % of Maintenance Labor - 

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,409 kW-hr, 7946 hr/yr, 93% utilization 531,079

SCR Catalyst 64.71 Catalyst Replacement 400,504

Ammonia (29% aqua.) 0.12 $/lb, 4,666 lb/hr, 7946 hr/yr, 93% utilization 4,157,919

Total Annual Direct Operating Costs 5,709,691

Indirect Operating Costs

Overhead 60% of total labor and material costs 91,281

Administration (2% total capital costs) 2% of total capital costs (TCI) 641,115

Property tax (1% total capital costs) 1% of total capital costs (TCI) 320,558

Insurance (1% total capital costs) 1% of total capital costs (TCI) 320,558

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 5,426,575 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 6,800,087

Total Annual Cost (Annualized Capital Cost + Operating Cost) 12,509,778

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 SCR Line4 SCR 13 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.b - NOx Control - Selective Catalytic Reduction with Reheat

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catayst Estimate amount of catalyst required 

Equipment Life 24,000 hours Vol. #1 2708 ft3

Cormetech, Inc.

FCW 0.3111 Flow #1 177,000 scfm Cormetech, Inc.

Rep part cost per unit $141 Flow #2 596,870 scfm

Vol #2 9131.8 ft3

Amount Required 9,132 ft3

Catalyst Cost 1,287,579

Y catalyst life factor 3 Years

Annualized Cost 400,504

Equivalent Duty 3,484 Plant Cap kW A 357,359

Est power platn eff 35% Unc Nox lb/mmBtu B 0.43 D=75*(300,000)*((B/1.5)^0.05*(C/100)^0.04)A)^0.35

Watt per Btu/hr 0.29307 Nox Red. Eff. C 80% E=D*A*0.0066

Equivalent power plant kW 357,359 Capital Cost $/kW D $64.50 $23,050,831.27 Total SCR Equipment

Uncontrolled Nox t/y 1,353.0 Fixed O&M E $152,135.49

Annual Operating Hrs 8000 Variable O&M F $624,082.60

Uncontrolled Nox lb/mmBtu 0.428 Ann Cap Factor G 0.82

Heat Input mmBtu/hr H 6,000

Electrical Use

Equivalent Duty 3,484 MMBtu/hr kW

NOx Cont Eff 80% Power 1,409.2

NOx in 0.43 lb/MMBtu

n catalyst layers 4 layers

Press drop catalyst 1 in H2O per layer

Press drop duct 3 in H2O 

Total 1409.2

Reagent Use & Other Operating Costs

Ammonia Use 56.0 lb/ft3 Density

1353 lb/hr Neat 623.3 gal/hr

29% solution Volume 14 day inventory 209,416 gal $158,329 Inventory Cost

4666 lb/hr

Design Basis Max Emis Control Eff (%)

lb/MMBtu 80%

Nitrous Oxides (NOx) 0.428

Actual 106,840 dscf/MMBtu

Method 19 Factor 9,200 dscf/MMBtu

Adjusted Duty 3,484 MMBtu/hr

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maintenance Total 1.5 % of Total Capital Investment 480,836 % of Total Capital Investment

Maint Mtls 0 % of Maintenance Labor NA 0 0% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1409.2 kW-hr 10,413,319 531,079 $/kwh, 1,409 kW-hr, 7946 hr/yr, 93% utilization

SCR Catalyst 141 $/ft3 400,504 Catalyst Replacement

Ammonia (29% aqua.) 0.12 $/lb 4666 lb/hr 34,477,146 4,157,919 $/lb, 4,666 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 SCR Line4 SCR 14 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.b - NOx

 Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Operating Unit: Line 4 waste gas

Emission Unit Number EU 259 Stack/Vent Number SV 118 Chemical Engineering

Design Capacity 300 mmbtu/hr Standardized Flow Rate 556,174 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 115 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 708,321

 Purchased Equipment Total (B) 22% of control device cost (A) 860,610

 Installation - Standard Costs 30% of purchased equip cost (B) 258,183

 Installation - Site Specific Costs NA

 Installation Total 258,183

 Total Direct Capital Cost, DC 1,118,793

 Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 266,789

Total Capital Investment (TCI) = DC + IC 1,385,582

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 15,416,187

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 243,468

Total Annual Cost (Annualized Capital Cost + Operating Cost) 15,659,655

Notes & Assumptions

1 Equipment cost estimate EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2.5.1 

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2 

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 Reheat Line4 Reheat 15 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.b - NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 708,321

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 

Instrumentation 10% of control device cost (A) 70,832

MN Sales Taxes 6.5% of control device cost (A) 46,041

Freight 5% of control device cost (A) 35,416

Purchased Equipment Total (B) 22% 860,610

Installation

Foundations & supports 8% of purchased equip cost (B) 68,849

Handling & erection 14% of purchased equip cost (B) 120,485

Electrical 4% of purchased equip cost (B) 34,424

Piping 2% of purchased equip cost (B) 17,212

Insulation 1% of purchased equip cost (B) 8,606

Painting 1% of purchased equip cost (B) 8,606

Installation Subtotal Standard Expenses 30% 258,183

Site Preparation, as required Site Specific NA

Buildings, as required Site Specific NA

Site Specific - Other Site Specific NA

Total Site Specific Costs NA

Installation Total 258,183

Total Direct Capital Cost, DC 1,118,793

Indirect Capital Costs

Engineering, supervision 10% of purchased equip cost (B) 86,061

Construction & field expenses 5% of purchased equip cost (B) 43,031

Contractor fees 10% of purchased equip cost (B) 86,061

Start-up 2% of purchased equip cost (B) 17,212

Performance test 1% of purchased equip cost (B) 8,606

Model Studies of purchased equip cost (B) 0

Contingencies 3% of purchased equip cost (B) 25,818

Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 266,789

Total Capital Investment (TCI) = DC + IC 1,385,582

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 1,385,582

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 2,408 kW-hr, 7946 hr/yr, 93% utilization 907,618

Natural Gas 9.26 $/mscf, 3,511 scfm, 7946 hr/yr, 93% utilization 14,413,142

Total Annual Direct Operating Costs 15,416,187

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 27,712

Property tax (1% total capital costs) 1% of total capital costs (TCI) 13,856

Insurance (1% total capital costs) 1% of total capital costs (TCI) 13,856

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 130,789 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 243,468

Total Annual Cost (Annualized Capital Cost + Operating Cost) 15,659,655

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 Reheat Line4 Reheat 16 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.b - NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst: Catalyst

Equipment Life 3 years

CRF 0.3811

Rep part cost per unit 0 $/ft3

Amount Required 39 ft3

Catalyst Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Thermal 650,000 19 0.6 2,408.3 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Blower, Catalytic 650,000 23 0.6 2,915.3 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Oxidizer Type thermal (catalytic or thermal) 2408.3

Reagent Use & Other Operating Costs Oxidizers - NA

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 2408.3 kW-hr 17,796,438 907,618 $/kwh, 2,408 kW-hr, 7946 hr/yr, 93% utilization

Natural Gas 9.26 $/mscf 3,511 scfm 1,556,915 14,413,142 $/mscf, 3,511 scfm, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 Reheat Line4 Reheat 17 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.b - NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Flue Gas Re-Heat Equipment Cost Estimate Basis Thermal Oxidizer with 70% Heat Recovery

Auxiliary Fuel Use Equation 3.19 

Twi 115 Deg F - Temperature of waste gas into heat recovery

Tfi 750 Deg F - Temperature of Flue gas into of heat recovery

Tref 77 Deg F - Reference temperature for fuel combustion calculations

FER 70% Factional Heat Recovery % Heat recovery section efficiency

Two 560 Deg F - Temperature of waste gas out of heat recovery

Tfo 306 Deg F - Temperature of flue gas into of heat recovery 

-hcaf 21502 Btu/lb Heat of combustion auxiliary fuel (methane)

-hwg 0 Btu/lb Heat of combustion waste gas

Cp wg 0.2684 Btu/lb - Deg F Heat Capacity of waste gas (air)

p wg 0.0739 lb/scf - Density of waste gas (air) at 77 Deg F

p af 0.0408 lb/scf - Density of auxiliary fuel (methane) at 77 Deg F

Qwg 596,870 scfm - Flow of waste gas 

Qaf 3,511 scfm - Flow of auxiliary fuel

Year 2005 Inflation Rate 3.0%

Cost Calculations 600,381 scfm Flue Gas Cost in 1989 $'s $594,076

Current Cost Using CHE Plant Cost Index $708,321

Heat Rec % A B

0 10,294 0.2355 Exponents per equation 3.24

0.3 13,149 0.2609 Exponents per equation 3.25

0.5 17,056 0.2502 Exponents per equation 3.26

0.7 21,342 0.2500 Exponents per equation 3.27

Indurator Flue Gas Heat Capacity - Basis Typical Composition

100 scfm 359 scf/lbmole

Gas Composition lb/hr f wt % Cp Gas Cp Flue

28 mw CO 0 v % 0

44 mw CO2 15 v % 184 22.0% 0.24 0.0528

18 mw H2O 10 v % 50 6.0% 0.46 0.0276

28 mw N2 60 v % 468 56.0% 0.27 0.1512

32 mw O2 15 v % 134 16.0% 0.23 0.0368

Cp Flue Gas 100 v % 836 100.0% 0.2684

Reference: OAQPS Control Cost Manual 5th Ed Feb 1996 - Chapter 3 Thermal & Catalytic Incinerators

 (EPA 453/B-96-001)

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 Reheat Line4 Reheat 18 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.c - NOx Control - Selective Catalytic Reduction with Reheat

Operating Unit: Line 5 waste gas

Emission Unit Number EU 280 Stack/Vent Number SV 127

Design Capacity 300 mmbtu/hr Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs EPRI Correlation

 Purchased Equipment 23,050,831

 Purchased Equipment Total SCR Only 24,549,135

SCR + Reheat 25,409,745

Total Capital Investment (TCI) = DC + IC SCR + Reheat 58,874,795

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. SCR + Reheat 21,125,878

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost SCR + Reheat 7,066,876

Total Annual Cost (Annualized Capital Cost + Operating Cost) SCR + Reheat 28,169,433

Emission Control Cost Calculation

Max Emis Annual Cont Eff Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,353.0 1,820.0 80% 364.0 1,456.0 19,347 

Notes & Assumptions

1 Estimated Equipment Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2.

2 For Calculation purposes, duty reflects increased flow rate, not actual duty.

3 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2

4 Capital Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.36 -2.43

5 Reagent Use per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.32 - 2.35

6 SCR Catalyst Volume per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.18 - 2.24

7 SCR Reactor Size per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.25 - 2.31

8 SCR Catalyst Replacement per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.50 - 2.53

9 SCR Electrical Demand per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.48

10 SCR Maintenance Costs EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.46

11 Control Efficiency = 80% reduction

12 Site specific electricity costs

13 Catalyst replacement every 3 years.

14 CUECost Workbook Version 1.0, USEPA Document Page 2

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 SCR Line5 SCR 19 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.c - NOx Control - Selective Catalytic Reduction with Reheat

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (1)

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 23,050,831

Instrumentation 10% of control device cost (A) NA

MN Sales Taxes 6.5% of control device cost (A) 1,498,304

Freight 5% of control device cost (A) NA

Purchased Equipment Total 24,549,135

Indirect Installation

General Facilities 0% of purchased equip cost (A) 0

Engineering & Home Office 0% of purchased equip cost (A) 0

Process Contingency 0% of purchased equip cost (A) 0

Site Specific-Other 11% Replacement Power, two weeks 2,643,899

Total Indirect Installation Costs (B) 11% of purchased equip cost (A) 2,643,899

Project Contingeny (C) 15% of (A + B) 4,078,955

Total Plant Cost (D) A + B + C 31,271,989

Allowance for Funds During Construction (E) 0 for SCR 0

Royalty Allowance (F) 0 for SCR 0

Pre Production Costs (G) 2% of (D+E)) 625,440

Inventory Capital Reagent Vol * $/gal 158,329

Total Capital Investment (TCI) = DC + IC D + E + F + G +H + I 32,055,758

Retrofit Factor (14) 60% of TCI 19,233,455

Sitework and foundations 1,400,000

Structural steel 4,800,000

Total Capital Investment Retrofit Installed 57,489,212

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Total 1.50 % of Total Capital Investment 480,836

Maintenance Materials NA % of Maintenance Labor - 

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,409 kW-hr, 7946 hr/yr, 93% utilization 531,079

SCR Catalyst 64.71 Catalyst Replacement 400,504

Ammonia (29% aqua.) 0.12 $/lb, 4,666 lb/hr, 7946 hr/yr, 93% utilization 4,157,919

Total Annual Direct Operating Costs 5,709,691

Indirect Operating Costs

Overhead 60% of total labor and material costs 91,281

Administration (2% total capital costs) 2% of total capital costs (TCI) 641,115

Property tax (1% total capital costs) 1% of total capital costs (TCI) 320,558

Insurance (1% total capital costs) 1% of total capital costs (TCI) 320,558

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 5,426,575 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 6,800,087

Total Annual Cost (Annualized Capital Cost + Operating Cost) 12,509,778

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 SCR Line5 SCR 20 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.c - NOx Control - Selective Catalytic Reduction with Reheat

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catayst Estimate amount of catalyst required 

Equipment Life 24,000 hours Vol. #1 2708 ft3

Cormetech, Inc.

FCW 0.3111 Flow #1 177,000 scfm Cormetech, Inc.

Rep part cost per unit $141 Flow #2 596,870 scfm

Vol #2 9131.8 ft3

Amount Required 9,132 ft3

Catalyst Cost 1,287,579

Y catalyst life factor 3 Years

Annualized Cost 400,504

Equivalent Duty 3,484 Plant Cap kW A 357,359

Est power platn eff 35% Unc Nox lb/mmBtu B 0.43 D=75*(300,000)*((B/1.5)^0.05*(C/100)^0.04)A)^0.35

Watt per Btu/hr 0.29307 Nox Red. Eff. C 80% E=D*A*0.0066

Equivalent power plant kW 357,359 Capital Cost $/kW D $64.50 $23,050,831.27 Total SCR Equipment

Uncontrolled Nox t/y 1,353.0 Fixed O&M E $152,135.49

Annual Operating Hrs 8000 Variable O&M F $624,082.60

Uncontrolled Nox lb/mmBtu 0.428 Ann Cap Factor G 0.82

Heat Input mmBtu/hr H 6,000

SCR Capital Cost

Electrical Use

Duty 3,484 MMBtu/hr kW

NOx Cont Eff 80% Power 1,409.2

NOx in 0.43 lb/MMBtu

n catalyst layers 4 layers

Press drop catalyst 1 in H2O per layer

Press drop duct 3 in H2O 

Total 1409.2

Reagent Use & Other Operating Costs

Ammonia Use 56.0 lb/ft3 Density

1353 lb/hr Neat 623.3 gal/hr

29% solution Volume 14 day inventory 209,416 gal $158,329 Inventory Cost

4666 lb/hr

Design Basis Max Emis Control Eff (%)

lb/MMBtu 80%

Nitrous Oxides (NOx) 0.428

Actual 106,840 dscf/MMBtu

Method 19 Factor 9,200 dscf/MMBtu

Adjusted Duty 3,484 MMBtu/hr

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maintenance Total 1.5 % of Total Capital Investment 480,836 % of Total Capital Investment

Maint Mtls 0 % of Maintenance Labor NA 0 0% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1409.2 kW-hr 10,413,319 531,079 $/kwh, 1,409 kW-hr, 7946 hr/yr, 93% utilization

SCR Catalyst 141 $/ft3 400,504 Catalyst Replacement

Ammonia (29% aqua.) 0.12 $/lb 4666 lb/hr 34,477,146 4,157,919 $/lb, 4,666 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 SCR Line5 SCR 21 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.c - NOx

 Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Operating Unit: Line 5 waste gas

Emission Unit Number EU 280 Stack/Vent Number SV 127 Chemical Engineering

Design Capacity 300 mmbtu/hr Standardized Flow Rate 556,174 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 115 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 708,321

 Purchased Equipment Total (B) 22% of control device cost (A) 860,610

 Installation - Standard Costs 30% of purchased equip cost (B) 258,183

 Installation - Site Specific Costs NA

 Installation Total 258,183

 Total Direct Capital Cost, DC 1,118,793

 Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 266,789

Total Capital Investment (TCI) = DC + IC 1,385,582

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 15,416,187

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 243,468

Total Annual Cost (Annualized Capital Cost + Operating Cost) 15,659,655

Notes & Assumptions

1 Equipment cost estimate EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2.5.1 

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2 

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 Reheat Line5 Reheat 22 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.c - NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 708,321

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 

Instrumentation 10% of control device cost (A) 70,832

MN Sales Taxes 6.5% of control device cost (A) 46,041

Freight 5% of control device cost (A) 35,416

Purchased Equipment Total (B) 22% 860,610

Installation

Foundations & supports 8% of purchased equip cost (B) 68,849

Handling & erection 14% of purchased equip cost (B) 120,485

Electrical 4% of purchased equip cost (B) 34,424

Piping 2% of purchased equip cost (B) 17,212

Insulation 1% of purchased equip cost (B) 8,606

Painting 1% of purchased equip cost (B) 8,606

Installation Subtotal Standard Expenses 30% 258,183

Site Preparation, as required Site Specific NA

Buildings, as required Site Specific NA

Site Specific - Other Site Specific NA

Total Site Specific Costs NA

Installation Total 258,183

Total Direct Capital Cost, DC 1,118,793

Indirect Capital Costs

Engineering, supervision 10% of purchased equip cost (B) 86,061

Construction & field expenses 5% of purchased equip cost (B) 43,031

Contractor fees 10% of purchased equip cost (B) 86,061

Start-up 2% of purchased equip cost (B) 17,212

Performance test 1% of purchased equip cost (B) 8,606

Model Studies of purchased equip cost (B) 0

Contingencies 3% of purchased equip cost (B) 25,818

Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 266,789

Total Capital Investment (TCI) = DC + IC 1,385,582

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 1,385,582

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 2,408 kW-hr, 7946 hr/yr, 93% utilization 907,618

Natural Gas 9.26 $/mscf, 3,511 scfm, 7946 hr/yr, 93% utilization 14,413,142

Total Annual Direct Operating Costs 15,416,187

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 27,712

Property tax (1% total capital costs) 1% of total capital costs (TCI) 13,856

Insurance (1% total capital costs) 1% of total capital costs (TCI) 13,856

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 130,789 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 243,468

Total Annual Cost (Annualized Capital Cost + Operating Cost) 15,659,655

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 Reheat Line5 Reheat 23 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.c - NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst: Catalyst

Equipment Life 3 years

CRF 0.3811

Rep part cost per unit 0 $/ft3

Amount Required 39 ft3

Catalyst Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Thermal 650,000 19 0.6 2,408.3 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Blower, Catalytic 650,000 23 0.6 2,915.3 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Oxidizer Type thermal (catalytic or thermal) 2408.3

Reagent Use & Other Operating Costs Oxidizers - NA

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 2408.3 kW-hr 17,796,438 907,618 $/kwh, 2,408 kW-hr, 7946 hr/yr, 93% utilization

Natural Gas 9.26 $/mscf 3,511 scfm 1,556,915 14,413,142 $/mscf, 3,511 scfm, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 Reheat Line5 Reheat 24 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.c - NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Flue Gas Re-Heat Equipment Cost Estimate Basis Thermal Oxidizer with 70% Heat Recovery

Auxiliary Fuel Use Equation 3.19 

Twi 115 Deg F - Temperature of waste gas into heat recovery

Tfi 750 Deg F - Temperature of Flue gas into of heat recovery

Tref 77 Deg F - Reference temperature for fuel combustion calculations

FER 70% Factional Heat Recovery % Heat recovery section efficiency

Two 560 Deg F - Temperature of waste gas out of heat recovery

Tfo 306 Deg F - Temperature of flue gas into of heat recovery 

-hcaf 21502 Btu/lb Heat of combustion auxiliary fuel (methane)

-hwg 0 Btu/lb Heat of combustion waste gas

Cp wg 0.2684 Btu/lb - Deg F Heat Capacity of waste gas (air)

p wg 0.0739 lb/scf - Density of waste gas (air) at 77 Deg F

p af 0.0408 lb/scf - Density of auxiliary fuel (methane) at 77 Deg F

Qwg 596,870 scfm - Flow of waste gas 

Qaf 3,511 scfm - Flow of auxiliary fuel

Year 2005 Inflation Rate 3.0%

Cost Calculations 600,381 scfm Flue Gas Cost in 1989 $'s $594,076

Current Cost Using CHE Plant Cost Index $708,321

Heat Rec % A B

0 10,294 0.2355 Exponents per equation 3.24

0.3 13,149 0.2609 Exponents per equation 3.25

0.5 17,056 0.2502 Exponents per equation 3.26

0.7 21,342 0.2500 Exponents per equation 3.27

Indurator Flue Gas Heat Capacity - Basis Typical Composition

100 scfm 359 scf/lbmole

Gas Composition lb/hr f wt % Cp Gas Cp Flue

28 mw CO 0 v % 0

44 mw CO2 15 v % 184 22.0% 0.24 0.0528

18 mw H2O 10 v % 50 6.0% 0.46 0.0276

28 mw N2 60 v % 468 56.0% 0.27 0.1512

32 mw O2 15 v % 134 16.0% 0.23 0.0368

Cp Flue Gas 100 v % 836 100.0% 0.2684

Reference: OAQPS Control Cost Manual 5th Ed Feb 1996 - Chapter 3 Thermal & Catalytic Incinerators

 (EPA 453/B-96-001)

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 Reheat Line5 Reheat 25 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.d - NOx Control - Selective Catalytic Reduction with Reheat

Operating Unit: Line 6 waste gas

Emission Unit Number EU 313 Stack/Vent Number SV 144

Design Capacity 300 mmbtu/hr Standardized Flow Rate 518,805 scfm @ 32o F

Expected Utilization Rate 93% Temperature 109 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 600,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 556,766 scfm @ 68o F

Dry Std Flow Rate 498,306 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs EPRI Correlation

 Purchased Equipment 22,013,215

 Purchased Equipment Total SCR Only 23,444,074

SCR + Reheat 24,289,858

Total Capital Investment (TCI) = DC + IC SCR + Reheat 56,748,729

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. SCR + Reheat 19,634,014

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost SCR + Reheat 6,807,183

Total Annual Cost (Annualized Capital Cost + Operating Cost) SCR + Reheat 26,419,264

Emission Control Cost Calculation

Max Emis Annual Cont Eff Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,202.3 1,776.0 80% 355.2 1,420.8 18,595 

Notes & Assumptions

1 Estimated Equipment Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2.

2 For Calculation purposes, duty reflects increased flow rate, not actual duty.

3 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2

4 Capital Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.36 -2.43

5 Reagent Use per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.32 - 2.35

6 SCR Catalyst Volume per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.18 - 2.24

7 SCR Reactor Size per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.25 - 2.31

8 SCR Catalyst Replacement per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.50 - 2.53

9 SCR Electrical Demand per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.48

10 SCR Maintenance Costs EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.46

11 Control Efficiency = 80% reduction

12 Site specific electricity costs

13 Catalyst replacement every 3 years.

14 CUECost Workbook Version 1.0, USEPA Document Page 2

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 SCR Line6 SCR 26 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.d - NOx Control - Selective Catalytic Reduction with Reheat

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (1)

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 22,013,215

Instrumentation 10% of control device cost (A) NA

MN Sales Taxes 6.5% of control device cost (A) 1,430,859

Freight 5% of control device cost (A) NA

Purchased Equipment Total 23,444,074

Indirect Installation

General Facilities 0% of purchased equip cost (A) 0

Engineering & Home Office 0% of purchased equip cost (A) 0

Process Contingency 0% of purchased equip cost (A) 0

Site Specific-Other 11% Replacement Power, two weeks 2,643,899

Total Indirect Installation Costs (B) 11% of purchased equip cost (A) 2,643,899

Project Contingeny (C) 15% of (A + B) 3,913,196

Total Plant Cost (D) A + B + C 30,001,168

Allowance for Funds During Construction (E) 0 for SCR 0

Royalty Allowance (F) 0 for SCR 0

Pre Production Costs (G) 2% of (D+E)) 600,023

Inventory Capital Reagent Vol * $/gal 140,694

Total Capital Investment (TCI) = DC + IC D + E + F + G +H + I 30,741,886

Retrofit Factor (14) 60% of TCI 18,445,131

Sitework and foundations 1,400,000

Structural steel 4,800,000

Total Capital Investment Retrofit Installed 55,387,017

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Total 1.50 % of Total Capital Investment 461,128

Maintenance Materials NA % of Maintenance Labor - 

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,309 kW-hr, 7946 hr/yr, 93% utilization 493,304

SCR Catalyst 64.71 Catalyst Replacement 373,594

Ammonia (29% aqua.) 0.12 $/lb, 4,146 lb/hr, 7946 hr/yr, 93% utilization 3,694,801

Total Annual Direct Operating Costs 5,162,181

Indirect Operating Costs

Overhead 60% of total labor and material costs 87,172

Administration (2% total capital costs) 2% of total capital costs (TCI) 614,838

Property tax (1% total capital costs) 1% of total capital costs (TCI) 307,419

Insurance (1% total capital costs) 1% of total capital costs (TCI) 307,419

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 5,228,143 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 6,544,990

Total Annual Cost (Annualized Capital Cost + Operating Cost) 11,707,171

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 SCR Line6 SCR 27 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.d - NOx Control - Selective Catalytic Reduction with Reheat

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catayst Estimate amount of catalyst required 

Equipment Life 24,000 hours Vol. #1 2708 ft3

Cormetech, Inc.

FCW 0.3111 Flow #1 177,000 scfm Cormetech, Inc.

Rep part cost per unit $141 Flow #2 556,766 scfm

Vol #2 8518.2 ft3

Amount Required 8,518 ft3

Catalyst Cost 1,201,067

Y catalyst life factor 3 Years

Annualized Cost 373,594

Equivalent Duty 3,250 Plant Cap kW A 333,349

Est power platn eff 35% Unc Nox lb/mmBtu B 0.41 D=75*(300,000)*((B/1.5)^0.05*(C/100)^0.04)A)^0.35

Watt per Btu/hr 0.29307 Nox Red. Eff. C 80% E=D*A*0.0066

Equivalent power plant kW 333,349 Capital Cost $/kW D $66.04 $22,013,215.04 Total SCR Equipment

Uncontrolled Nox t/y 1,202.3 Fixed O&M E $145,287.22

Annual Operating Hrs 8000 Variable O&M F $586,106.42

Uncontrolled Nox lb/mmBtu 0.408 Ann Cap Factor G 0.82

Heat Input mmBtu/hr H 6,000

SCR Capital Cost

Electrical Use

Duty 3,250 MMBtu/hr kW

NOx Cont Eff 80% Power 1,308.9

NOx in 0.41 lb/MMBtu

n catalyst layers 4 layers

Press drop catalyst 1 in H2O per layer

Press drop duct 3 in H2O 

Total 1308.9

Reagent Use & Other Operating Costs

Ammonia Use 56.0 lb/ft3 Density

1202 lb/hr Neat 553.8 gal/hr

29% solution Volume 14 day inventory 186,091 gal $140,694 Inventory Cost

4146 lb/hr

Design Basis Max Emis Control Eff (%)

lb/MMBtu 80%

Nitrous Oxides (NOx) 0.408

Actual 99,661 dscf/MMBtu

Method 19 Factor 9,200 dscf/MMBtu

Adjusted Duty 3,250 MMBtu/hr

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maintenance Total 1.5 % of Total Capital Investment 461,128 % of Total Capital Investment

Maint Mtls 0 % of Maintenance Labor NA 0 0% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1308.9 kW-hr 9,672,634 493,304 $/kwh, 1,309 kW-hr, 7946 hr/yr, 93% utilization

SCR Catalyst 141 $/ft3 373,594 Catalyst Replacement

Ammonia (29% aqua.) 0.12 $/lb 4146 lb/hr 30,637,009 3,694,801 $/lb, 4,146 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 SCR Line6 SCR 28 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.d - NOx

 Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Operating Unit: Line 6 waste gas

Emission Unit Number EU 313 Stack/Vent Number SV 144 Chemical Engineering

Design Capacity 300 mmbtu/hr Standardized Flow Rate 518,805 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 109 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 600,000 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 556,766 scfm @ 68o F

Dry Std Flow Rate 498,306 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 696,118

 Purchased Equipment Total (B) 22% of control device cost (A) 845,784

 Installation - Standard Costs 30% of purchased equip cost (B) 253,735

 Installation - Site Specific Costs NA

 Installation Total 253,735

 Total Direct Capital Cost, DC 1,099,519

 Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 262,193

Total Capital Investment (TCI) = DC + IC 1,361,712

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 14,471,833

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 240,260

Total Annual Cost (Annualized Capital Cost + Operating Cost) 14,712,093

Notes & Assumptions

1 Equipment cost estimate EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2.5.1 

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2 

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 Reheat Line6 Reheat 29 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.d - NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 696,118

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 

Instrumentation 10% of control device cost (A) 69,612

MN Sales Taxes 6.5% of control device cost (A) 45,248

Freight 5% of control device cost (A) 34,806

Purchased Equipment Total (B) 22% 845,784

Installation

Foundations & supports 8% of purchased equip cost (B) 67,663

Handling & erection 14% of purchased equip cost (B) 118,410

Electrical 4% of purchased equip cost (B) 33,831

Piping 2% of purchased equip cost (B) 16,916

Insulation 1% of purchased equip cost (B) 8,458

Painting 1% of purchased equip cost (B) 8,458

Installation Subtotal Standard Expenses 30% 253,735

Site Preparation, as required Site Specific NA

Buildings, as required Site Specific NA

Site Specific - Other Site Specific NA

Total Site Specific Costs NA

Installation Total 253,735

Total Direct Capital Cost, DC 1,099,519

Indirect Capital Costs

Engineering, supervision 10% of purchased equip cost (B) 84,578

Construction & field expenses 5% of purchased equip cost (B) 42,289

Contractor fees 10% of purchased equip cost (B) 84,578

Start-up 2% of purchased equip cost (B) 16,916

Performance test 1% of purchased equip cost (B) 8,458

Model Studies of purchased equip cost (B) 0

Contingencies 3% of purchased equip cost (B) 25,374

Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 262,193

Total Capital Investment (TCI) = DC + IC 1,361,712

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 1,361,712

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 2,223 kW-hr, 7946 hr/yr, 93% utilization 837,802

Natural Gas 9.26 $/mscf, 3,298 scfm, 7946 hr/yr, 93% utilization 13,538,605

Total Annual Direct Operating Costs 14,471,833

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 27,234

Property tax (1% total capital costs) 1% of total capital costs (TCI) 13,617

Insurance (1% total capital costs) 1% of total capital costs (TCI) 13,617

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 128,536 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 240,260

Total Annual Cost (Annualized Capital Cost + Operating Cost) 14,712,093

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 Reheat Line6 Reheat 30 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.d - NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst: Catalyst

Equipment Life 3 years

CRF 0.3811

Rep part cost per unit 0 $/ft3

Amount Required 39 ft3

Catalyst Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Thermal 600,000 19 0.6 2,223.0 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Blower, Catalytic 600,000 23 0.6 2,691.0 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Oxidizer Type thermal (catalytic or thermal) 2223.0

Reagent Use & Other Operating Costs Oxidizers - NA

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 2223.0 kW-hr 16,427,481 837,802 $/kwh, 2,223 kW-hr, 7946 hr/yr, 93% utilization

Natural Gas 9.26 $/mscf 3,298 scfm 1,462,447 13,538,605 $/mscf, 3,298 scfm, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 Reheat Line6 Reheat 31 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.d - NOx Control - Cost of Flue Gas Re-Heating (Thermal Oxidizer)

Flue Gas Re-Heat Equipment Cost Estimate Basis Thermal Oxidizer with 70% Heat Recovery

Auxiliary Fuel Use Equation 3.19 

Twi 109 Deg F - Temperature of waste gas into heat recovery

Tfi 750 Deg F - Temperature of Flue gas into of heat recovery

Tref 77 Deg F - Reference temperature for fuel combustion calculations

FER 70% Factional Heat Recovery % Heat recovery section efficiency

Two 558 Deg F - Temperature of waste gas out of heat recovery

Tfo 301 Deg F - Temperature of flue gas into of heat recovery 

-hcaf 21502 Btu/lb Heat of combustion auxiliary fuel (methane)

-hwg 0 Btu/lb Heat of combustion waste gas

Cp wg 0.2684 Btu/lb - Deg F Heat Capacity of waste gas (air)

p wg 0.0739 lb/scf - Density of waste gas (air) at 77 Deg F

p af 0.0408 lb/scf - Density of auxiliary fuel (methane) at 77 Deg F

Qwg 556,766 scfm - Flow of waste gas 

Qaf 3,298 scfm - Flow of auxiliary fuel

Year 2005 Inflation Rate 3.0%

Cost Calculations 560,065 scfm Flue Gas Cost in 1989 $'s $583,841

Current Cost Using CHE Plant Cost Index $696,118

Heat Rec % A B

0 10,294 0.2355 Exponents per equation 3.24

0.3 13,149 0.2609 Exponents per equation 3.25

0.5 17,056 0.2502 Exponents per equation 3.26

0.7 21,342 0.2500 Exponents per equation 3.27

Indurator Flue Gas Heat Capacity - Basis Typical Composition

100 scfm 359 scf/lbmole

Gas Composition lb/hr f wt % Cp Gas Cp Flue

28 mw CO 0 v % 0

44 mw CO2 15 v % 184 22.0% 0.24 0.0528

18 mw H2O 10 v % 50 6.0% 0.46 0.0276

28 mw N2 60 v % 468 56.0% 0.27 0.1512

32 mw O2 15 v % 134 16.0% 0.23 0.0368

Cp Flue Gas 100 v % 836 100.0% 0.2684

Reference: OAQPS Control Cost Manual 5th Ed Feb 1996 - Chapter 3 Thermal & Catalytic Incinerators

 (EPA 453/B-96-001)

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 Reheat Line6 Reheat 32 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.e - NOx Control - Selective Catalytic Reduction with Reheat

Operating Unit: Line 7 waste gas

Emission Unit Number EU 332 Stack/Vent Number SV 151

Design Capacity 300 mmbtu/hr Standardized Flow Rate 518,805 scfm @ 32o F

Expected Utilization Rate 93% Temperature 109 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 600,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 556,766 scfm @ 68o F

Dry Std Flow Rate 498,306 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs EPRI Correlation

 Purchased Equipment 22,013,215

 Purchased Equipment Total SCR Only 23,444,074

SCR + Reheat 24,289,858

Total Capital Investment (TCI) = DC + IC SCR + Reheat 56,748,729

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. SCR + Reheat 19,634,014

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost SCR + Reheat 6,807,183

Total Annual Cost (Annualized Capital Cost + Operating Cost) SCR + Reheat 26,419,264

Emission Control Cost Calculation

Max Emis Annual Cont Eff Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,202.3 1,928.0 80% 385.6 1,542.4 17,129 

Notes & Assumptions

1 Estimated Equipment Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2.

2 For Calculation purposes, duty reflects increased flow rate, not actual duty.

3 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2

4 Capital Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.36 -2.43

5 Reagent Use per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.32 - 2.35

6 SCR Catalyst Volume per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.18 - 2.24

7 SCR Reactor Size per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.25 - 2.31

8 SCR Catalyst Replacement per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.50 - 2.53

9 SCR Electrical Demand per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.48

10 SCR Maintenance Costs EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 2 Eq 2.46

11 Control Efficiency = 80% reduction

12 Site specific electricity costs

13 Catalyst replacement every 3 years.

14 CUECost Workbook Version 1.0, USEPA Document Page 2

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 SCR Line7 SCR 33 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.e - NOx Control - Selective Catalytic Reduction with Reheat

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (1)

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 22,013,215

Instrumentation 10% of control device cost (A) NA

MN Sales Taxes 6.5% of control device cost (A) 1,430,859

Freight 5% of control device cost (A) NA

Purchased Equipment Total 23,444,074

Indirect Installation

General Facilities 0% of purchased equip cost (A) 0

Engineering & Home Office 0% of purchased equip cost (A) 0

Process Contingency 0% of purchased equip cost (A) 0

Site Specific-Other 11% Replacement Power, two weeks 2,643,899

Total Indirect Installation Costs (B) 11% of purchased equip cost (A) 2,643,899

Project Contingeny (C) 15% of (A + B) 3,913,196

Total Plant Cost (D) A + B + C 30,001,168

Allowance for Funds During Construction (E) 0 for SCR 0

Royalty Allowance (F) 0 for SCR 0

Pre Production Costs (G) 2% of (D+E)) 600,023

Inventory Capital Reagent Vol * $/gal 140,694

Total Capital Investment (TCI) = DC + IC D + E + F + G +H + I 30,741,886

Retrofit Factor (14) 60% of TCI 18,445,131

Sitework and foundations 1,400,000

Structural steel 4,800,000

Total Capital Investment Retrofit Installed 55,387,017

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Total 1.50 % of Total Capital Investment 461,128

Maintenance Materials NA % of Maintenance Labor - 

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,309 kW-hr, 7946 hr/yr, 93% utilization 493,304

SCR Catalyst 64.71 Catalyst Replacement 373,594

Ammonia (29% aqua.) 0.12 $/lb, 4,146 lb/hr, 7946 hr/yr, 93% utilization 3,694,801

Total Annual Direct Operating Costs 5,162,181

Indirect Operating Costs

Overhead 60% of total labor and material costs 87,172

Administration (2% total capital costs) 2% of total capital costs (TCI) 614,838

Property tax (1% total capital costs) 1% of total capital costs (TCI) 307,419

Insurance (1% total capital costs) 1% of total capital costs (TCI) 307,419

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 5,228,143 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 6,544,990

Total Annual Cost (Annualized Capital Cost + Operating Cost) 11,707,171

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 SCR Line7 SCR 34 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.e - NOx Control - Selective Catalytic Reduction with Reheat

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catayst Estimate amount of catalyst required 

Equipment Life 24,000 hours Vol. #1 2708 ft3

Cormetech, Inc.

FCW 0.3111 Flow #1 177,000 scfm Cormetech, Inc.

Rep part cost per unit $141 Flow #2 556,766 scfm

Vol #2 8518.2 ft3

Amount Required 8,518 ft3

Catalyst Cost 1,201,067

Y catalyst life factor 3 Years

Annualized Cost 373,594

Equivalent Duty 3,250 Plant Cap kW A 333,349

Est power platn eff 35% Unc Nox lb/mmBtu B 0.41 D=75*(300,000)*((B/1.5)^0.05*(C/100)^0.04)A)^0.35

Watt per Btu/hr 0.29307 Nox Red. Eff. C 80% E=D*A*0.0066

Equivalent power plant kW 333,349 Capital Cost $/kW D $66.04 $22,013,215.04 Total SCR Equipment

Uncontrolled Nox t/y 1,202.3 Fixed O&M E $145,287.22

Annual Operating Hrs 8000 Variable O&M F $586,106.42

Uncontrolled Nox lb/mmBtu 0.408 Ann Cap Factor G 0.82

Heat Input mmBtu/hr H 6,000

SCR Capital Cost

Electrical Use

Duty 3,250 MMBtu/hr kW

NOx Cont Eff 80% Power 1,308.9

NOx in 0.41 lb/MMBtu

n catalyst layers 4 layers

Press drop catalyst 1 in H2O per layer

Press drop duct 3 in H2O 

Total 1308.9

Reagent Use & Other Operating Costs

Ammonia Use 56.0 lb/ft3 Density

1202 lb/hr Neat 553.8 gal/hr

29% solution Volume 14 day inventory 186,091 gal $140,694 Inventory Cost

4146 lb/hr

Design Basis Max Emis Control Eff (%)

lb/MMBtu 80%

Nitrous Oxides (NOx) 0.408

Actual 99,661 dscf/MMBtu

Method 19 Factor 9,200 dscf/MMBtu

Adjusted Duty 3,250 MMBtu/hr

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maintenance Total 1.5 % of Total Capital Investment 461,128 % of Total Capital Investment

Maint Mtls 0 % of Maintenance Labor NA 0 0% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1308.9 kW-hr 9,672,634 493,304 $/kwh, 1,309 kW-hr, 7946 hr/yr, 93% utilization

SCR Catalyst 141 $/ft3 373,594 Catalyst Replacement

Ammonia (29% aqua.) 0.12 $/lb 4146 lb/hr 30,637,009 3,694,801 $/lb, 4,146 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 SCR Line7 SCR 35 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.e - NOx

 Control - Selective Catalytic Reduction with Reheat

Operating Unit: Line 7 waste gas

Emission Unit Number EU 332 Stack/Vent Number SV 151 Chemical Engineering

Design Capacity 300 mmbtu/hr Standardized Flow Rate 518,805 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 109 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 600,000 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 556,766 scfm @ 68o F

Dry Std Flow Rate 498,306 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 696,118

 Purchased Equipment Total (B) 22% of control device cost (A) 845,784

 Installation - Standard Costs 30% of purchased equip cost (B) 253,735

 Installation - Site Specific Costs NA

 Installation Total 253,735

 Total Direct Capital Cost, DC 1,099,519

 Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 262,193

Total Capital Investment (TCI) = DC + IC 1,361,712

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 14,471,833

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 240,260

Total Annual Cost (Annualized Capital Cost + Operating Cost) 14,712,093

Notes & Assumptions

1 Equipment cost estimate EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2.5.1 

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2 

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 Reheat Line7 Reheat 36 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.e - NOx Control - Selective Catalytic Reduction with Reheat

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 696,118

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 

Instrumentation 10% of control device cost (A) 69,612

MN Sales Taxes 6.5% of control device cost (A) 45,248

Freight 5% of control device cost (A) 34,806

Purchased Equipment Total (B) 22% 845,784

Installation

Foundations & supports 8% of purchased equip cost (B) 67,663

Handling & erection 14% of purchased equip cost (B) 118,410

Electrical 4% of purchased equip cost (B) 33,831

Piping 2% of purchased equip cost (B) 16,916

Insulation 1% of purchased equip cost (B) 8,458

Painting 1% of purchased equip cost (B) 8,458

Installation Subtotal Standard Expenses 30% 253,735

Site Preparation, as required Site Specific NA

Buildings, as required Site Specific NA

Site Specific - Other Site Specific NA

Total Site Specific Costs NA

Installation Total 253,735

Total Direct Capital Cost, DC 1,099,519

Indirect Capital Costs

Engineering, supervision 10% of purchased equip cost (B) 84,578

Construction & field expenses 5% of purchased equip cost (B) 42,289

Contractor fees 10% of purchased equip cost (B) 84,578

Start-up 2% of purchased equip cost (B) 16,916

Performance test 1% of purchased equip cost (B) 8,458

Model Studies of purchased equip cost (B) 0

Contingencies 3% of purchased equip cost (B) 25,374

Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 262,193

Total Capital Investment (TCI) = DC + IC 1,361,712

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 1,361,712

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 61.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 2,223 kW-hr, 7946 hr/yr, 93% utilization 837,802

Natural Gas 9.26 $/mscf, 3,298 scfm, 7946 hr/yr, 93% utilization 13,538,605

Total Annual Direct Operating Costs 14,471,833

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 27,234

Property tax (1% total capital costs) 1% of total capital costs (TCI) 13,617

Insurance (1% total capital costs) 1% of total capital costs (TCI) 13,617

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 128,536 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 240,260

Total Annual Cost (Annualized Capital Cost + Operating Cost) 14,712,093

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 Reheat Line7 Reheat 37 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.e - NOx Control - Selective Catalytic Reduction with Reheat

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst: Catalyst

Equipment Life 3 years

CRF 0.3811

Rep part cost per unit 0 $/ft3

Amount Required 39 ft3

Catalyst Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Thermal 600,000 19 0.6 2,223.0 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Blower, Catalytic 600,000 23 0.6 2,691.0 EPA Cost Cont Manual 6th ed - Oxidizders Chapter 2.5.2.1

Oxidizer Type thermal (catalytic or thermal) 2223.0

Reagent Use & Other Operating Costs Oxidizers - NA

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 2223.0 kW-hr 16,427,481 837,802 $/kwh, 2,223 kW-hr, 7946 hr/yr, 93% utilization

Natural Gas 9.26 $/mscf 3,298 scfm 1,462,447 13,538,605 $/mscf, 3,298 scfm, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 Reheat Line7 Reheat 38 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.3.e - NOx Control - Selective Catalytic Reduction with Reheat

Flue Gas Re-Heat Equipment Cost Estimate Basis Thermal Oxidizer with 70% Heat Recovery

Auxiliary Fuel Use Equation 3.19 

Twi 109 Deg F - Temperature of waste gas into heat recovery

Tfi 750 Deg F - Temperature of Flue gas into of heat recovery

Tref 77 Deg F - Reference temperature for fuel combustion calculations

FER 70% Factional Heat Recovery % Heat recovery section efficiency

Two 558 Deg F - Temperature of waste gas out of heat recovery

Tfo 301 Deg F - Temperature of flue gas into of heat recovery 

-hcaf 21502 Btu/lb Heat of combustion auxiliary fuel (methane)

-hwg 0 Btu/lb Heat of combustion waste gas

Cp wg 0.2684 Btu/lb - Deg F Heat Capacity of waste gas (air)

p wg 0.0739 lb/scf - Density of waste gas (air) at 77 Deg F

p af 0.0408 lb/scf - Density of auxiliary fuel (methane) at 77 Deg F

Qwg 556,766 scfm - Flow of waste gas 

Qaf 3,298 scfm - Flow of auxiliary fuel

Year 2005 Inflation Rate 3.0%

Cost Calculations 560,065 scfm Flue Gas Cost in 1989 $'s $583,841

Current Cost Using CHE Plant Cost Index $696,118

Heat Rec % A B

0 10,294 0.2355 Exponents per equation 3.24

0.3 13,149 0.2609 Exponents per equation 3.25

0.5 17,056 0.2502 Exponents per equation 3.26

0.7 21,342 0.2500 Exponents per equation 3.27

Indurator Flue Gas Heat Capacity - Basis Typical Composition

100 scfm 359 scf/lbmole

Gas Composition lb/hr f wt % Cp Gas Cp Flue

28 mw CO 0 v % 0

44 mw CO2 15 v % 184 22.0% 0.24 0.0528

18 mw H2O 10 v % 50 6.0% 0.46 0.0276

28 mw N2 60 v % 468 56.0% 0.27 0.1512

32 mw O2 15 v % 134 16.0% 0.23 0.0368

Cp Flue Gas 100 v % 836 100.0% 0.2684

Reference: OAQPS Control Cost Manual 5th Ed Feb 1996 - Chapter 3 Thermal & Catalytic Incinerators

 (EPA 453/B-96-001)

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 Reheat Line7 Reheat 39 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.4.a: NOX Control - Low-NOX Burners

Operating Unit: Line 4 waste gas

Emission Unit Number EU 259 Stack/Vent Number SV 118

Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

Size 165 mmbtu/hr

CONTROL EQUIPMENT COSTS

Capital Costs(1)

Total Capital Investment (TCI) = DC + IC 1,474,892

Operating Costs(2)

Total Annual Cost (Annualized Capital Cost) 139,219

Capital Recovery Factor

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Capital Recovery Cost 139,219

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Control Eff(3) Exit Conc. Controlled Emis Reduction Control Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,812.0 1,353.0 10% 1630.8 181.2 768 

Sulfur Dioxide (SO2) 447.5 146.3 0% NA NA NA

Notes & Assumptions

1 Total installed capital cost based on recent Low-NOX burner installation on Line 6 pre-heat section

Cost is ratioed to Line 4 burner size using 6/10 rule based on Line 6 burner size of 117 mmbtu/hr and Line 6 cost of $1.2 million

2 Total annualized cost is equal to the annualized capital cost.

3 Control efficiency based on estimated reduction of line 6 total NOX emissions based on NOX CEMS
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.4.b: NOX Control - Low-NOX Burners

Operating Unit: Line 5 waste gas

Emission Unit Number EU 280 Stack/Vent Number SV 127

Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

Size 165 mmbtu/hr

CONTROL EQUIPMENT COSTS

Capital Costs(1)

Total Capital Investment (TCI) = DC + IC 1,474,892

Operating Costs(2)

Total Annual Cost (Annualized Capital Cost) 139,219

Capital Recovery Factor

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Capital Recovery Cost 139,219

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Control Eff(3) Exit Conc. Controlled Emis Reduction Control Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,820.0 1,353.0 10% 1638.0 182.0 765 

Sulfur Dioxide (SO2) 447.5 146.3 0% NA NA NA

Notes & Assumptions

1 Total installed capital cost based on recent Low-NOX burner installation on Line 6 pre-heat section

Cost is ratioed to Line 5 burner size using 6/10 rule based on Line 6 burner size of 117 mmbtu/hr and Line 6 cost of $1.2 million

2 Total annualized cost is equal to the annualized capital cost.

3 Control efficiency based on estimated reduction of line 6 total NOX emissions based on NOX CEMS
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.4.c: NOX Control - Low-NOX Burners

Operating Unit: Line 7 waste gas

Emission Unit Number EU 332 Stack/Vent Number SV 151

Standardized Flow Rate 518,805 scfm @ 32o F

Expected Utilization Rate 93% Temperature 109 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 600,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 556,766 scfm @ 68o F

Dry Std Flow Rate 498,306 dscfm @ 68o F

Size 165 mmbtu/hr

CONTROL EQUIPMENT COSTS

Capital Costs(1)

Total Capital Investment (TCI) = DC + IC 1,200,000

Operating Costs(2)

Total Annual Cost (Annualized Capital Cost) 113,272

Capital Recovery Factor

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Capital Recovery Cost 113,272

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Control Eff(3) Exit Conc. Controlled Emis Reduction Control Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,928.0 1,202.3 10% 1735.2 192.8 588 

Sulfur Dioxide (SO2) 544.8 184.8 0% NA NA NA

Notes & Assumptions

1 Total installed capital cost based on recent Low-NOX burner installation on Line 6 pre-heat section

2 Total annualized cost is equal to the annualized capital cost.

3 Control efficiency based on estimated reduction of line 6 total NOX emissions based on NOX CEMS
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.5.a: NOX Control - Ported Kilns

Operating Unit: Line 3 waste gas

Emission Unit Number EU 223 Stack/Vent Number SV 103

Standardized Flow Rate 268,515 scfm @ 32o F

Expected Utilization Rate 93% Temperature 130 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 322,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 288,163 scfm @ 68o F

Dry Std Flow Rate 257,906 dscfm @ 68o F

Size 165 mmbtu/hr

CONTROL EQUIPMENT COSTS

Capital Costs(1)

Minntac Line 4/5 Budget Estimate = 5,000,000 $ 

Total Capital Investment (TCI) = DC + IC 3,616,464

Minntac Line 4/5 volumetric flow = 650,000 acfm

Operating Costs(2) Minntac Line 3 volumetric flow = 378,824 acfm

Total Annual Cost (Annualized Capital Cost) 341,369

Use "6/10 Rule" to calculate Line 3 Cost = 3,616,464 $ 

Capital Recovery Factor

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Capital Recovery Cost 341,369

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Control Eff(3) Controlled Emis Reduction Control Cost

Pollutant Lb/Hr T/Yr % T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,345.0 876.9 5% 1277.8 67.3 5,076 

Notes & Assumptions

1 Capital costs based on Minntac Line 4/5 budget estimate and scaled to Line 3 stack flow rate.

2 Total annualized cost is equal to the annualized capital cost.

3 Control efficiency based on report, "NOX Emissions Analysis Pre and Post Installation of Air Injection Ports on Line 7 at USS/Minntac."
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.5.b: NOX Control - Ported Kilns

Operating Unit: Line 4 waste gas

Emission Unit Number EU 259 Stack/Vent Number SV 118

Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

Size 165 mmbtu/hr

CONTROL EQUIPMENT COSTS

Capital Costs(1)

Total Capital Investment (TCI) = DC + IC 5,000,000 Minntac Line 4/5 Budget Estimate = 5,000,000 $ 

Operating Costs(2)

Total Annual Cost (Annualized Capital Cost) 471,965

Capital Recovery Factor

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Capital Recovery Cost 471,965

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Control Eff(3) Controlled Emis Reduction Control Cost

Pollutant Lb/Hr T/Yr % T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,812.0 1,353.0 5% 1721.4 90.6 5,209 

Notes & Assumptions

1 Capital costs based on Minntac Line 4/5 budget estimate.

2 Total annualized cost is equal to the annualized capital cost.

3 Control efficiency based on report, "NOX Emissions Analysis Pre and Post Installation of Air Injection Ports on Line 7 at USS/Minntac."
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.5.c: NOX Control - Ported Kilns

Operating Unit: Line 5 waste gas

Emission Unit Number EU 280 Stack/Vent Number SV 127

Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

Size 165 mmbtu/hr

CONTROL EQUIPMENT COSTS

Capital Costs(1)

Total Capital Investment (TCI) = DC + IC 5,000,000 Minntac Line 4/5 Budget Estimate = 5,000,000 $ 

Operating Costs(2)

Total Annual Cost (Annualized Capital Cost) 471,965

Capital Recovery Factor

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Capital Recovery Cost 471,965

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Control Eff(3) Controlled Emis Reduction Control Cost

Pollutant Lb/Hr T/Yr % T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,820.0 1,353.0 5% 1729.0 91.0 5,186 

Notes & Assumptions

1 Capital costs based on Minntac Line 4/5 budget estimate.

2 Total annualized cost is equal to the annualized capital cost.

3 Control efficiency based on report, "NOX Emissions Analysis Pre and Post Installation of Air Injection Ports on Line 7 at USS/Minntac."
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.a: SO2 Control - Wet Walled Electrostatic Precipitator

Operating Unit: Line 3 waste gas

Emission Unit Number EU 223 Stack/Vent Number SV 103

Standardized Flow Rate 268,515 scfm @ 32o F

Expected Utilization Rate 93% Temperature 130 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 322,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 288,163 scfm @ 68o F

Dry Std Flow Rate 257,906 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 4,994,311

 Purchased Equipment Total (B) 22% of control device cost (A) 6,068,088

 Installation - Standard Costs 67% of purchased equip cost (B) 4,065,619

 Installation - Site Specific Costs 6,200,000

 Installation Total 4,065,619

 Total Direct Capital Cost, DC 10,133,707

 Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 3,458,810

Total Capital Investment (TCI) = DC + IC 27,948,027

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 2,023,179

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 3,299,144

Total Annual Cost (Annualized Capital Cost + Operating Cost) 5,322,323

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 876.9 1,345.0 0% 1345.0 - NA

Sulfur Dioxide (SO2) 329.3 98.6 80% 65.9 263.5 20,201 

Notes & Assumptions

1 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 3.

2 Original estimate from Durr. Used 0.6 power law factor to adjust price to stack flow rate acfm from bid basis of 291,000 acfm

3 CUECost Workbook Version 1.0, USEPA Document Page 2

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Line3 WWESP 9/7/2006 Page 46 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.a: SO2 Control - Wet Walled Electrostatic Precipitator

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A)1

Purchased Equipment Costs (A)2 - ESP + auxiliary equipment 4,994,311

Instrumentation 10% of control device cost (A) 499,431

MN Sales Taxes 6.5% of control device cost (A) 324,630

Freight 5% of control device cost (A) 249,716

Purchased Equipment Total (B) 22% 6,068,088

Installation

Foundations & supports 4% of purchased equip cost (B) 242,724

Handling & erection 50% of purchased equip cost (B) 3,034,044

Electrical 8% of purchased equip cost (B) 485,447

Piping 1% of purchased equip cost (B) 60,681

Insulation 2% of purchased equip cost (B) 121,362

Painting 2% of purchased equip cost (B) 121,362

Installation Subtotal Standard Expenses 67% 4,065,619

Total Direct Capital Cost, DC 10,133,707

Indirect Capital Costs

Engineering, supervision 20% of purchased equip cost (B) 1,213,618

Construction & field expenses 20% of purchased equip cost (B) 1,213,618

Contractor fees 10% of purchased equip cost (B) 606,809

Start-up 1% of purchased equip cost (B) 60,681

Performance test 1% of purchased equip cost (B) 60,681

Model Studies 2% of purchased equip cost (B) 121,362

Contingencies 3% of purchased equip cost (B) 182,043

Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 3,458,810

Total Capital Investment (TCI) = DC + IC 13,592,517

Retrofit multiplier3

60% of TCI 8,155,510

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific NA

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 27,948,027

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Labor 61.00 $/Hr, 15.0 hr/wk, 7946 hr/yr 6,283

Maintenance Materials 1.00 % of Maintenance Labor 49,943

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 761 kW-hr, 7946 hr/yr, 93% utilization 286,765

Water 0.08 $/mgal, 1,610 gpm, 7946 hr/yr, 93% utilization 57,108

WW Treat Neutralization 1.69 $/mgal, 1,610 gpm, 7946 hr/yr, 93% utilization 1,205,171

Caustic 305.96 $/ton, 246 lb/hr, 7946 hr/yr, 93% utilization 278,556

Total Annual Direct Operating Costs 2,023,179

Indirect Operating Costs

Overhead 60% of total labor and material costs 117,347

Administration (2% total capital costs) 2% of total capital costs (TCI) 271,850

Property tax (1% total capital costs) 1% of total capital costs (TCI) 135,925

Insurance (1% total capital costs) 1% of total capital costs (TCI) 135,925

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 2,638,096 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 3,299,144

Total Annual Cost (Annualized Capital Cost + Operating Cost) 5,322,323

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line3 WWESP 9/7/2006 Page 47 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.a: SO2 Control - Wet Walled Electrostatic Precipitator

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit

Amount Required 0

Total Rep Parts Cost 0

Installation Labor 0

Total Installed Cost 0

Annualized Cost 0

Electrical Use

Flow acfm D P in H2O kW

Fan Power 322,000 10 582.8 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.46

Fluid Head (ft) Pump Eff.

Pump Power 60 60% 30.3 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.47

Plate Area

ESP Power 76,157 147.7 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.48

Total 760.9

Reagent Use & Other Operating Costs

gpm

Water 5.00 gal/min-kacfm 1610.00 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.6

lb/hr

Reagent Use 2.50 lb NaOH/lb SO2 246.40 lb/hr caustic

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 15.0 hr/wk 660 6,283 $/Hr, 15.0 hr/wk, 7946 hr/yr

Maint Mtls 1 % of Purchase Cost NA 49,943 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.1

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 760.9 kW-hr 5,622,840 286,765 $/kwh, 761 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/mgal 1,610.0 gpm 713,853 57,108 $/mgal, 1,610 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/mgal 1,610.0 gpm 713,853 1,205,171 $/mgal, 1,610 gpm, 7946 hr/yr, 93% utilization

Caustic 305.96 $/ton 246.4 lb/hr 910 278,556 $/ton, 246 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line3 WWESP 9/7/2006 Page 48 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.b: SO2 Control - Wet Walled Electrostatic Precipitator

Operating Unit: Line 4 waste gas

Emission Unit Number EU 259 Stack/Vent Number SV 118

Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 7,612,198

 Purchased Equipment Total (B) 22% of control device cost (A) 9,248,821

 Installation - Standard Costs 67% of purchased equip cost (B) 6,196,710

 Installation - Site Specific Costs 6,200,000

 Installation Total 6,196,710

 Total Direct Capital Cost, DC 15,445,530

 Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 5,271,828

Total Capital Investment (TCI) = DC + IC 39,347,773

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 3,768,592

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 4,679,741

Total Annual Cost (Annualized Capital Cost + Operating Cost) 8,448,332

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,353.0 1,812.0 0% 1812.0 - NA

Sulfur Dioxide (SO2) 447.5 146.3 80% 89.5 358.0 23,597 

Notes & Assumptions

1 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 3.

2 Original estimate from Durr. Used 0.6 power law factor to adjust price to stack flow rate acfm from bid basis of 291,000 acfm

3 CUECost Workbook Version 1.0, USEPA Document Page 2

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 WWESP 9/7/2006 Page 49 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.b: SO2 Control - Wet Walled Electrostatic Precipitator

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A)1

Purchased Equipment Costs (A)2 - ESP + auxiliary equipment 7,612,198

Instrumentation 10% of control device cost (A) 761,220

MN Sales Taxes 6.5% of control device cost (A) 494,793

Freight 5% of control device cost (A) 380,610

Purchased Equipment Total (B) 22% 9,248,821

Installation

Foundations & supports 4% of purchased equip cost (B) 369,953

Handling & erection 50% of purchased equip cost (B) 4,624,410

Electrical 8% of purchased equip cost (B) 739,906

Piping 1% of purchased equip cost (B) 92,488

Insulation 2% of purchased equip cost (B) 184,976

Painting 2% of purchased equip cost (B) 184,976

Installation Subtotal Standard Expenses 67% 6,196,710

Total Direct Capital Cost, DC 15,445,530

Indirect Capital Costs

Engineering, supervision 20% of purchased equip cost (B) 1,849,764

Construction & field expenses 20% of purchased equip cost (B) 1,849,764

Contractor fees 10% of purchased equip cost (B) 924,882

Start-up 1% of purchased equip cost (B) 92,488

Performance test 1% of purchased equip cost (B) 92,488

Model Studies 2% of purchased equip cost (B) 184,976

Contingencies 3% of purchased equip cost (B) 277,465

Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 5,271,828

Total Capital Investment (TCI) = DC + IC 20,717,358

Retrofit multiplier3

60% of TCI 12,430,415

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific NA

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 39,347,773

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Labor 61.00 $/Hr, 15.0 hr/wk, 7946 hr/yr 12,683

Maintenance Materials 1.00 % of Maintenance Labor 76,122

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,536 kW-hr, 7946 hr/yr, 93% utilization 578,873

Water 0.08 $/mgal, 3,250 gpm, 7946 hr/yr, 93% utilization 115,281

WW Treat Neutralization 1.69 $/mgal, 3,250 gpm, 7946 hr/yr, 93% utilization 2,432,799

Caustic 305.96 $/ton, 366 lb/hr, 7946 hr/yr, 93% utilization 413,481

Total Annual Direct Operating Costs 3,768,592

Indirect Operating Costs

Overhead 60% of total labor and material costs 136,895

Administration (2% total capital costs) 2% of total capital costs (TCI) 414,347

Property tax (1% total capital costs) 1% of total capital costs (TCI) 207,174

Insurance (1% total capital costs) 1% of total capital costs (TCI) 207,174

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 3,714,151 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 4,679,741

Total Annual Cost (Annualized Capital Cost + Operating Cost) 8,448,332

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 WWESP 9/7/2006 Page 50 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.b: SO2 Control - Wet Walled Electrostatic Precipitator

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit

Amount Required 0

Total Rep Parts Cost 0

Installation Labor 0

Total Installed Cost 0

Annualized Cost 0

Electrical Use

Flow acfm D P in H2O kW

Fan Power 650,000 10 1,176.5 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.46

Fluid Head (ft) Pump Eff.

Pump Power 60 60% 61.2 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.47

Plate Area

ESP Power 153,733 298.2 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.48

Total 1,536.0

Reagent Use & Other Operating Costs

gpm

Water 5.00 gal/min-kacfm 3250.00 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.6

lb/hr

Reagent Use 2.50 lb NaOH/lb SO2 365.75 lb/hr caustic

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 15.0 hr/wk 660 12,683 $/Hr, 15.0 hr/wk, 7946 hr/yr

Maint Mtls 1 % of Purchase Cost NA 76,122 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.1

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1536.0 kW-hr 11,350,454 578,873 $/kwh, 1,536 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/mgal 3,250.0 gpm 1,441,007 115,281 $/mgal, 3,250 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/mgal 3,250.0 gpm 1,441,007 2,432,799 $/mgal, 3,250 gpm, 7946 hr/yr, 93% utilization

Caustic 305.96 $/ton 365.8 lb/hr 1,351 413,481 $/ton, 366 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line4 WWESP 9/7/2006 Page 51 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.c: SO2 Control - Wet Walled Electrostatic Precipitator

Operating Unit: Line 5 waste gas

Emission Unit Number EU 280 Stack/Vent Number SV 127

Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 7,612,198

 Purchased Equipment Total (B) 22% of control device cost (A) 9,248,821

 Installation - Standard Costs 67% of purchased equip cost (B) 6,196,710

 Installation - Site Specific Costs 6,200,000

 Installation Total 6,196,710

 Total Direct Capital Cost, DC 15,445,530

 Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 5,271,828

Total Capital Investment (TCI) = DC + IC 39,347,773

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 3,768,592

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 4,679,741

Total Annual Cost (Annualized Capital Cost + Operating Cost) 8,448,332

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,353.0 1,820.0 0% 1820.0 - NA

Sulfur Dioxide (SO2) 447.5 146.3 80% 89.5 358.0 23,597 

Notes & Assumptions

1 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 3.

2 Original estimate from Durr. Used 0.6 power law factor to adjust price to stack flow rate acfm from bid basis of 291,000 acfm

3 CUECost Workbook Version 1.0, USEPA Document Page 2

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 WWESP 9/7/2006 Page 52 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.c: SO2 Control - Wet Walled Electrostatic Precipitator

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A)1

Purchased Equipment Costs (A)2 - ESP + auxiliary equipment 7,612,198

Instrumentation 10% of control device cost (A) 761,220

MN Sales Taxes 6.5% of control device cost (A) 494,793

Freight 5% of control device cost (A) 380,610

Purchased Equipment Total (B) 22% 9,248,821

Installation

Foundations & supports 4% of purchased equip cost (B) 369,953

Handling & erection 50% of purchased equip cost (B) 4,624,410

Electrical 8% of purchased equip cost (B) 739,906

Piping 1% of purchased equip cost (B) 92,488

Insulation 2% of purchased equip cost (B) 184,976

Painting 2% of purchased equip cost (B) 184,976

Installation Subtotal Standard Expenses 67% 6,196,710

Total Direct Capital Cost, DC 15,445,530

Indirect Capital Costs

Engineering, supervision 20% of purchased equip cost (B) 1,849,764

Construction & field expenses 20% of purchased equip cost (B) 1,849,764

Contractor fees 10% of purchased equip cost (B) 924,882

Start-up 1% of purchased equip cost (B) 92,488

Performance test 1% of purchased equip cost (B) 92,488

Model Studies 2% of purchased equip cost (B) 184,976

Contingencies 3% of purchased equip cost (B) 277,465

Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 5,271,828

Total Capital Investment (TCI) = DC + IC 20,717,358

Retrofit multiplier3

60% of TCI 12,430,415

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific NA

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 39,347,773

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Labor 61.00 $/Hr, 15.0 hr/wk, 7946 hr/yr 12,683

Maintenance Materials 1.00 % of Maintenance Labor 76,122

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,536 kW-hr, 7946 hr/yr, 93% utilization 578,873

Water 0.08 $/mgal, 3,250 gpm, 7946 hr/yr, 93% utilization 115,281

WW Treat Neutralization 1.69 $/mgal, 3,250 gpm, 7946 hr/yr, 93% utilization 2,432,799

Caustic 305.96 $/ton, 366 lb/hr, 7946 hr/yr, 93% utilization 413,481

Total Annual Direct Operating Costs 3,768,592

Indirect Operating Costs

Overhead 60% of total labor and material costs 136,895

Administration (2% total capital costs) 2% of total capital costs (TCI) 414,347

Property tax (1% total capital costs) 1% of total capital costs (TCI) 207,174

Insurance (1% total capital costs) 1% of total capital costs (TCI) 207,174

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 3,714,151 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 4,679,741

Total Annual Cost (Annualized Capital Cost + Operating Cost) 8,448,332

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 WWESP 9/7/2006 Page 53 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.c: SO2 Control - Wet Walled Electrostatic Precipitator

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit

Amount Required 0

Total Rep Parts Cost 0

Installation Labor 0

Total Installed Cost 0

Annualized Cost 0

Electrical Use

Flow acfm D P in H2O kW

Fan Power 650,000 10 1,176.5 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.46

Fluid Head (ft) Pump Eff.

Pump Power 60 60% 61.2 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.47

Plate Area

ESP Power 153,733 298.2 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.48

Total 1,536.0

Reagent Use & Other Operating Costs

gpm

Water 5.00 gal/min-kacfm 3250.00 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.6

lb/hr

Reagent Use 2.50 lb NaOH/lb SO2 365.75 lb/hr caustic

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 15.0 hr/wk 660 12,683 $/Hr, 15.0 hr/wk, 7946 hr/yr

Maint Mtls 1 % of Purchase Cost NA 76,122 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.1

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1536.0 kW-hr 11,350,454 578,873 $/kwh, 1,536 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/mgal 3,250.0 gpm 1,441,007 115,281 $/mgal, 3,250 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/mgal 3,250.0 gpm 1,441,007 2,432,799 $/mgal, 3,250 gpm, 7946 hr/yr, 93% utilization

Caustic 305.96 $/ton 365.8 lb/hr 1,351 413,481 $/ton, 366 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line5 WWESP 9/7/2006 Page 54 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.d: SO2 Control - Wet Walled Electrostatic Precipitator

Operating Unit: Line 6 waste gas

Emission Unit Number EU 313 Stack/Vent Number SV 144

Standardized Flow Rate 518,805 scfm @ 32o F

Expected Utilization Rate 93% Temperature 109 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 600,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 556,766 scfm @ 68o F

Dry Std Flow Rate 498,306 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 6,928,558

 Purchased Equipment Total (B) 22% of control device cost (A) 8,418,198

 Installation - Standard Costs 67% of purchased equip cost (B) 5,640,193

 Installation - Site Specific Costs 6,200,000

 Installation Total 5,640,193

 Total Direct Capital Cost, DC 14,058,391

 Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 4,798,373

Total Capital Investment (TCI) = DC + IC 36,370,821

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 3,620,521

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 4,319,107

Total Annual Cost (Annualized Capital Cost + Operating Cost) 7,939,628

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,202.3 1,776.0 0% 1776.0 - NA

Sulfur Dioxide (SO2) 544.8 184.8 80% 109.0 435.9 18,216 

Notes & Assumptions

1 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 3.

2 Original estimate from Durr. Used 0.6 power law factor to adjust price to stack flow rate acfm from bid basis of 291,000 acfm

3 CUECost Workbook Version 1.0, USEPA Document Page 2

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 WWESP 9/7/2006 Page 55 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.d: SO2 Control - Wet Walled Electrostatic Precipitator

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A)1

Purchased Equipment Costs (A)2 - ESP + auxiliary equipment 6,928,558

Instrumentation 10% of control device cost (A) 692,856

MN Sales Taxes 6.5% of control device cost (A) 450,356

Freight 5% of control device cost (A) 346,428

Purchased Equipment Total (B) 22% 8,418,198

Installation

Foundations & supports 4% of purchased equip cost (B) 336,728

Handling & erection 50% of purchased equip cost (B) 4,209,099

Electrical 8% of purchased equip cost (B) 673,456

Piping 1% of purchased equip cost (B) 84,182

Insulation 2% of purchased equip cost (B) 168,364

Painting 2% of purchased equip cost (B) 168,364

Installation Subtotal Standard Expenses 67% 5,640,193

Total Direct Capital Cost, DC 14,058,391

Indirect Capital Costs

Engineering, supervision 20% of purchased equip cost (B) 1,683,640

Construction & field expenses 20% of purchased equip cost (B) 1,683,640

Contractor fees 10% of purchased equip cost (B) 841,820

Start-up 1% of purchased equip cost (B) 84,182

Performance test 1% of purchased equip cost (B) 84,182

Model Studies 2% of purchased equip cost (B) 168,364

Contingencies 3% of purchased equip cost (B) 252,546

Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 4,798,373

Total Capital Investment (TCI) = DC + IC 18,856,763

Retrofit multiplier3

60% of TCI 11,314,058

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific NA

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 36,370,821

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Labor 61.00 $/Hr, 15.0 hr/wk, 7946 hr/yr 10,842

Maintenance Materials 1.00 % of Maintenance Labor 69,286

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,397 kW-hr, 7946 hr/yr, 93% utilization 526,675

Water 0.08 $/mgal, 3,000 gpm, 7946 hr/yr, 93% utilization 106,413

WW Treat Neutralization 1.69 $/mgal, 3,000 gpm, 7946 hr/yr, 93% utilization 2,245,661

Caustic 305.96 $/ton, 462 lb/hr, 7946 hr/yr, 93% utilization 522,292

Total Annual Direct Operating Costs 3,620,521

Indirect Operating Costs

Overhead 60% of total labor and material costs 131,688

Administration (2% total capital costs) 2% of total capital costs (TCI) 377,135

Property tax (1% total capital costs) 1% of total capital costs (TCI) 188,568

Insurance (1% total capital costs) 1% of total capital costs (TCI) 188,568

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 3,433,148 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 4,319,107

Total Annual Cost (Annualized Capital Cost + Operating Cost) 7,939,628

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 WWESP 9/7/2006 Page 56 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.d: SO2 Control - Wet Walled Electrostatic Precipitator

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit

Amount Required 0

Total Rep Parts Cost 0

Installation Labor 0

Total Installed Cost 0

Annualized Cost 0

Electrical Use

Flow acfm D P in H2O kW

Fan Power 600,000 10 1,086.0 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.46

Fluid Head (ft) Pump Eff.

Pump Power 60 60% 56.5 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.47

Plate Area

ESP Power 131,418 255.0 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.48

Total 1,397.5

Reagent Use & Other Operating Costs

gpm

Water 5.00 gal/min-kacfm 3000.00 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.6

lb/hr

Reagent Use 2.50 lb NaOH/lb SO2 462.00 lb/hr caustic

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 15.0 hr/wk 660 10,842 $/Hr, 15.0 hr/wk, 7946 hr/yr

Maint Mtls 1 % of Purchase Cost NA 69,286 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.1

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1397.5 kW-hr 10,326,966 526,675 $/kwh, 1,397 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/mgal 3,000.0 gpm 1,330,160 106,413 $/mgal, 3,000 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/mgal 3,000.0 gpm 1,330,160 2,245,661 $/mgal, 3,000 gpm, 7946 hr/yr, 93% utilization

Caustic 305.96 $/ton 462.0 lb/hr 1,707 522,292 $/ton, 462 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line6 WWESP 9/7/2006 Page 57 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.e: SO2 Control - Wet Walled Electrostatic Precipitator

Operating Unit: Line 7 waste gas

Emission Unit Number EU 332 Stack/Vent Number SV 151

Standardized Flow Rate 518,805 scfm @ 32o F

Expected Utilization Rate 93% Temperature 109 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 600,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 556,766 scfm @ 68o F

Dry Std Flow Rate 498,306 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 7,255,257

 Purchased Equipment Total (B) 22% of control device cost (A) 8,815,138

 Installation - Standard Costs 67% of purchased equip cost (B) 5,906,142

 Installation - Site Specific Costs 6,200,000

 Installation Total 5,906,142

 Total Direct Capital Cost, DC 14,721,280

 Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 5,024,628

Total Capital Investment (TCI) = DC + IC 37,793,453

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 3,632,323

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 4,491,439

Total Annual Cost (Annualized Capital Cost + Operating Cost) 8,123,761

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,202.3 1,928.0 0% 1928.0 - NA

Sulfur Dioxide (SO2) 544.8 184.8 80% 109.0 435.9 18,638 

Notes & Assumptions

1 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 3.

2 Original estimate from Durr. Used 0.6 power law factor to adjust price to stack flow rate acfm from bid basis of 291,000 acfm

3 CUECost Workbook Version 1.0, USEPA Document Page 2

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 WWESP 9/7/2006 Page 58 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.e: SO2 Control - Wet Walled Electrostatic Precipitator

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A)1

Purchased Equipment Costs (A)2 - ESP + auxiliary equipment 7,255,257

Instrumentation 10% of control device cost (A) 725,526

MN Sales Taxes 6.5% of control device cost (A) 471,592

Freight 5% of control device cost (A) 362,763

Purchased Equipment Total (B) 22% 8,815,138

Installation

Foundations & supports 4% of purchased equip cost (B) 352,606

Handling & erection 50% of purchased equip cost (B) 4,407,569

Electrical 8% of purchased equip cost (B) 705,211

Piping 1% of purchased equip cost (B) 88,151

Insulation 2% of purchased equip cost (B) 176,303

Painting 2% of purchased equip cost (B) 176,303

Installation Subtotal Standard Expenses 67% 5,906,142

Total Direct Capital Cost, DC 14,721,280

Indirect Capital Costs

Engineering, supervision 20% of purchased equip cost (B) 1,763,028

Construction & field expenses 20% of purchased equip cost (B) 1,763,028

Contractor fees 10% of purchased equip cost (B) 881,514

Start-up 1% of purchased equip cost (B) 88,151

Performance test 1% of purchased equip cost (B) 88,151

Model Studies 2% of purchased equip cost (B) 176,303

Contingencies 3% of purchased equip cost (B) 264,454

Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 5,024,628

Total Capital Investment (TCI) = DC + IC 19,745,908

Retrofit multiplier3

60% of TCI 11,847,545

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific NA

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 37,793,453

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 61.00 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr 121,177

Supervisor 15% 15% of Operator Costs 18,176

Maintenance

Maintenance Labor 61.00 $/Hr, 15.0 hr/wk, 7946 hr/yr 11,707

Maintenance Materials 1.00 % of Maintenance Labor 72,553

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,418 kW-hr, 7946 hr/yr, 93% utilization 534,344

Water 0.08 $/mgal, 3,000 gpm, 7946 hr/yr, 93% utilization 106,413

WW Treat Neutralization 1.69 $/mgal, 3,000 gpm, 7946 hr/yr, 93% utilization 2,245,661

Caustic 305.96 $/ton, 462 lb/hr, 7946 hr/yr, 93% utilization 522,292

Total Annual Direct Operating Costs 3,632,323

Indirect Operating Costs

Overhead 60% of total labor and material costs 134,168

Administration (2% total capital costs) 2% of total capital costs (TCI) 394,918

Property tax (1% total capital costs) 1% of total capital costs (TCI) 197,459

Insurance (1% total capital costs) 1% of total capital costs (TCI) 197,459

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 3,567,435 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 4,491,439

Total Annual Cost (Annualized Capital Cost + Operating Cost) 8,123,761

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 WWESP 9/7/2006 Page 59 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.6.e: SO2 Control - Wet Walled Electrostatic Precipitator

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit

Amount Required 0

Total Rep Parts Cost 0

Installation Labor 0

Total Installed Cost 0

Annualized Cost 0

Electrical Use

Flow acfm D P in H2O kW

Fan Power 600,000 10 1,086.0 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.46

Fluid Head (ft) Pump Eff.

Pump Power 60 60% 56.5 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.47

Plate Area

ESP Power 141,907 275.3 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3 Eq 3.48

Total 1,417.8

Reagent Use & Other Operating Costs

gpm

Water 5.00 gal/min-kacfm 3000.00 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.6

lb/hr

Reagent Use 2.50 lb NaOH/lb SO2 462.00 lb/hr caustic

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61 $/Hr 2.0 hr/8 hr shift 1,987 121,177 $/Hr, 2.0 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 18,176 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 15.0 hr/wk 660 11,707 $/Hr, 15.0 hr/wk, 7946 hr/yr

Maint Mtls 1 % of Purchase Cost NA 72,553 EPA Cont Cost Manual 6th ed - Sec 6 Ch 3.4.1.1

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1417.8 kW-hr 10,477,342 534,344 $/kwh, 1,418 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/mgal 3,000.0 gpm 1,330,160 106,413 $/mgal, 3,000 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/mgal 3,000.0 gpm 1,330,160 2,245,661 $/mgal, 3,000 gpm, 7946 hr/yr, 93% utilization

Caustic 305.96 $/ton 462.0 lb/hr 1,707 522,292 $/ton, 462 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See summary page for notes and assumptions

Y:\23\00 MN Taconite BART (2006)\Facility Control Cost Spreadsheets\Minntac\Minntac Control Costs

Line7 WWESP 9/7/2006 Page 60 of 75
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.a: SO2

 Control - Wet Scrubber

Operating Unit: Line 3 waste gas

Emission Unit Number EU 223 Stack/Vent Number SV 103

Standardized Flow Rate 268,515 scfm @ 32o F

Expected Utilization Rate 93% Temperature 130 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 322,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 288,163 scfm @ 68o F

Dry Std Flow Rate 257,906 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 3,453,270

 Purchased Equipment Total (B) 22% of control device cost (A) 4,195,723

 Installation - Standard Costs 85% of purchased equip cost (B) 3,566,365

 Installation - Site Specific Costs 6,200,000

 Installation Total 3,566,365

 Total Direct Capital Cost, DC 7,762,088

 Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 629,358

Total Capital Investment (TCI) = DC + IC 19,626,314

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 570,934

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 2,245,499

Total Annual Cost (Annualized Capital Cost + Operating Cost) 2,816,433

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 876.9 1,345.0 0% 1345.0 - NA

Sulfur Dioxide (SO2) 329.3 98.6 60% 131.7 197.6 14,253 

Notes & Assumptions

1 Original estimate from STS Consultants. Use 0.6 Power law factor to adjust price to stack flow rate from bid basis of 500,000 acfm. 

2 Liquid/Gas ratio = 38 L/G = Gal/1,000 acf

3 Water Makeup Rate/Wastewater Discharge = 2.0% of circulating water rate

4 Evaporation rate calculated from steam table in Basic Principles and Calculations in Chemical Engineering Third Edition.

5 CUECost Workbook Version 1.0, USEPA Document Page 2

Line3 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.a: SO2 Control - Wet Scrubber

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1)

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 3,453,270

Instrumentation 10% of control device cost (A) 345,327

MN Sales Taxes 6.5% of control device cost (A) 224,463

Freight 5% of control device cost (A) 172,663

Purchased Equipment Total (B) 22% 4,195,723

Installation

Foundations & supports 12% of purchased equip cost (B) 503,487

Handling & erection 40% of purchased equip cost (B) 1,678,289

Electrical 1% of purchased equip cost (B) 41,957

Piping 30% of purchased equip cost (B) 1,258,717

Insulation 1% of purchased equip cost (B) 41,957

Painting 1% of purchased equip cost (B) 41,957

Installation Subtotal Standard Expenses 85% 3,566,365

Total Direct Capital Cost, DC 7,762,088

Indirect Capital Costs

Engineering, supervision 5% of purchased equip cost (B) 209,786

Construction & field expenses 0% of purchased equip cost (B) 0

Contractor fees 5% of purchased equip cost (B) 209,786

Start-up 1% of purchased equip cost (B) 41,957

Performance test 1% of purchased equip cost (B) 41,957

Model Studies NA of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) 125,872

Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 629,358

Total Capital Investment (TCI) = DC + IC 8,391,446

Retrofit multiplier560% of TCI 5,034,868

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific 0

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 19,626,314

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 37.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 40.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 662 kW-hr, 7946 hr/yr, 93% utilization 249,567

Water 0.08 $/kgal, 302 gpm, 7946 hr/yr, 93% utilization 10,717

WW Treat Neutralization 1.69 $/kgal, 245 gpm, 7946 hr/yr, 93% utilization 183,186

Lime 91.40 $/ton, 95 lb/hr, 7946 hr/yr, 93% utilization 32,037

Total Annual Direct Operating Costs 570,934

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 167,829

Property tax (1% total capital costs) 1% of total capital costs (TCI) 83,914

Insurance (1% total capital costs) 1% of total capital costs (TCI) 83,914

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 1,852,585 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 2,245,499

Total Annual Cost (Annualized Capital Cost + Operating Cost) 2,816,433

See Summary page for notes and assumptions

Line3 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.a: SO2 Control - Wet Scrubber

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst:

Equipment Life 20 years

CRF 0.0000

Rep part cost per unit 0 $/ft3

Amount Required 0 ft3

Packing Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0.00 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Scrubber 322,000 8.55 0.7 - 460.2 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.48

Flow Liquid SPGR ∆ P ft H2O Efficiency Hp kW

Circ Pump 12,236 gpm 1 60 0.7 - 197.2 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

H2O WW Disch 302 gpm 1 60 0.7 - 4.9 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

Other 

Total 662.2

Reagent Use & Other Operating Costs

Caustic Use 98.56 lb/hr SO2 2.50 lb NaOH/lb SO2 246.40 lb/hr Caustic

Lime Use 98.56 lb/hr SO2 0.96 lb Lime/lb SO2 94.86 lb/hr lime, lime addition at 1.1 times the stoichiometric ratio 

Liquid/Gas ratio 38.0 * L/G = Gal/1,000 acf

Circulating Water Rate2

12,236 gpm

Water Makeup Rate/WW Disch3

 = 2.0% of circulating water rate + evap. loss = 302 gpm

Evaporation Loss4

 = 57.42 gpm

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 662.2 kW-hr 4,893,479 249,567 $/kwh, 662 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/kgal 302.1 gpm 133,963 10,717 $/kgal, 302 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/kgal 244.7 gpm 108,506 183,186 $/kgal, 245 gpm, 7946 hr/yr, 93% utilization

Lime 91.4 $/ton 94.9 lb/hr 351 32,037 $/ton, 95 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Line3 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.b: SO2

 Control - Wet Scrubber

Operating Unit: Line 4 waste gas

Emission Unit Number EU 259 Stack/Vent Number SV 118

Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs (1)

 Purchased Equipment (A) 5,263,384

 Purchased Equipment Total (B) 22% of control device cost (A) 6,395,011

 Installation - Standard Costs 85% of purchased equip cost (B) 5,435,759

 Installation - Site Specific Costs 6,200,000

 Installation Total 5,435,759

 Total Direct Capital Cost, DC 11,830,771

 Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 959,252

Total Capital Investment (TCI) = DC + IC 26,664,036

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 1,038,186

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 3,085,753

Total Annual Cost (Annualized Capital Cost + Operating Cost) 4,123,939

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,353.0 1,812.0 0% 1812.0 - NA

Sulfur Dioxide (SO2) 447.5 146.3 60% 179.0 268.5 15,358 

Notes & Assumptions

1 Original estimate from STS Consultants. Use 0.6 Power law factor to adjust price to stack flow rate from bid basis of 500,000 acfm. 

2 Liquid/Gas ratio = 38 L/G = Gal/1,000 acf

3 Water Makeup Rate/Wastewater Discharge = 2.0% of circulating water rate

4 Evaporation rate calculated from steam table in Basic Principles and Calculations in Chemical Engineering Third Edition.

5 CUECost Workbook Version 1.0, USEPA Document Page 2

Line4 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.b: SO2 Control - Wet Scrubber

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1)

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 5,263,384

Instrumentation 10% of control device cost (A) 526,338

MN Sales Taxes 7% of control device cost (A) 342,120

Freight 5% of control device cost (A) 263,169

Purchased Equipment Total (B) 22% 6,395,011

Installation

Foundations & supports 12% of purchased equip cost (B) 767,401

Handling & erection 40% of purchased equip cost (B) 2,558,004

Electrical 1% of purchased equip cost (B) 63,950

Piping 30% of purchased equip cost (B) 1,918,503

Insulation 1% of purchased equip cost (B) 63,950

Painting 1% of purchased equip cost (B) 63,950

Installation Subtotal Standard Expenses 85% 5,435,759

Total Direct Capital Cost, DC 11,830,771

Indirect Capital Costs

Engineering, supervision 5% of purchased equip cost (B) 319,751

Construction & field expenses 0% of purchased equip cost (B) 0

Contractor fees 5% of purchased equip cost (B) 319,751

Start-up 1% of purchased equip cost (B) 63,950

Performance test 1% of purchased equip cost (B) 63,950

Model Studies NA of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) 191,850

Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 959,252

Total Capital Investment (TCI) = DC + IC 12,790,022

Retrofit multiplier560% of TCI 7,674,013

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific 0

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 26,664,036

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 37.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 40.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,337 kW-hr, 7946 hr/yr, 93% utilization 503,785

Water 0.08 $/kgal, 610 gpm, 7946 hr/yr, 93% utilization 21,634

WW Treat Neutralization 1.69 $/kgal, 494 gpm, 7946 hr/yr, 93% utilization 369,785

Lime 91.40 $/ton, 141 lb/hr, 7946 hr/yr, 93% utilization 47,555

Total Annual Direct Operating Costs 1,038,186

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 255,800

Property tax (1% total capital costs) 1% of total capital costs (TCI) 127,900

Insurance (1% total capital costs) 1% of total capital costs (TCI) 127,900

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 2,516,896 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 3,085,753

Total Annual Cost (Annualized Capital Cost + Operating Cost) 4,123,939

See Summary page for notes and assumptions

Line4 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.b: SO2 Control - Wet Scrubber

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst:

Equipment Life 20 years

CRF 0.0000

Rep part cost per unit 0 $/ft3

Amount Required 0 ft3

Packing Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0.00 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Scrubber 650,000 8.55 0.7 - 928.9 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.48

Flow Liquid SPGR ∆ P ft H2O Efficiency Hp kW

Circ Pump 24,700 gpm 1 60 0.7 - 398.0 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

H2O WW Disch 610 gpm 1 60 0.7 - 9.8 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

Other 

Total 1336.7

Reagent Use & Other Operating Costs

Caustic Use 146.30 lb/hr SO2 2.50 lb NaOH/lb SO2 365.75 lb/hr Caustic

Lime Use 146.30 lb/hr SO2 0.96 lb Lime/lb SO2 140.81 lb/hr lime, lime addition at 1.1 times the stoichiometric ratio 

Liquid/Gas ratio 38.0 * L/G = Gal/1,000 acf

Circulating Water Rate2

24,700 gpm

Water Makeup Rate/WW Disch3

 = 2.0% of circulating water rate + evap. loss = 610 gpm

Evaporation Loss4

 = 115.90 gpm

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1336.7 kW-hr 9,878,141 503,785 $/kwh, 1,337 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/kgal 609.9 gpm 270,423 21,634 $/kgal, 610 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/kgal 494.0 gpm 219,033 369,785 $/kgal, 494 gpm, 7946 hr/yr, 93% utilization

Lime 91.4 $/ton 140.8 lb/hr 520 47,555 $/ton, 141 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Line4 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.c: SO2

 Control - Wet Scrubber

Operating Unit: Line 5 waste gas

Emission Unit Number EU 280 Stack/Vent Number SV 127

Standardized Flow Rate 556,174 scfm @ 32o F

Expected Utilization Rate 93% Temperature 115 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 650,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 596,870 scfm @ 68o F

Dry Std Flow Rate 534,198 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs (1)

 Purchased Equipment (A) 5,263,384

 Purchased Equipment Total (B) 22% of control device cost (A) 6,395,011

 Installation - Standard Costs 85% of purchased equip cost (B) 5,435,759

 Installation - Site Specific Costs 6,200,000

 Installation Total 5,435,759

 Total Direct Capital Cost, DC 11,830,771

 Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 959,252

Total Capital Investment (TCI) = DC + IC 26,664,036

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 1,038,186

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 3,085,753

Total Annual Cost (Annualized Capital Cost + Operating Cost) 4,123,939

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,353.0 1,820.0 0% 1820.0 - NA

Sulfur Dioxide (SO2) 447.5 146.3 60% 179.0 268.5 15,358 

Notes & Assumptions

1 Original estimate from STS Consultants. Use 0.6 Power law factor to adjust price to stack flow rate from bid basis of 500,000 acfm. 

2 Liquid/Gas ratio = 38 L/G = Gal/1,000 acf

3 Water Makeup Rate/Wastewater Discharge = 2.0% of circulating water rate

4 Evaporation rate calculated from steam table in Basic Principles and Calculations in Chemical Engineering Third Edition.

5 CUECost Workbook Version 1.0, USEPA Document Page 2

Line5 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.c: SO2 Control - Wet Scrubber

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1)

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 5,263,384

Instrumentation 10% of control device cost (A) 526,338

MN Sales Taxes 7% of control device cost (A) 342,120

Freight 5% of control device cost (A) 263,169

Purchased Equipment Total (B) 22% 6,395,011

Installation

Foundations & supports 12% of purchased equip cost (B) 767,401

Handling & erection 40% of purchased equip cost (B) 2,558,004

Electrical 1% of purchased equip cost (B) 63,950

Piping 30% of purchased equip cost (B) 1,918,503

Insulation 1% of purchased equip cost (B) 63,950

Painting 1% of purchased equip cost (B) 63,950

Installation Subtotal Standard Expenses 85% 5,435,759

Total Direct Capital Cost, DC 11,830,771

Indirect Capital Costs

Engineering, supervision 5% of purchased equip cost (B) 319,751

Construction & field expenses 0% of purchased equip cost (B) 0

Contractor fees 5% of purchased equip cost (B) 319,751

Start-up 1% of purchased equip cost (B) 63,950

Performance test 1% of purchased equip cost (B) 63,950

Model Studies NA of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) 191,850

Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 959,252

Total Capital Investment (TCI) = DC + IC 12,790,022

Retrofit multiplier560% of TCI 7,674,013

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific 0

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 26,664,036

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 37.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 40.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,337 kW-hr, 7946 hr/yr, 93% utilization 503,785

Water 0.08 $/kgal, 610 gpm, 7946 hr/yr, 93% utilization 21,634

WW Treat Neutralization 1.69 $/kgal, 494 gpm, 7946 hr/yr, 93% utilization 369,785

Lime 91.40 $/ton, 141 lb/hr, 7946 hr/yr, 93% utilization 47,555

Total Annual Direct Operating Costs 1,038,186

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 255,800

Property tax (1% total capital costs) 1% of total capital costs (TCI) 127,900

Insurance (1% total capital costs) 1% of total capital costs (TCI) 127,900

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 2,516,896 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 3,085,753

Total Annual Cost (Annualized Capital Cost + Operating Cost) 4,123,939

See Summary page for notes and assumptions

Line5 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.c: SO2 Control - Wet Scrubber

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst:

Equipment Life 20 years

CRF 0.0000

Rep part cost per unit 0 $/ft3

Amount Required 0 ft3

Packing Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0.00 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Scrubber 650,000 8.55 0.7 - 928.9 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.48

Flow Liquid SPGR ∆ P ft H2O Efficiency Hp kW

Circ Pump 24,700 gpm 1 60 0.7 - 398.0 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

H2O WW Disch 610 gpm 1 60 0.7 - 9.8 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

Other 

Total 1336.7

Reagent Use & Other Operating Costs

Caustic Use 146.30 lb/hr SO2 2.50 lb NaOH/lb SO2 365.75 lb/hr Caustic

Lime Use 146.30 lb/hr SO2 0.96 lb Lime/lb SO2 140.81 lb/hr lime, lime addition at 1.1 times the stoichiometric ratio 

Liquid/Gas ratio 38.0 * L/G = Gal/1,000 acf

Circulating Water Rate2

24,700 gpm

Water Makeup Rate/WW Disch3

 = 2.0% of circulating water rate + evap. loss = 610 gpm

Evaporation Loss4

 = 115.90 gpm

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1336.7 kW-hr 9,878,141 503,785 $/kwh, 1,337 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/kgal 609.9 gpm 270,423 21,634 $/kgal, 610 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/kgal 494.0 gpm 219,033 369,785 $/kgal, 494 gpm, 7946 hr/yr, 93% utilization

Lime 91.4 $/ton 140.8 lb/hr 520 47,555 $/ton, 141 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Line5 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.d: SO2

 Control - Wet Scrubber

Operating Unit: Line 6 waste gas

Emission Unit Number EU 313 Stack/Vent Number SV 144

Standardized Flow Rate 518,805 scfm @ 32o F

Expected Utilization Rate 93% Temperature 109 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 600,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 556,766 scfm @ 68o F

Dry Std Flow Rate 498,306 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs (1)

 Purchased Equipment (A) 5,016,580

 Purchased Equipment Total (B) 22% of control device cost (A) 6,095,145

 Installation - Standard Costs 85% of purchased equip cost (B) 5,180,873

 Installation - Site Specific Costs 6,200,000

 Installation Total 5,180,873

 Total Direct Capital Cost, DC 11,276,018

 Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 914,272

Total Capital Investment (TCI) = DC + IC 25,704,464

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 981,838

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 2,971,187

Total Annual Cost (Annualized Capital Cost + Operating Cost) 3,953,025

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,202.3 1,776.0 0% 1776.0 - NA

Sulfur Dioxide (SO2) 544.8 184.8 60% 217.9 326.9 12,093 

Notes & Assumptions

1 Original estimate from STS Consultants. Use 0.6 Power law factor to adjust price to stack flow rate from bid basis of 500,000 acfm. 

2 Liquid/Gas ratio = 38 L/G = Gal/1,000 acf

3 Water Makeup Rate/Wastewater Discharge = 2.0% of circulating water rate

4 Evaporation rate calculated from steam table in Basic Principles and Calculations in Chemical Engineering Third Edition.

5 CUECost Workbook Version 1.0, USEPA Document Page 2

Line6 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.d: SO2 Control - Wet Scrubber

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1)

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 5,016,580

Instrumentation 10% of control device cost (A) 501,658

MN Sales Taxes 7% of control device cost (A) 326,078

Freight 5% of control device cost (A) 250,829

Purchased Equipment Total (B) 22% 6,095,145

Installation

Foundations & supports 12% of purchased equip cost (B) 731,417

Handling & erection 40% of purchased equip cost (B) 2,438,058

Electrical 1% of purchased equip cost (B) 60,951

Piping 30% of purchased equip cost (B) 1,828,543

Insulation 1% of purchased equip cost (B) 60,951

Painting 1% of purchased equip cost (B) 60,951

Installation Subtotal Standard Expenses 85% 5,180,873

Total Direct Capital Cost, DC 11,276,018

Indirect Capital Costs

Engineering, supervision 5% of purchased equip cost (B) 304,757

Construction & field expenses 0% of purchased equip cost (B) 0

Contractor fees 5% of purchased equip cost (B) 304,757

Start-up 1% of purchased equip cost (B) 60,951

Performance test 1% of purchased equip cost (B) 60,951

Model Studies NA of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) 182,854

Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 914,272

Total Capital Investment (TCI) = DC + IC 12,190,290

Retrofit multiplier560% of TCI 7,314,174

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific 0

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 25,704,464

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 37.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 40.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,234 kW-hr, 7946 hr/yr, 93% utilization 465,032

Water 0.08 $/kgal, 563 gpm, 7946 hr/yr, 93% utilization 19,970

WW Treat Neutralization 1.69 $/kgal, 456 gpm, 7946 hr/yr, 93% utilization 341,340

Lime 91.40 $/ton, 178 lb/hr, 7946 hr/yr, 93% utilization 60,069

Total Annual Direct Operating Costs 981,838

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 243,806

Property tax (1% total capital costs) 1% of total capital costs (TCI) 121,903

Insurance (1% total capital costs) 1% of total capital costs (TCI) 121,903

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 2,426,320 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 2,971,187

Total Annual Cost (Annualized Capital Cost + Operating Cost) 3,953,025

See Summary page for notes and assumptions

Line6 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.d: SO2 Control - Wet Scrubber

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst:

Equipment Life 20 years

CRF 0.0000

Rep part cost per unit 0 $/ft3

Amount Required 0 ft3

Packing Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0.00 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Scrubber 600,000 8.55 0.7 - 857.4 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.48

Flow Liquid SPGR ∆ P ft H2O Efficiency Hp kW

Circ Pump 22,800 gpm 1 60 0.7 - 367.4 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

H2O WW Disch 563 gpm 1 60 0.7 - 9.1 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

Other 

Total 1233.9

Reagent Use & Other Operating Costs

Caustic Use 184.80 lb/hr SO2 2.50 lb NaOH/lb SO2 462.00 lb/hr Caustic

Lime Use 184.80 lb/hr SO2 0.96 lb Lime/lb SO2 177.87 lb/hr lime, lime addition at 1.1 times the stoichiometric ratio 

Liquid/Gas ratio 38.0 * L/G = Gal/1,000 acf

Circulating Water Rate2

22,800 gpm

Water Makeup Rate/WW Disch3

 = 2.0% of circulating water rate + evap. loss = 563 gpm

Evaporation Loss4

 = 106.99 gpm

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1233.9 kW-hr 9,118,284 465,032 $/kwh, 1,234 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/kgal 563.0 gpm 249,621 19,970 $/kgal, 563 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/kgal 456.0 gpm 202,184 341,340 $/kgal, 456 gpm, 7946 hr/yr, 93% utilization

Lime 91.4 $/ton 177.9 lb/hr 657 60,069 $/ton, 178 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Line6 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.e: SO2

 Control - Wet Scrubber

Operating Unit: Line 7 waste gas

Emission Unit Number EU 332 Stack/Vent Number SV 151

Standardized Flow Rate 518,805 scfm @ 32o F

Expected Utilization Rate 93% Temperature 109 Deg F

Expected Annual Hours of Operation 7,946 Hours Moisture Content 10.5%

Annual Interest Rate 7.0% Actual Flow Rate 600,000 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 556,766 scfm @ 68o F

Dry Std Flow Rate 498,306 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs (1)

 Purchased Equipment (A) 5,016,580

 Purchased Equipment Total (B) 22% of control device cost (A) 6,095,145

 Installation - Standard Costs 85% of purchased equip cost (B) 5,180,873

 Installation - Site Specific Costs 6,200,000

 Installation Total 5,180,873

 Total Direct Capital Cost, DC 11,276,018

 Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 914,272

Total Capital Investment (TCI) = DC + IC 25,704,464

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 981,838

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 2,971,187

Total Annual Cost (Annualized Capital Cost + Operating Cost) 3,953,025

Actual

Emission Control Cost Calculation Emis

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 1,202.3 1,928.0 0% 1928.0 - NA

Sulfur Dioxide (SO2) 544.8 184.8 60% 217.9 326.9 12,093 

Notes & Assumptions

1 Original estimate from STS Consultants. Use 0.6 Power law factor to adjust price to stack flow rate from bid basis of 500,000 acfm. 

2 Liquid/Gas ratio = 38 L/G = Gal/1,000 acf

3 Water Makeup Rate/Wastewater Discharge = 2.0% of circulating water rate

4 Evaporation rate calculated from steam table in Basic Principles and Calculations in Chemical Engineering Third Edition.

5 CUECost Workbook Version 1.0, USEPA Document Page 2

Line7 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.e: SO2 Control - Wet Scrubber

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1)

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 5,016,580

Instrumentation 10% of control device cost (A) 501,658

MN Sales Taxes 7% of control device cost (A) 326,078

Freight 5% of control device cost (A) 250,829

Purchased Equipment Total (B) 22% 6,095,145

Installation

Foundations & supports 12% of purchased equip cost (B) 731,417

Handling & erection 40% of purchased equip cost (B) 2,438,058

Electrical 1% of purchased equip cost (B) 60,951

Piping 30% of purchased equip cost (B) 1,828,543

Insulation 1% of purchased equip cost (B) 60,951

Painting 1% of purchased equip cost (B) 60,951

Installation Subtotal Standard Expenses 85% 5,180,873

Total Direct Capital Cost, DC 11,276,018

Indirect Capital Costs

Engineering, supervision 5% of purchased equip cost (B) 304,757

Construction & field expenses 0% of purchased equip cost (B) 0

Contractor fees 5% of purchased equip cost (B) 304,757

Start-up 1% of purchased equip cost (B) 60,951

Performance test 1% of purchased equip cost (B) 60,951

Model Studies NA of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) 182,854

Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 914,272

Total Capital Investment (TCI) = DC + IC 12,190,290

Retrofit multiplier560% of TCI 7,314,174

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific 0

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 25,704,464

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 37.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Supervisor 15% 15% of Operator Costs 4,544

Maintenance

Maintenance Labor 40.00 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr 30,294

Maintenance Materials 100% of maintenance labor costs 30,294

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 1,234 kW-hr, 7946 hr/yr, 93% utilization 465,032

Water 0.08 $/kgal, 563 gpm, 7946 hr/yr, 93% utilization 19,970

WW Treat Neutralization 1.69 $/kgal, 456 gpm, 7946 hr/yr, 93% utilization 341,340

Lime 91.40 $/ton, 178 lb/hr, 7946 hr/yr, 93% utilization 60,069

Total Annual Direct Operating Costs 981,838

Indirect Operating Costs

Overhead 60% of total labor and material costs 57,256

Administration (2% total capital costs) 2% of total capital costs (TCI) 243,806

Property tax (1% total capital costs) 1% of total capital costs (TCI) 121,903

Insurance (1% total capital costs) 1% of total capital costs (TCI) 121,903

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 2,426,320 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 2,971,187

Total Annual Cost (Annualized Capital Cost + Operating Cost) 3,953,025

See Summary page for notes and assumptions

Line7 Wet Scrubber
US Steel - Minntac

BART Report - Attachment A: Emission Control Cost Analysis

Table A.7.e: SO2 Control - Wet Scrubber

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst:

Equipment Life 20 years

CRF 0.0000

Rep part cost per unit 0 $/ft3

Amount Required 0 ft3

Packing Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0.00 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Scrubber 600,000 8.55 0.7 - 857.4 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.48

Flow Liquid SPGR ∆ P ft H2O Efficiency Hp kW

Circ Pump 22,800 gpm 1 60 0.7 - 367.4 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

H2O WW Disch 563 gpm 1 60 0.7 - 9.1 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

Other 

Total 1233.9

Reagent Use & Other Operating Costs

Caustic Use 184.80 lb/hr SO2 2.50 lb NaOH/lb SO2 462.00 lb/hr Caustic

Lime Use 184.80 lb/hr SO2 0.96 lb Lime/lb SO2 177.87 lb/hr lime, lime addition at 1.1 times the stoichiometric ratio 

Liquid/Gas ratio 38.0 * L/G = Gal/1,000 acf

Circulating Water Rate2

22,800 gpm

Water Makeup Rate/WW Disch3

 = 2.0% of circulating water rate + evap. loss = 563 gpm

Evaporation Loss4

 = 106.99 gpm

Operating Cost Calculations Annual hours of operation: 7,946

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Supervisor 15% of Op. NA 4,544 15% of Operator Costs

Maintenance

Maint Labor 61.00 $/Hr 0.5 hr/8 hr shift 497 30,294 $/Hr, 0.5 hr/8 hr shift, 7946 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 30,294 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.051 $/kwh 1233.9 kW-hr 9,118,284 465,032 $/kwh, 1,234 kW-hr, 7946 hr/yr, 93% utilization

Water 0.08 $/kgal 563.0 gpm 249,621 19,970 $/kgal, 563 gpm, 7946 hr/yr, 93% utilization

WW Treat Neutralization 1.69 $/kgal 456.0 gpm 202,184 341,340 $/kgal, 456 gpm, 7946 hr/yr, 93% utilization

Lime 91.4 $/ton 177.9 lb/hr 657 60,069 $/ton, 178 lb/hr, 7946 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Line7 Wet Scrubber