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Given/Assumed

Flow rate (acfm) 1,148,000 Barr 9/11/2009

Flue Gas Temperature (degrees F) 300 Barr 9/11/2009

Uncontrolled SO2 emissions (TPY) 1153.2 Barr 9/11/09

SO2 molar weight 64

GSA and Baghouse (@ 910,000 acfm) $ 11,500,000 calculated from EPA cost info for 910,000 acfm @ 280 F at USS 6/18/12 USS email to EPA

Freight $ 1,074,758 EPA

Sales taxes 6.0% Barr 9/11/09

Retrofit factor 1.0 assumed

SO2 Control efficiency 95% PETC report

Operating Hours per Year 7,680 Barr 9/11/09

Operating Hours per Shift 8 assumed

Operating Shifts per Year 960 calculated

Utilization 100% Barr 9/11/09

Operating Labor Cost ($/hr) $85.00 Barr 9/11/09

Maintenance Labor Cost ($/hr) $85.00 Barr 9/11/09

Lime molar weight 56

Chemical usage molar ratio 1.4 PETC report

Chemical cost ($/ton) $ 125.00 EPA

Solvent usage (gal/kacfm)) 2.7 calculated from ESSAR Steel PSD application updated 5/09/11

Solvent cost ($/kgal) $0.40 Barr 9/11/09

CaSO4 molar weight 172 dihydrate

Waste disposal ($/ton) $ 33.00 from ESSAR Steel PSD application updated 5/09/11

Gas Cleanaing System Electricity Cost $ 252,308 calculated from EPA cost info of $ 200,000 /yr for 910,000 acfm at USS

ID Fan Power $ 177,404 calculated from EPA cost info of $ 1,125,000 /yr for 910,000 acfm at USS USS 7/19/12

Equipment Life (yr) 20 Barr 9/11/09

Interest Rate (%) 7.00% Barr 9/11/09
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Capital Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 5

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

Absorber + auxiliary equipment, EC A $13,220,203 six-tenths power law

Instrumentation 0.10 A $1,322,020

Sales taxes 0.060 A $793,212

Freight A $1,074,758

Purchased equipment cost, PEC B= 1.18 A $16,410,194

Direct installation costs

Foundations & supports 0.12 B $1,969,223

Handling & erection 0.40 B $6,564,078

Electrical 0.01 B $164,102

Piping 0.30 B $4,923,058

Insulation 0.01 B $164,102

Painting 0.01 B $164,102

Direct installation costs x 1 x 0.85 B $13,948,665

Site preparation As required, SP

Buildings As required, Bldg.

Total Direct Costs, DC 1.85 B+SP+Bldg $30,358,859

Indirect Costs (installation)

Engineering 0.10 B $1,641,019

Construction and field expenses 0.10 B $1,641,019

Contractor fees 0.10 B $1,641,019

Start-up 0.01 B $164,102

Performance test 0.01 B $164,102

Contingencies 0.03 B $492,306

Total Indirect Costs, IC 0.35 B $5,743,568

Total Capital Investment = DC + IC 2.20 B+SP+Bldg $36,102,427
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Annual Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 5

Cost Item Cost

Direct Annual Costs, DC

Operating labor

Operator 0.5 hr/shift $ 40,800

Supervisor 15% of operator $ 6,120

Operating materials

Solvent 2.7 gal/kacfm * 1,148,000 acfm = 3,100 gpm = $ 571,318

Chemicals 1.4 lb-mole CaO/lb-mole SO2 * 36,038 lb-moles SO2/yr = 49,451 lb-mole CaO/yr

 49,451 lb-mole CaO/yr * 56 lb/lb-mole = 2,769,282 lb CaO/yr

 2,769,282 lb CaO/yr/ 2,000 lb/ton * $ 125.00 / ton = $ 173,080

Waste Disposal 1,096 ton SO2 removed/yr = 34,236 mole SO2 removed/yr = 34,236 mole CaSO4-2H2O produced/yr =

 34,236 mole CaSO4-2H2O produced/yr * 172 lb/lb-mole = 2,944 tpy CaSO4-2H2O

 2,944 tpy CaSO4-2H2O * $ 33.00 /ton = $ 97,161

27% of CaO is wasted = 376 tpy * $ 33.00 /ton = $ 12,394

Maintenance

Labor 0.5 hr/shift $ 40,800

Material 100.00% of maintenance $ 40,800

Electricity Gas Cleanaing System Electricity Cost $ 252,308

ID Fan Power $ 177,404

Total DC $ 1,412,185

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs $ 77,112

Administrative charges 2% of Total Capital Investment $ 722,049

Property tax exempt in MN $ -

Insurance 1% of Total Capital Investment $ 361,024

Capital recovery 0.0944 * Total Capital Investment $ 3,407,814

Total IC $ 4,567,998

Total Annual Cost DC + IC $ 5,980,184
Tilden Indurating Line #1 SO2

Uncontrolled emissions (TPY) 1,153.2

Control efficiency (%) 95%

Emission reduction (TPY) 1,096

Controlled emissions (TPY) 58

Total annualized cost ($/yr) $5,980,184

Cost/ton removed ($/T) $5,459