**Tilden Indurating Line #1**

**Given/A ssumed**  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 Y ear 7,680 Barr 9/11/09 Operating Hours per Shift 8 assumed Operating Shifts per Y ear 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) $0.40 Barr 9/11/09 CaSO4 molar weight 172 dihydrate Wa ste disposal ($/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 (y r) 20 Barr 9/11/09 Interest Rate (%) 7.00% Barr 9/11/09

### Tilden Indurating Line #1

**Capital Cost factors for Gas A bsorbers--OA**  **QPS Control Cost Manual, Chap 5**

Cost Item Factor Cost Direct Costs Purchased equipment costs Absorber + auxiliary

equipment, EC A $13,220,203 six-tenths pow er 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**Tilden Indurating Line #1**

**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 $

Wa ste 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% Em ission reduction (TPY) 1,096 Controlled emissions (TPY) 58 Total annualized cost ($/y r) $5,980,184 Cost/ton removed ($/T) $5,459