**Example Complete Cost Estimate for a 4.0 A /C Baghouse Installation (Costs are all based on 2009 dollars)** 

**Variable Designation**  Unit Size (Gross) A Retrofit Factor B Gross Heat Rate C Ty pe of Coal D Baghouse Air-to-Cloth Ratio E Heat Input F

Flue Gas Rate G Aux Power H Aux Power Cost J Bag Cost K Cage Cost L Operating Labor Rate M **CA PITA**  **L COST CA LCULA**  **TION** Include = Equipm ent, installation, buildings, foundations, electrical, and retrofit difficulty BM ($) = if(E = 6.0 Air-to-Cloth then 422; E = 4.0 Air-to-Cloth then 476)*B*G^0.81 BM ($/kW ) = **TOTA L PROJECT COST**  A1 = 10% of BM A2 = 5% of BM A3 = 5% of BM **CECC ($) = BM + A 1 + A**  **2 + A 3**  **CECC ($/kW) =**

B1 = 5% of CECC B2 = 6% of CECC + B1
**TPC ($) = CECC + B1 + B2 + C1 + C2 TPC ($/kW) =**  **FIXED O&M COST** FOMO ($/kW •yr) = (0 additional operators)*2080*M/(A*1000)

FOMM ($/kW •yr) = BM*0.005/(B*A*1000) FOMA ($/kW •yr) = 0.03*(FOMO + 0.4*FOMM) **FOM ($/kW•yr) = FOMO + FOMM + FOMA VA** **RIA BLE O&M COST** 

VOMB ($/MW h) = if (e = 6.0 Air-to-Cloth then 0.004; E = 4.0 Airto-Cloth then 0.005)*(K/3 + L/9) **VOM ($/MWh) = VOMB Example Complete Cost Estimate for a 4.0 A**  **/C Baghouse Installation (Costs are all based on 2009 dollars) Units**  **Value Calculation**  (MW ) **570** <--- User Input

**1** <--- User Input (An "average" retrofit has a factor = 1.0) (Btu/kW h) **8975** <--- User Input

PRB <--- User Input 4 <--- User Input; A/C Ratio (Btu/Hr) 5.12E+09 = A*C*1000
(acfm) 2,046,300 Downstream of an air preheater; For Bituminous Coal = A*C*0.435; For PRB Coal = A*C*0.400; For Lignite Coal = A*C*0.362 (%) **0.60** 0.6 default value should be used for model input. ($/kW h) **0.06** ($/bag) **80** ($/cage) **30** ($/hr) **60** Labor cost including all benefits
**EXA MP**  **LE COMMENTS** 

$ 61,587,431 Base module for an additional baghouse, including ID or booster fans, piping, ductwork, etc. 108 Base module cost per kW

$ 6,158,743 Engineering and Construction Management Costs $ 3,079,372 Labor adjustment for 6 x 10 hour shift premium, per diem, etc. $ 3,079,372 Contractor profit and fees **$ 73,904,917**  Capital, engineering and construction cost subtotal

**130** Capital, engineering and construction cost subtotal per kW
$ 3,695,246 Owners costs inclusing all "home office" costs (owners engineering, ma nagem ent, and procurement activities) $ 4,656,010 AFUDC for baghouse; 6% for a 2-year engineering and construction cycle
**$ 82,256,173**  Total project cost; **(Note C1 and C2 are non functional - see Bill Stevens email 10-3-11)**  **144** Total project cost per kW

$ 0 Fixed O&M additional operating labor costs $ 0.54 Fixed O&M additional maintenance material and labor costs $ 0.01 Fixed O&M additional administrative labor costs **$ 0.55**  Total Fixed O&M costs$ 0.15 Variable O&M costs for bags and cages.

**$ 0.15** Notes**Example Complete Cost Estimate for a 4.0 A /C Baghouse Installation (Costs are all based on 2009 dollars)** 

**Variable Designation**  Unit Size (Gross) A Retrofit Factor B Gross Heat Rate C Ty pe of Coal D Baghouse Air-to-Cloth Ratio E Heat Input F

Flue Gas Rate G Aux Power H Aux Power Cost J Bag Cost K Cage Cost L Operating Labor Rate M **CA PITA**  **L COST CA LCULA**  **TION** Include = Equipm ent, installation, buildings, foundations, electrical, and retrofit difficulty BM ($) = if(E = 6.0 Air-to-Cloth then 422; E = 4.0 Air-to-Cloth then 476)*B*G^0.81 BM ($/kW ) = **TOTA L PROJECT COST**  A1 = 10% of BM A2 = 5% of BM A3 = 5% of BM **CECC ($) = BM + A 1 + A**  **2 + A 3**  **CECC ($/kW) =**

B1 = 5% of CECC B2 = 6% of CECC + B1
**TPC ($) = CECC + B1 + B2 + C1 + C2 TPC ($/kW) =**  **FIXED O&M COST** FOMO ($/kW •yr) = (0 additional operators)*2080*M/(A*1000)

FOMM ($/kW •yr) = BM*0.005/(B*A*1000) FOMA ($/kW •yr) = 0.03*(FOMO + 0.4*FOMM) **FOM ($/kW•yr) = FOMO + FOMM + FOMA VA** **RIA BLE O&M COST** 

VOMB ($/MW h) = if (e = 6.0 Air-to-Cloth then 0.004; E = 4.0 Airto-Cloth then 0.005)*(K/3 + L/9) **VOM ($/MWh) = VOMB Example Complete Cost Estimate for a 4.0 A**  **/C Baghouse Installation (Costs are all based on 2009 dollars) Units**  **Value Calculation**  (MW ) **285** <--- User Input

**1** <--- User Input (An "average" retrofit has a factor = 1.0) (Btu/kW h) **8975** <--- User Input

PRB <--- User Input 4 <--- User Input; A/C Ratio (Btu/Hr) 2.56E+09 = A*C*1000
(acfm) 1,023,150 Downstream of an air preheater; For Bituminous Coal = A*C*0.435; For PRB Coal = A*C*0.400; For Lignite Coal = A*C*0.362 (%) **0.60** 0.6 default value should be used for model input. ($/kW h) **0.06** ($/bag) **80** ($/cage) **30** ($/hr) **60** Labor cost including all benefits
**EXA MP**  **LE COMMENTS** 

$ 35,128,353 Base module for an additional baghouse, including ID or booster fans, piping, ductwork, etc. 123 Base module cost per kW

$ 3,512,835 Engineering and Construction Management Costs $ 1,756,418 Labor adjustment for 6 x 10 hour shift premium, per diem, etc. $ 1,756,418 Contractor profit and fees **$ 42,154,024**  Capital, engineering and construction cost subtotal

**148** Capital, engineering and construction cost subtotal per kW
$ 2,107,701 Owners costs inclusing all "home office" costs (owners engineering, ma nagem ent, and procurement activities) $ 2,655,704 AFUDC for baghouse; 6% for a 2-year engineering and construction cycle
**$ 46,917,429**  Total project cost; **(Note C1 and C2 are non functional - see Bill Stevens email 10-3-11)**  **165** Total project cost per kW

$ 0 Fixed O&M additional operating labor costs $ 0.62 Fixed O&M additional maintenance material and labor costs $ 0.01 Fixed O&M additional administrative labor costs **$ 0.62**  Total Fixed O&M costs$ 0.15 Variable O&M costs for bags and cages.

**$ 0.15** Notes**Example Complete Cost Estimate for a 4.0 A /C Baghouse Installation (Costs are all based on 2009 dollars)** 

**Variable Designation**  Unit Size (Gross) A Retrofit Factor B Gross Heat Rate C Ty pe of Coal D Baghouse Air-to-Cloth Ratio E Heat Input F

Flue Gas Rate G Aux Power H Aux Power Cost J Bag Cost K Cage Cost L Operating Labor Rate M **CA PITA**  **L COST CA LCULA**  **TION** Include = Equipm ent, installation, buildings, foundations, electrical, and retrofit difficulty BM ($) = if(E = 6.0 Air-to-Cloth then 422; E = 4.0 Air-to-Cloth then 476)*B*G^0.81 BM ($/kW ) = **TOTA L PROJECT COST**  A1 = 10% of BM A2 = 5% of BM A3 = 5% of BM **CECC ($) = BM + A 1 + A**  **2 + A 3**  **CECC ($/kW) =**

B1 = 5% of CECC B2 = 6% of CECC + B1
**TPC ($) = CECC + B1 + B2 + C1 + C2 TPC ($/kW) =**  **FIXED O&M COST** FOMO ($/kW •yr) = (0 additional operators)*2080*M/(A*1000)

FOMM ($/kW •yr) = BM*0.005/(B*A*1000) FOMA ($/kW •yr) = 0.03*(FOMO + 0.4*FOMM) **FOM ($/kW•yr) = FOMO + FOMM + FOMA VA** **RIA BLE O&M COST** 

VOMB ($/MW h) = if (e = 6.0 Air-to-Cloth then 0.004; E = 4.0 Airto-Cloth then 0.005)*(K/3 + L/9) **VOM ($/MWh) = VOMB Example Complete Cost Estimate for a 4.0 A**  **/C Baghouse Installation (Costs are all based on 2009 dollars) Units**  **Value Calculation**  (MW ) **572** <--- User Input

**1** <--- User Input (An "average" retrofit has a factor = 1.0) (Btu/kW h) **9580** <--- User Input

PRB <--- User Input 4 <--- User Input; A/C Ratio (Btu/Hr) 5.48E+09 = A*C*1000
(acfm) 2,191,904 Downstream of an air preheater; For Bituminous Coal = A*C*0.435; For PRB Coal = A*C*0.400; For Lignite Coal = A*C*0.362 (%) **0.60** 0.6 default value should be used for model input. ($/kW h) **0.06** ($/bag) **80** ($/cage) **30** ($/hr) **60** Labor cost including all benefits
**EXA MP**  **LE COMMENTS** 

$ 65,113,703 Base module for an additional baghouse, including ID or booster fans, piping, ductwork, etc. 114 Base module cost per kW

$ 6,511,370 Engineering and Construction Management Costs $ 3,255,685 Labor adjustment for 6 x 10 hour shift premium, per diem, etc. $ 3,255,685 Contractor profit and fees **$ 78,136,443**  Capital, engineering and construction cost subtotal

**137** Capital, engineering and construction cost subtotal per kW
$ 3,906,822 Owners costs inclusing all "home office" costs (owners engineering, ma nagem ent, and procurement activities) $ 4,922,596 AFUDC for baghouse; 6% for a 2-year engineering and construction cycle
**$ 86,965,861**  Total project cost; **(Note C1 and C2 are non functional - see Bill Stevens email 10-3-11)**  **152** Total project cost per kW

$ 0 Fixed O&M additional operating labor costs $ 0.57 Fixed O&M additional maintenance material and labor costs $ 0.01 Fixed O&M additional administrative labor costs **$ 0.58**  Total Fixed O&M costs$ 0.15 Variable O&M costs for bags and cages.

**$ 0.15** Notes**Example Complete Cost Estimate for a 4.0 A /C Baghouse Installation (Costs are all based on 2009 dollars)** 

**Variable Designation**  Unit Size (Gross) A Retrofit Factor B Gross Heat Rate C Ty pe of Coal D Baghouse Air-to-Cloth Ratio E Heat Input F

Flue Gas Rate G Aux Power H Aux Power Cost J Bag Cost K Cage Cost L Operating Labor Rate M **CA PITA**  **L COST CA LCULA**  **TION** Include = Equipm ent, installation, buildings, foundations, electrical, and retrofit difficulty BM ($) = if(E = 6.0 Air-to-Cloth then 422; E = 4.0 Air-to-Cloth then 476)*B*G^0.81 BM ($/kW ) = **TOTA L PROJECT COST**  A1 = 10% of BM A2 = 5% of BM A3 = 5% of BM **CECC ($) = BM + A 1 + A**  **2 + A 3**  **CECC ($/kW) =**

B1 = 5% of CECC B2 = 6% of CECC + B1
**TPC ($) = CECC + B1 + B2 + C1 + C2 TPC ($/kW) =**  **FIXED O&M COST** FOMO ($/kW •yr) = (0 additional operators)*2080*M/(A*1000)

FOMM ($/kW •yr) = BM*0.005/(B*A*1000) FOMA ($/kW •yr) = 0.03*(FOMO + 0.4*FOMM) **FOM ($/kW•yr) = FOMO + FOMM + FOMA VA** **RIA BLE O&M COST** 

VOMB ($/MW h) = if (e = 6.0 Air-to-Cloth then 0.004; E = 4.0 Airto-Cloth then 0.005)*(K/3 + L/9) **VOM ($/MWh) = VOMB Example Complete Cost Estimate for a 4.0 A**  **/C Baghouse Installation (Costs are all based on 2009 dollars) Units**  **Value Calculation**  (MW ) **286** <--- User Input

**1** <--- User Input (An "average" retrofit has a factor = 1.0) (Btu/kW h) **9580** <--- User Input

PRB <--- User Input 4 <--- User Input; A/C Ratio (Btu/Hr) 2.74E+09 = A*C*1000
(acfm) 1,095,952 Downstream of an air preheater; For Bituminous Coal = A*C*0.435; For PRB Coal = A*C*0.400; For Lignite Coal = A*C*0.362 (%) **0.60** 0.6 default value should be used for model input. ($/kW h) **0.06** ($/bag) **80** ($/cage) **30** ($/hr) **60** Labor cost including all benefits
**EXA MP**  **LE COMMENTS** 

$ 37,139,675 Base module for an additional baghouse, including ID or booster fans, piping, ductwork, etc. 130 Base module cost per kW

$ 3,713,967 Engineering and Construction Management Costs $ 1,856,984 Labor adjustment for 6 x 10 hour shift premium, per diem, etc. $ 1,856,984 Contractor profit and fees **$ 44,567,610**  Capital, engineering and construction cost subtotal

**156** Capital, engineering and construction cost subtotal per kW
$ 2,228,380 Owners costs inclusing all "home office" costs (owners engineering, ma nagem ent, and procurement activities) $ 2,807,759 AFUDC for baghouse; 6% for a 2-year engineering and construction cycle
**$ 49,603,749**  Total project cost; **(Note C1 and C2 are non functional - see Bill Stevens email 10-3-11)**  **173** Total project cost per kW

$ 0 Fixed O&M additional operating labor costs $ 0.65 Fixed O&M additional maintenance material and labor costs $ 0.01 Fixed O&M additional administrative labor costs **$ 0.66**  Total Fixed O&M costs$ 0.15 Variable O&M costs for bags and cages.

**$ 0.15** Notes**Example Complete Cost Estimate for a 6.0 A /C Baghouse Installation (Costs are all based on 2009 dollars)** 

**Variable Designation**  Unit Size (Gross) A Retrofit Factor B Gross Heat Rate C Ty pe of Coal D Baghouse Air-to-Cloth Ratio E Heat Input F

Flue Gas Rate G Aux Power H Aux Power Cost J Bag Cost K Cage Cost L Operating Labor Rate M **CA PITA**  **L COST CA LCULA**  **TION** Include = Equipm ent, installation, buildings, foundations, electrical, and retrofit difficulty BM ($) = if(E = 6.0 Air-to-Cloth then 422; E = 4.0 Air-to-Cloth then 476)*B*G^0.81 BM ($/kW ) = **TOTA L PROJECT COST**  A1 = 10% of BM A2 = 5% of BM A3 = 5% of BM **CECC ($) = BM + A 1 + A**  **2 + A 3**  **CECC ($/kW) =**

B1 = 5% of CECC B2 = 6% of CECC + B1 **TPC ($) = CECC + B1 + B2 + C1 + C2 TPC ($/kW) =**  **FIXED O&M COST** FOMO ($/kW •yr) = (0 additional operators)*2080*M/(A*1000)

FOMM ($/kW •yr) = BM*0.005/(B*A*1000) FOMA ($/kW •yr) = 0.03*(FOMO + 0.4*FOMM) **FOM ($/kW•yr) = FOMO + FOMM + FOMA VA** **RIA BLE O&M COST** VOMB ($/MW h) = if (e = 6.0 Air-to-Cloth then 0.004; E = 4.0 Airto-Cloth then 0.005)*(K/3 + L/9) **VOM ($/MWh) = VOMB Example Complete Cost Estimate for a 6.0 A**  **/C Baghouse Installation (Costs are all based on 2009 dollars) Units**  **Value Calculation**  (MW ) **500** <--- User Input

**1** <--- User Input (An "average" retrofit has a factor = 1.0) (Btu/kW h) **9500** <--- User Input

Bitum inous <--- User Input 6 <--- User Input; A/C Ratio (Btu/Hr) 4.75E+09 = A*C*1000
(acfm) 2,066,250 Downstream of an air preheater; For Bituminous Coal = A*C*0.435; For PRB Coal = A*C*0.400; For Lignite Coal = A*C*0.362 (%) **0.60** 0.6 default value should be used for model input. ($/kW h) **0.06** ($/bag) **80** ($/cage) **30** ($/hr) **60** Labor cost including all benefits Notes **EXA MP**  **LE COMMENTS** 

$ 55,031,401 Base module for an additional baghouse, including ID or booster fans, piping, ductwork, etc. 110 Base module cost per kW

$ 5,503,140 Engineering and Construction Management Costs $ 2,751,570 Labor adjustment for 6 x 10 hour shift premium, per diem, etc. $ 2,751,570 Contractor profit and fees **$ 66,037,682**  Capital, engineering and construction cost subtotal

**132** Capital, engineering and construction cost subtotal per kW
$ 3,301,884 Owners costs inclusing all "home office" costs (owners engineering, ma nagem ent, and procurement activities) $ 4,160,374 AFUDC for baghouse; 6% for a 2-year engineering and construction cycle **$ 73,499,940**  Total project cost; **{What are C1 and C2?}**

**147** Total project cost per kW

$ 0 Fixed O&M additional operating labor costs $ 0.55 Fixed O&M additional maintenance material and labor costs $ 0.01 Fixed O&M additional administrative labor costs **$ 0.56**  Total Fixed O&M costs$ 0.12 Variable O&M costs for bags and cages.

**$ 0.12** Sooner Muskogee

MW 570 285 572 286 Btu/Kw 8975 8975 9580 9580 A/C Ratio 4 4 4 4 Cost 73,904,917 42,154,024 78,136,443 44,567,610 Ratio **0.88 0.88**