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

Type 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

CAPITAL COST CALCULATION

Include = Equipment, 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) =

TOTAL PROJECT COST

A1 = 10% of BM

A2 = 5% of BM

A3 = 5% of BM

CECC ($) = BM + A1 + A2 + A3

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
VARIABLE O&M COST

VOMB ($/MWh) = 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
2009 dollars)

Units Value Calculation

(MW) 570 <--- User Input

1 <--- User Input (An "average" retrofit has a factor = 1.0)

(Btu/kWh) 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.

($/kWh) 0.06

($/bag) 80

($/cage) 30

($/hr) 60 Labor cost including all benefits

EXAMPLE 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, 

management, 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

Type 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

CAPITAL COST CALCULATION

Include = Equipment, 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) =

TOTAL PROJECT COST

A1 = 10% of BM

A2 = 5% of BM

A3 = 5% of BM

CECC ($) = BM + A1 + A2 + A3

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
VARIABLE O&M COST

VOMB ($/MWh) = 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
2009 dollars)

Units Value Calculation

(MW) 285 <--- User Input

1 <--- User Input (An "average" retrofit has a factor = 1.0)

(Btu/kWh) 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.

($/kWh) 0.06

($/bag) 80

($/cage) 30

($/hr) 60 Labor cost including all benefits

EXAMPLE 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, 

management, 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

Type 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

CAPITAL COST CALCULATION

Include = Equipment, 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) =

TOTAL PROJECT COST

A1 = 10% of BM

A2 = 5% of BM

A3 = 5% of BM

CECC ($) = BM + A1 + A2 + A3

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
VARIABLE O&M COST

VOMB ($/MWh) = 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
2009 dollars)

Units Value Calculation

(MW) 572 <--- User Input

1 <--- User Input (An "average" retrofit has a factor = 1.0)

(Btu/kWh) 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.

($/kWh) 0.06

($/bag) 80

($/cage) 30

($/hr) 60 Labor cost including all benefits

EXAMPLE 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, 

management, 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

Type 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

CAPITAL COST CALCULATION

Include = Equipment, 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) =

TOTAL PROJECT COST

A1 = 10% of BM

A2 = 5% of BM

A3 = 5% of BM

CECC ($) = BM + A1 + A2 + A3

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
VARIABLE O&M COST

VOMB ($/MWh) = 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
2009 dollars)

Units Value Calculation

(MW) 286 <--- User Input

1 <--- User Input (An "average" retrofit has a factor = 1.0)

(Btu/kWh) 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.

($/kWh) 0.06

($/bag) 80

($/cage) 30

($/hr) 60 Labor cost including all benefits

EXAMPLE 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, 

management, 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

Type 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

CAPITAL COST CALCULATION

Include = Equipment, 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) =

TOTAL PROJECT COST

A1 = 10% of BM

A2 = 5% of BM

A3 = 5% of BM

CECC ($) = BM + A1 + A2 + A3

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

VARIABLE O&M COST
VOMB ($/MWh) = 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
2009 dollars)

Units Value Calculation

(MW) 500 <--- User Input

1 <--- User Input (An "average" retrofit has a factor = 1.0)

(Btu/kWh) 9500 <--- User Input

Bituminous <--- 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.

($/kWh) 0.06

($/bag) 80

($/cage) 30

($/hr) 60 Labor cost including all benefits Notes

EXAMPLE 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, 

management, 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