These worksheets are derived from the algorithms present in, "IPM Model – Revisions to Cost and Performance

for APC Technologies, SCR Cost Development Methodology, Final August 2010, Project 12301-007, Perrin Quarles Associates, Inc. Prepared by Sargent & Lundy."

### Summary of Cost Differences Between NOx Control at 0.08 lbs/MMBtu and 0.05 lbs/MMBtu

**Cost Category NOx Controlled to 0.08**  **lbs/MMBtu NOx Controlled to** 

**0.05 lbs/MMBtu** SCR $58,104,000 $60,265,000 Reagent Preparation $2,178,000 $2,280,000 Engineering and construction management $6,569,000 $6,796,000 Labor adjustment for 6 X 10 shifts, per diem, etc. $6,569,000 $6,796,000 Contractor profit and fees $6,569,000 $6,796,000 Total capital, engineering, and construction $85,400,000 $88,344,000 Total project $95,050,000 $98,327,000 Variable O&M urea ($/MW h) $0.32 $0.38 Variable O&M catalyst ($/MW h) $0.24 $0.27 Total variable O&M ($/MW h) $0.79 $0.89

### Summary of Cost Differences Between NOx Control at 0.08 lbs/MMBtu and 0.05 lbs/MMBtu

**Percent Increase**  3.59 4.47 3.34 3.34 3.34 3.33 3.33 16.75 12.13 10.89

### GGS SCR Capital Cost Estimate Worksheet Assuming NOx Control at 0.08 lbs/MMBtu

**Variable Designation**  **Units Value**  **Calculation** Unit Size A (MW) 700 Input Retrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0) Heat Rate C (Btu/kWh) 7588 Input NOxRate D (lb/MMBtu) 0.23 Input SO 2Rate E (lb/MMBtu) 0.15 Input Type of Coal F PRB Input Coal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07 Heat Rate Factor H 0.7588 C/10000 Heat Input I (Btu/hr) 5.31E+09 A*C*1000 Capacity Factor J (%) 100 Input NOxRemoval Efficiency K (%) 65.2 Input NOxRemoval Factor L 0.815 K/80 NOxRemoved M (lb/hr) 797 D*I/10 6 *K/100 Urea Rate (100%) N (lb/hr) 556 M*0.525*60/46*1.01/0.99 Steam Required O (lb/hr) 629 N*1.13 Aux Power P (%) 0.51 0.56*(G*H) 0.43; Auxilliary power Urea Cost 50% wt sol. R ($/ton) 400 Input Catalyst Cost S ($/m3) 7000 Input Aux Power Cost T ($/kWh) 0.046 Input Steam Cost U ($/klb) 4 Input Operating Labor Rate V ($/hr) 40.6 Labor cost including all benefits



### Costs are all based on 2009 dollars **Capital Cost Calculation** Include: equipment, installation, buildings, foundations, electrical, and retrofit difficulty. BMR ($) = 180000*(B)*(L) 0.2 *(A*G*H)^ 0.92 $58,104,000 SCR (inlet ductwork, reactor, bypass) island cost BMF ($) = 410000*(M) 0.25 $2,178,000 Base reagent preparation cost BMA ($) = If E >= 3 then 65000*(B)*(A*G*H) 0.78; else 0 $0 Air heater modification / SO BMB ($) = 380000*(B)*(A*G*H) 0.42 $5,411,000 ID or booster fans & auxiliary power modification costs BM ($) = BMR + BMF + BMA + BMB $65,693,000 Total bare module cost including retrofit factor BM ($/kW) $94 Base cost per kW
**Total Project Cost** A1 = 10% of BM $6,569,000 Engineering and construction management costs A2 = 10% of BM $6,569,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $6,569,000 Contractor profit and fees **CECC($) = BM+A1+A2+A3 $85,400,000**  Capital, engineering and construction cost subtotal **CECC($/kW) = $122**  Capital, engineering and construction cost subtotal per kW

B1 = 5% of CECC $4,270,000 Owners costs including "home office" costs (owners engineering, management, and procurement activities)B2 = 6% of (CECC + B1) $5,380,000 AFUDC (based on approximately 3% per year for a 2 year engineering and construction cycle)

**TPC ($) = CECC + B1 + B2 $95,050,000**  Total project cost **TPC ($/kW) = $136**  Total project cost per kWInput (An "average" retrofit has a factor = 1.0)

Bituminous =1.0, PRB=1.05, Lignite=1.07

SCR (inlet ductwork, reactor, bypass) island cost Base reagent preparation cost Air heater modification / SO 3control (bituminous only & > 3 lb/MMbtu) ID or booster fans & auxiliary power modification costs Total bare module cost including retrofit factor

Engineering and construction management costs Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. Contractor profit and fees
Capital, engineering and construction cost subtotal Capital, engineering and construction cost subtotal per kW
Owners costs including "home office" costs (owners engineering, management, and procurement activities)AFUDC (based on approximately 3% per year for a 2 year engineering and construction cycle)

Total project cost per kW

### GGS SCR Capital Cost Estimate Worksheet Assuming NOx Control at 0.08 lbs/MMBtu

**Variable Designation**  **Units Value**  **Calculation** Unit Size A (MW) 700 Input Retrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0) Heat Rate C (Btu/kWh) 7588 Input NOxRate D (lb/MMBtu) 0.23 Input SO 2Rate E (lb/MMBtu) 0.15 Input Type of Coal F PRB Input Coal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07 Heat Rate Factor H 0.7588 C/10000 Heat Input I (Btu/hr) 5.31E+09 A*C*1000 Capacity Factor J (%) 100 Input NOxRemoval Efficiency K (%) 65.2 Input NOxRemoval Factor L 0.815 K/80 NOxRemoved M (lb/hr) 797 D*I/10 6 *K/100 Urea Rate (100%) N (lb/hr) 556 M*0.525*60/46*1.01/0.99 Steam Required O (lb/hr) 629 N*1.13 Aux Power P (%) 1 0.56*(G*H) 0.43; Auxilliary power Urea Cost 50% wt sol. R ($/ton) 400 Input Catalyst Cost S ($/m3) 7000 Input Aux Power Cost T ($/kWh) 0 Input Steam Cost U ($/klb) 4 Input Operating Labor Rate V ($/hr) 41 Labor cost including all benefits



### Costs are all based on 2009 dollars **Fixed O&M Cost** FOMO ($/kW yr) = (1/2 operator time assumed)*2080*V/(A*1000) $0.060 Fixed O&M additional operating labor costs FOMM ($/kW yr) = IF A < 500 then $200,000 ELSE $300,000 $0.429 Fixed O&M maintenance material and labor costs **FOM ($/kW yr) = FOMO + FOMM $0.489**  Total fixed O&M costs

**Variable O&M** VOMR ($/MWh) = N*R/A/1000 $0.318 Variable O&M costs for urea VOMW($/MW h) = 0.3*(G)2.9*(L)0.71 /8760/J*100*S $0.239 Variable O&M costs for catalyst replacement and disposal VOMM ($/MWh) = O*U/A/1000 $0.004 Variable O&M costs for steam VOMP ($/MWh) = P*T*10 $0.234 Variable O&M costs for additional auxillary power required **VOM ($/MWh) = VOMR + VOMW + VOMM $0.794**  Total variable O&M costsInput (An "average" retrofit has a factor = 1.0)

Bituminous =1.0, PRB=1.05, Lignite=1.07

Fixed O&M additional operating labor costs Fixed O&M maintenance material and labor costs

Variable O&M costs for urea Variable O&M costs for catalyst replacement and disposal Variable O&M costs for steam Variable O&M costs for additional auxillary power required

Total variable O&M costs

### GGS SCR Capital Cost Estimate Worksheet Assuming NOx Control at 0.05 lbs/MMBtu

**Variable Designation**  **Units Value**  **Calculation** Unit Size A (MW) 700 Input Retrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0) Heat Rate C (Btu/kWh) 7588 Input NOxRate D (lb/MMBtu) 0.23 Input SO 2Rate E (lb/MMBtu) 0.15 Input Type of Coal F PRB Input Coal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07 Heat Rate Factor H 0.7588 C/10000 Heat Input I (Btu/hr) 5.31E+09 A*C*1000 Capacity Factor J (%) 100 Input NOxRemoval Efficiency K (%) 78.26 Input NOxRemoval Factor L 0.97825 K/80 NOxRemoved M (lb/hr) 956 D*I/10 6 *K/100 Urea Rate (100%) N (lb/hr) 668 M*0.525*60/46*1.01/0.99 Steam Required O (lb/hr) 755 N*1.13 Aux Power P (%) 0.51 0.56*(G*H) 0.43; Auxilliary power Urea Cost 50% wt sol. R ($/ton) 400 Input Catalyst Cost S ($/m3) 7000 Input Aux Power Cost T ($/kWh) 0.046 Input Steam Cost U ($/klb) 4 Input Operating Labor Rate V ($/hr) 40.6 Labor cost including all benefits



### Costs are all based on 2009 dollars **Capital Cost Calculation** Include: equipment, installation, buildings, foundations, electrical, and retrofit difficulty. BMR ($) = 180000*(B)*(L) 0.2 *(A*G*H)^ 0.92 $60,265,000 SCR (inlet ductwork, reactor, bypass) island cost BMF ($) = 410000*(M) 0.25 $2,280,000 Base reagent preparation cost BMA ($) = If E >= 3 then 65000*(B)*(A*G*H) 0.78; else 0 $0 Air heater modification / SO BMB ($) = 380000*(B)*(A*G*H) 0.42 $5,411,000 ID or booster fans & auxiliary power modification costs BM ($) = BMR + BMF + BMA + BMB $67,956,000 Total bare module cost including retrofit factor BM ($/kW) $97 Base cost per kW
**Total Project Cost** A1 = 10% of BM $6,796,000 Engineering and construction management costs A2 = 10% of BM $6,796,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $6,796,000 Contractor profit and fees **CECC($) = BM+A1+A2+A3 $88,344,000**  Capital, engineering and construction cost subtotal **CECC($/kW) = $126**  Capital, engineering and construction cost subtotal per kW

B1 = 5% of CECC $4,417,200 Owners costs including "home office" costs (owners engineering, management, and procurement activities)B2 = 6% of (CECC + B1) $5,566,000 AFUDC (based on approximately 3% per year for a 2 year engineering and construction cycle)

**TPC ($) = CECC + B1 + B2 $98,327,200**  Total project cost **TPC ($/kW) = $140**  Total project cost per kWInput (An "average" retrofit has a factor = 1.0)

Bituminous =1.0, PRB=1.05, Lignite=1.07

SCR (inlet ductwork, reactor, bypass) island cost Base reagent preparation cost Air heater modification / SO 3control (bituminous only & > 3 lb/MMbtu) ID or booster fans & auxiliary power modification costs Total bare module cost including retrofit factor

Engineering and construction management costs Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. Contractor profit and fees
Capital, engineering and construction cost subtotal Capital, engineering and construction cost subtotal per kW
Owners costs including "home office" costs (owners engineering, management, and procurement activities)AFUDC (based on approximately 3% per year for a 2 year engineering and construction cycle)

Total project cost per kW

### GGS SCR Capital Cost Estimate Worksheet Assuming NOx Control at 0.05 lbs/MMBtu

**Variable Designation**  **Units Value**  **Calculation** Unit Size A (MW) 700 Input Retrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0) Heat Rate C (Btu/kWh) 7588 Input NOxRate D (lb/MMBtu) 0.23 Input SO 2Rate E (lb/MMBtu) 0.15 Input Type of Coal F PRB Input Coal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07 Heat Rate Factor H 0.7588 C/10000 Heat Input I (Btu/hr) 5.31E+09 A*C*1000 Capacity Factor J (%) 100 Input NOxRemoval Efficiency K (%) 78.26 Input NOxRemoval Factor L 0.97825 K/80 NOxRemoved M (lb/hr) 956 D*I/10 6 *K/100 Urea Rate (100%) N (lb/hr) 668 M*0.525*60/46*1.01/0.99 Steam Required O (lb/hr) 755 N*1.13 Aux Power P (%) 0.51 0.56*(G*H) 0.43; Auxilliary power Urea Cost 50% wt sol. R ($/ton) 400 Input Catalyst Cost S ($/m3) 7000 Input Aux Power Cost T ($/kWh) 0.046 Input Steam Cost U ($/klb) 4 Input Operating Labor Rate V ($/hr) 40.6 Labor cost including all benefits



### Costs are all based on 2009 dollars **Fixed O&M Cost** FOMO ($/kW yr) = (1/2 operator time assumed)*2080*V/(A*1000) $0.060 Fixed O&M additional operating labor costs FOMM ($/kW yr) = IF A < 500 then $200,000 ELSE $300,000 $0.429 Fixed O&M maintenance material and labor costs **FOM ($/kW yr) = FOMO + FOMM $0.489**  Total fixed O&M costs

**Variable O&M** VOMR ($/MWh) = N*R/A/1000 $0.382 Variable O&M costs for urea VOMW($/MW h) = 0.3*(G)2.9*(L)0.71 /8760/J*100*S $0.272 Variable O&M costs for catalyst replacement and disposal VOMM ($/MWh) = O*U/A/1000 $0.004 Variable O&M costs for steam VOMP ($/MWh) = P*T*10 $0.234 Variable O&M costs for additional auxillary power required **VOM ($/MWh) = VOMR + VOMW + VOMM $0.891**  Total variable O&M costsInput (An "average" retrofit has a factor = 1.0)

Bituminous =1.0, PRB=1.05, Lignite=1.07

Fixed O&M additional operating labor costs Fixed O&M maintenance material and labor costs

Variable O&M costs for urea Variable O&M costs for catalyst replacement and disposal Variable O&M costs for steam Variable O&M costs for additional auxillary power required

Total variable O&M costs