UTAC Line 2 GSA

Given/Assumed

Flow rate (acfm) 1,128,438 Barr 9/28/12 Table 18

Flue Gas Temperature (degrees F) 280 Barr 9/28/12 Table 18

Pellet production (LT/hr) 417 calculated from Barr Table 18

SO2 emission factor (lb/LT) 0.55 calculated from Barr Table 18

Safety factor

Uncontrolled SO2 emissions (lb/hr) 227.7 calculated

Uncontrolled SO2 emissions (TPY) 910 Cliffs 11/9/12 response

Savings from shutdown of exsiting emission controls $ (1,307,161) Barr 9/28/12 Table 18 795000

SO2 molar weight 64

ESP $ 5,057,000 vendor quote

GSA $ 7,100,400 vendor quote

Baghouse $ 10,900,400 vendor quote

Auxiliary equipment Barr 9/28/12 Table 11

Sales taxes 6.8% Barr 9/28/12 Table 2

Site preparation Barr 9/28/12 Table 11

Buildings Barr 9/28/12 Table 11

Lost production costs $ 7,700,000 Barr 9/28/12 Table 18

Total Capital Investment $ 92,103,386 Barr 9/28/12 Table 18

Controlled SO2 emissions (lb/hr) 38.3 calculated from Barr 9/28/12 Table 18 for 5 ppm 

SO2 Control efficiency 83.2% calculated

Operating Hours per Year 7,992 Barr 9/28/12 Table 18

Operating Hours per Shift 8 assumed

Operating Shifts per Year 999 calculated

Utilization 100% Barr 9/28/12 Table 18

Operating Labor Cost ($/hr) $31.75 Barr 9/28/12 Table 16

Maintenance Labor Cost ($/hr) $32.50 Barr 9/28/12 Table 16

Hydrated Lime molar weight 74

Chemical usage molar ratio 1.3 Barr 9/28/12 Table 16

Chemical cost ($/ton) $ 145.00 Barr 9/28/12 Table 16

Solvent usage (gpm) 0 Barr 9/28/12 Table 16

Solvent cost ($/kgal) $2.07 Barr 9/28/12 Table 16

CaSO4 molar weight 172 dihydrate

Waste disposal ($/ton) $ 50.00 Barr 9/28/12 Table 16

Compressed air cost ($/kscf) $ 0.38 Barr 9/28/12 Table 16

Compressed air use (scfm/kacfm) 2 Barr 9/28/12 Table 16

Electricity cost ($/kWh) $ 0.064 Barr 9/28/12 Table 16

Electricity use (kW/hr) 6,438 Barr 9/28/12 Table 16

Equipment Life (yr) 30 EPA R10

PM10 emissions (lb/day) 3,180 8/30/06 BART report

Number of filter bags 4488 Barr 9/28/12 Table 16

Bag/cage cost $ 180 Barr 9/28/12 Table 16

Bag life 3 Barr 9/28/12 Table 16

Bag replacement (min/bag) 10 OAQPS Control Cost Manual for pulse jet

Interest Rate (%) 7.00% Barr 9/28/12 Table 18
UTAC Line 2 GSA

Capital Cost factors for ESPs--OAQPS Control Cost Manual, Chap 6.2

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

ESP + auxiliary equipment, EC A $5,057,000

Instrumentation 0.10 A $505,700

Sales taxes 0.07 A $343,876

Freight 0.05 A $252,850

Purchased equipment cost, PEC B= 1.22 A $6,159,426

Direct installation costs

Foundations & supports 0.04 B $246,377

Handling & erection 0.50 B $3,079,713

Electrical 0.08 B $492,754

Piping 0.01 B $61,594

Insulation 0.02 B $123,189

Painting 0.02 B $123,189

Direct installation costs x x 0.67 B $4,126,815

Site preparation As required, SP

Buildings As required, Bldg.

Total Direct Costs, DC 1.85 B+SP+Bldg $10,286,241

Indirect Costs (installation)

Engineering 0.20 B $1,231,885

Construction and field expenses 0.20 B $1,231,885

Contractor fees 0.10 B $615,943

Start-up 0.01 B $61,594

Performance test 0.01 B $61,594

Model Study 0.02 B $123,189

Contingencies 0.03 B $184,783

Total Indirect Costs, IC 0.57 B $3,510,873

Total Capital Investment = DC + IC 2.24 B+SP+Bldg $13,797,114
UTAC Line 2 GSA

Annual Cost factors for ESPs--OAQPS Control Cost Manual, Chap 6.2

Cost Item Cost

Direct Annual Costs, DC

Operating labor

Operator 3 hr/day $ 31,718

Supervisor 15% of operator $ 4,758

Operating materials

Maintenance

Labor for collector area < 50,000 sq ft $ 4,125

Material 1.00% of ESP PEC $ 61,594

Utilities

Electricity-fan kW/hr * 7,992 hr/yr * $ 0.064 /kWh = $ -

Electricity-operating

Waste Disposal 529 ton PM removed/yr * $ 50.00 /ton = $ 26,474

Total Direct Costs (DC) = $ 102,195

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs $ 61,317

Administrative charges 2% of Total Capital Investment

Property tax 1% of Total Capital Investment exempt in MN

Insurance 1% of Total Capital Investment

Capital recovery 0.0806 * Total Capital Investment

Total Indirect Costs (IC) = $ 61,317

Total Annual Cost DC + IC $ 163,512
UTAC Line 2 GSA

Capital Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 5.2

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

Absorber + auxiliary equipment, EC A $7,100,400

Instrumentation 0.10 A $710,040

Sales taxes 0.07 A $482,827

Freight 0.05 A $355,020

Purchased equipment cost, PEC B= 1.22 A $8,648,287

Direct installation costs

Foundations & supports 0.12 B $1,037,794

Handling & erection 0.40 B $3,459,315

Electrical 0.01 B $86,483

Piping 0.30 B $2,594,486

Insulation 0.01 B $86,483

Painting 0.01 B $86,483

Direct installation costs x x 0.85 B $7,351,044

Site preparation As required, SP $0

Buildings As required, Bldg. $0

Total Direct Costs, DC 1.85 $15,999,331

Indirect Costs (installation)

Engineering 0.10 B $864,829

Construction and field expenses 0.10 B $864,829

Contractor fees 0.10 B $864,829

Start-up 0.01 B $86,483

Performance test 0.01 B $86,483

Contingencies 0.03 B $259,449

Total Indirect Costs, IC 0.35 B $3,026,901

Lost production costs $7,700,000

Total Capital Investment = DC + IC 2.20 B+SP+Bldg $26,726,232
UTAC Line 2 GSA

Annual Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 5.2

Cost Item Cost

Direct Annual Costs, DC

Operating labor

Operator 0.5 hr/shift $ 15,859

Supervisor 15% of operator $ 2,379

Operating materials

Solvent 0 gpm * $ 2.07 /kgal = $ -

Chemicals 227.73 lb SO2/hr = 910.0 tpy SO2

1.3 lb-mole CaO/lb-mole SO2 * 28,438 lb-moles SO2/yr = 36,969 lb-mole CaO/yr

 36,969 lb-mole CaO/yr * 74 lb/lb-mole = 2,739,015 lb CaO/yr

 2,739,015 lb CaO/yr/ 2,000 lb/ton * $ 145.00 / ton = $ 198,579

Waste Disposal 757 ton SO2 removed/yr = 23,661 mole SO2 removed/yr = 23,661 mole CaSO4-2H2O produced/yr =

 23,661 mole CaSO4-2H2O produced/yr * 172 lb/lb-mole = 2,035 tpy CaSO4-2H2O

 2,035 tpy CaSO4-2H2O * $ 50.00 /ton = $ 101,741

23% of CaO is wasted = 316 tpy * $ 50.00 /ton = $ 15,802

Maintenance

Labor 1 hr/shift $ 32,468

Material 100.00% of maintenance $ 32,468

Electricity kW/hr * 7,992 hr/yr * $ 0.064 /kWh = $ -

Savings from shutdown of exsiting emission controls $ (1,307,161)

Total Direct Costs (DC) = $ (907,867)

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs $ 49,904

Administrative charges 2% of Total Capital Investment

Property tax 1% of Total Capital Investment exempt in MN

Insurance 1% of Total Capital Investment

Capital recovery 0.0806 * Total Capital Investment

Total Indirect Costs (IC) = $ 49,904

Total Annual Cost DC + IC $ (857,963)
UTAC Line 2 GSA

Capital Cost factors for Fabric Filters--OAQPS Control Cost Manual, Chap 6.1

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

ESP + auxiliary equipment, EC A $5,057,000

Instrumentation 0.10 A $505,700

Sales taxes 0.07 A $343,876

Freight 0.05 A $252,850

Purchased equipment cost, PEC B= 1.22 A $6,159,426

Direct installation costs

Foundations & supports 0.04 B $246,377

Handling & erection 0.50 B $3,079,713

Electrical 0.08 B $492,754

Piping 0.01 B $61,594

Insulation 0.07 B $431,160

Painting 0.04 B $246,377

Direct installation costs x x 0.74 B $4,557,975

Site preparation As required, SP

Buildings As required, Bldg.

Total Direct Costs, DC 1.85 B+SP+Bldg $10,717,401

Indirect Costs (installation)

Engineering 0.10 B $615,943

Construction and field expenses 0.20 B $1,231,885

Contractor fees 0.10 B $615,943

Start-up 0.01 B $61,594

Performance test 0.01 B $61,594

Contingencies 0.03 B $184,783

Total Indirect Costs, IC 0.45 B $2,771,742

Total Capital Investment = DC + IC 2.19 B+SP+Bldg $13,489,143
UTAC Line 2 GSA

Annual Cost factors for Fabric Filter Systems--OAQPS Control Cost Manual, Chap 6.1

Cost Item Cost

Direct Annual Costs, DC

Operating labor

Operator 2 hr/shift $ 63,437

Supervisor 15% of operator $ 9,515

Operating materials

Maintenance

Labor 0.5 hr/shift $ 16,234

Material 100.00% of maintenance $ 16,234

Replacement parts, bags

 4,488 bags * 0.17 hr/bag * $33 /hr = $24,310

 4,488 bags/cages * $ 180 /bag/cage = $ 807,840

CRF = 0.3811 7% sales tax 5% freight

$24,310 labor + $ 903,165 bags & cages * 0.3811 CRF = $ 353,416

Utilities

Electricity 6,438 kW/hr * 7,992 hr/yr * $ 0.064 /kWh = $ 3,292,960

Compressed air 2 scfm/kacfm * 1,128,438 acfm * $ 0.38 /kscf = $ 411,243

Waste Disposal 529 ton PM removed/yr * $ 50.00 /ton = $ 26,474

Total Direct Costs (DC) = $ 3,751,795

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs $ 63,252

Administrative charges 2% of Total Capital Investment

Property tax 1% of Total Capital Investment exempt in MN

Insurance 1% of Total Capital Investment

Capital recovery 0.0806 * Total Capital Investment

Total Indirect Costs (IC) = $ 63,252

Total Annual Cost DC + IC $ 3,815,047
UTAC Line 2 GSA SO2

Uncontrolled emissions (TPY) 910

Control efficiency (%) 83%

Emission reduction (TPY) 757

Controlled emissions (TPY) 153

UTAC Line 2 GSA PM10

Uncontrolled emissions (TPY) 529

Control efficiency (%) 100%

Emission reduction (TPY) 529

Controlled emissions (TPY) 0

Total Capital Investment $ 99,803,386 Barr 9/28/12 Table 17

Total Direct Annual Cost $ 2,946,123 sum of ESP+ABS+FF

Total Indirect Annual Cost $ 11,211,370 sum of (Overhead for ESP+ABS+FF)+(3% of TCI for Administrative Charges + Insurance) + Capital Recovery Cost

Total annualized cost ($/yr) $ 14,157,494

Cost/ton removed ($/T) $ 11,004