**UTA C 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

### UTA**C Line 2 GSA**

**Capital Cost factors for ESPs--OA QPS Control Cost Manual, Chap 6.2** 

Cost Item Factor Cost Direct Costs Purchased equipment costs ESP + auxiliary equipment, EC A $5,057,000 Instrumentation 0.10A $505,700 Sales taxes 0.07A $343,876 Freight 0.05A $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 $** 

### UTA**C Line 2 GSA**

**Capital Cost factors for Gas A bsorbers--OA** **QPS 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--OA QPS 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 $