# List of Worksheets **Emissions -** This lists some historical emissions data **Plant Data Summary -** This is key input data and assumptions for the cost estimating worksheets **NOx-LNB** This has the calculations for combustion controls based upon a post combustion control emissions **NOx-SNCR** This has the calculations for SNCR based upon a post combustion control emissions **NOx-SCR** This has the calculations for SCR based upon a post combustion control emissions **Jim Bridger** This summarizes cost and emissions calculations for units at Jim Bridger plant**Facility Name Facility ID (ORISPL)**  **Unit ID**

**2001 2002**  **2003 Avg.**  **2011 2012** **Avg 2001**  **2002 2003** **Avg 2011**  **2012 Avg**  **2001 2002**  **2003 Avg**  **Capacity (MW) Heat Rate (Btu/kW-h)**  **Avg Capacity Factor**

**2003 NOx Control(s) Boiler type**  **Current Comb. Controls WY BART**  **recommendation (30- day rolling avg.)**  **2011NOx 2012.00** 

Jim Bridger 8066 BW71 9,390 7,413 8,494 8,432 3,356 3,283 3,319 0.3980 0.3894 0.3890 0.3921 0.1929 0.1800 0.1865 4.719E+07 3.807E+07 4.367E+07 4.298E+07 530 10464 88.5% LNB w CCOFA Tangentially-fired LNB with CCOFA and SOFA 0.26 0.1929 0.1800 Jim Bridger 8066 BW72 7,568 7,359 7,798 7,575 3,367 3,536 3,452 0.3614 0.3653 0.3848 0.3705 0.1853 0.1868 0.1861 4.189E+07 4.029E+07 4.053E+07 4.090E+07 530 10364 85.0% LNB w CCOFA Tangentially-fired LNB with CCOFA and SOFA 0.26 0.1853 0.1868 Jim Bridger 8066 BW73 8,345 8,313 6,852 7,836 2,857 3,726 3,291 0.3669 0.3676 0.3830 0.3725 0.1977 0.1965 0.1971 4.549E+07 4.523E+07 3.578E+07 4.217E+07 530 10416 87.2% LNB w CCOFA Tangentially-fired LNB with CCOFA and SOFA 0.26 0.1977 0.1965 Jim Bridger 8066 BW74 8,816 7,559 8,006 8,127 3,595 3,217 3,406 0.3895 0.3937 0.4061 0.3964 0.1981 0.1936 0.1959 4.527E+07 3.841E+07 3.943E+07 4.103E+07 530 10470 84.4% LNB w CCOFA Tangentially-fired LNB with CCOFA and SOFA 0.26 0.1981 0.1936 Notes: 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 3 1 1 4 4 1 1

**1** Data is from Air Markets Program Data **2** From NEEDS v 4.10 **3** Calculated from avg heat input for 2001-2003, capacity and heat rate **4** From Jim Bridger BART analysis, WY DEQ, May 28, 2009 **NOx Emissions (tpy) NOx Emissions (lb/MMBtu)**  **Heat Input (MMBtu) NEEDS Data** 

## 1 2 3 4 5 6 8 9 10 11 13 14 15 16 17 18 19 20 21 23

**Capacity baseline rate**  **2001-2003**



## Unique ID Name Plant Code **Unit MW gross**  **Fuel** 

## WY BART recommendation (30- day rolling avg.) **2011 2012**  **2001-2003 Estim. Capac.**  **Factor Heat Rate**  **Burner 2003**  **Controls Add'l** 

**Controls 2011** 

**Controls Add'l** 

**Controls Final NOx with** 

**Comb Controls % red'n from 2003** 

**emissions with comb controls**  **SCR Retrofit Factor**



## 8066_BW71 Jim Bridger 8066.00 BW71 530 C 

## 0.26 0.1929 0.1800 0.39 0.8846 10464 

## T LNBO SOFA LNB with SOFA 0.1800 54.1% 1.25 Tangentially-fired 8066_BW72 Jim Bridger 8066.00 BW72 530 C 

## 0.26 0.1853 0.1868 0.37 0.8500 10364 

## T LNBO SOFA LNB with SOFA 0.1853 50.0% 1.50 Tangentially-fired 8066_BW73 Jim Bridger 8066.00 BW73 530 C 

## 0.26 0.1977 0.1965 0.37 0.8720 10416 

## T LNBO SOFA LNB with SOFA 0.1965 47.2% 1.50 Tangentially-fired 8066_BW74 Jim Bridger 8066.00 BW74 530 C 

## 0.26 0.1981 0.1936 0.40 0.8442 10470 

## T LNBO SOFA LNB with SOFA 0.1936 51.2% 1.25 Tangentially-fired

Notes: 1 2 

## 2 3 4 5 

## 2 2 1 1 6 7.00

Notes **1**

**2 3**  **4**
**5**

**6 7** 

**Economic Assumptions: Capital Recovery Factor**  9.44% **Combustion control legend** Interest Rate 7.00% LNB Low NOx Burner Period (yrs) 20 LNBO Low NOx Burner and Overfire Air OFA Overfire Air **Insurance** 0.30%From Integrated Planning Model ver 4.10 documentationpage 8-11 LNC3 For tangential units, LNB with separated OFA **Property Taxes** 0.90%From Integrated Planning Model ver 4.10 documentationpage 8-11 SOFA Separated OFA
**Cost of Urea (50% wt soln)** 450$/ton 10/12/12 email from Doug Kirk, Fuel Tech Corp. **Cost of Power** 0.06$/kWhr IPM model assumptions **Cost of Oper Labor** 60$/hr IPM model assumptions **Cost of SCR catalyst** 5500$/m3 Cichanowicz, 2010 **Cost of steam** 4.00$/1000lb IPM model assumptions **cost of dilution water** 1.00$/1000gal IPM model assumptions These are subjective factors that account for a presumed retrofit difficulty. The rationale for the selection of each of these factors is described in the memo submitted with this workbook **Annual Reported Rates**



## Rate with combustion controls. This is the lower of the 2011 or 2012 annual average emission rates. This is the current permit limit with the new LNBs and Separated OFA from May 28, 2009 BART analysis by WY DEQ.

Determined from data reported to US EPA and available on the Clean Air Markets Division Web Site Baseline rate for 2003 is average for 2001-2003 reported rates. Capacity factor estimated for 2001-2003 from reported heat input, NEEDS heat rate and NEEDS capacity in MW. Used to calculate annual NOx emissions from average annual rate Heat rate from NEEDS v4.10

### Variable **Designation Units**  **Value Calculation** 

Unique ID 8066_BW71 8066_BW728066_BW73 8066_BW74 Plant Jim Bridger Jim Bridger Jim Bridger Jim Bridger Unit BW71 BW72 BW73 BW74 Unit Size A MW 530 530 530 530user input Gross Heat Rate C Btu/kwhr 10463.96 10363.92 10415.53 10469.83 user input NOx Rate D lb/Mmbtu 0.392130019 0.370511944 0.372488381 0.396420902 user input CF J % 88.46% 85.00% 87.20% 84.42%user input NOx Controls SOFA SOFA SOFA SOFA Retrofit Factor B 1.00 1.00 1.00 1.00 1 = typical retrofit Heat Input I Btu/hr 5.55E+09 5.49E+09 5.52E+09 5.55E+09A*C*1000

NOx Removal Eff K % 54.10% 49.99% 47.25% 51.16%from Plant Data Sheet NOx Removed M lb/hr 1176.45 1017.35 971.50 1125.46 D*I/10^6*K Aux Power Cost T $/kwh 0.06 0.06 0.06 0.06 Steam Cost U $/Klb 4.00 4.00 4.00 4.00 Operating Labor Rate V $/hr 60.00 60.00 60.00 60.00Total Labor Cost

**May 2009 reported cost, excluding AFUDC and Owner's cost** 17500000 7900000 From March 2008 Addendum

**TPC ($) (excluding AFUDC and Owners cost) =** 10,313,623 10,313,623 10,313,623 10,313,623 **Total project cost**

**TPC ($/kw) = 19.5**  **19.5 19.5**  **19.5 Fixed O&M Cost** 
**FOM ($/yr) =** 70000.00 70000.00 70000.00 70000.00**Total Fixed O&M Cost** From may 28, 2009 report from WY DEQ
**VOM ($/MWhr) =** 0.00 0.00 0.00 0.00**Total Variable O&M Cost**

CR = 9.44% 9.44% 9.44% 9.44% Property Taxes and Insurance 1.20% 1.20% 1.20% 1.20% Total Charge Rate 10.64% 10.64% 10.64% 10.64%

**Cost of control - $/Ton** CF 88% 85% 87% 84% Control Efficiency 54% 50% 47% 51% **Uncontrolled Rate** NOx Rate (lb/hr) 2175 2035 2056 2200 NOx Rate (lb/MMBtu) 0.39 0.37 0.37 0.40 NOx (TPY) **8426 7577**  **7853 8133**  **Controlled Rate** NOx Rate (lb/hr) 998 1018 1085 1074 NOx Rate (lb/MMBtu) 0.18 0.19 0.20 0.19 NOx (TPY) **3868 3789**  **4143 3972** 
**Tons/Year Removed** 4558 3787 3710 4161
**Total Cost/year** $1,167,297 $1,167,297 $1,167,297 $1,167,297TPC*CR+FOM+VOM(MW*8760)*CF **$/Ton** $256 $308 $315 $281 Cost from 2009 Addendum to BART report by WY DEQ May 28, 2009. Costs adjusted for owner's costs and AFUDC per factors in Appendices of Dec 2007 reports by CH2MHill

black is per IPM algorithm, red is calcuated from input cost

### Variable **Designation Units**  **Value Calculation** 

Unique ID 8066_BW71 8066_BW72 8066_BW73 8066_BW74 Plant Jim Bridger Jim Bridger Jim Bridger Jim Bridger Unit BW71 BW72 BW73 BW74 Unit Size A MW 530 530 530 530 Heat Rate C Btu/kwhr 10463.96 10363.92 10415.53 10469.83 NOx Rate D lb/Mmbtu 0.18 0.19 0.20 0.19 CF I % 88.46% 85.00% 87.20% 84.42% Type of fuel prb prb prb prbPRB assumed for conservativeness Coal Factor F 1.05 1.05 1.05 1.05 Bit=1; PRB=1.05; Lig=1.07; gas=1 Retrofit Factor B 1 1 1 1 1 = typical retrofit HR Factor G 1.046396 1.036392 1.041553 1.046983C/10000 Heat Input H Btu/hr 5.55E+09 5.49E+09 5.52E+09 5.55E+09A*C*1000

NOx Removal Eff J % 20% 20% 20% 20% percent reduction will be lower at lower NOx levels NOx Removed K lb/hr 2.00E+02 2.04E+02 2.17E+02 2.15E+02 D*H/10^6*j Urea rate (100%) L lb/hr 520.83 531.04 565.94 560.50 K/UF/46*30 0.25 Urea Utilization Factor Water Required M lb/hr 4687 4779 5093 5044L*9 Aux. Power N % 0.05 0.05 0.05 0.05 Dilution water rate O (1000gph) 0.562 0.574 0.611 0.605 M*0.12/1000 http://www.epa.gov/airmarkets/progsregs/epa-ipm/BaseCasev410.html#documentation Urea Cost (50% sol) P $/ton 450 450 450 450

Aux Power Cost Q $/kwh 0.06 0.06 0.06 0.06 Dilution water Cost R $/Kgal 1 1 1 1 Operating Labor Rate S $/hr 60 60 60 60Total Labor Cost

**Includes equipment, inatallation,buildings,electrical, retrofit difficulty**

BMS ($) = 8778468 8778468 8778468 8778468SNCR BMA ($) = APH (SO@> 3lb/Mmbtu); 65000*B*(A*G)^.78 BMB ($) = BOP
BM ($) = 8,778,468 8,778,468 8,778,468 8,778,468 Total base cost BM ($/KW) = 17 17 17 17
**Total Project Cost** A1 = 5% of BM ($) = 438923 438923 438923 438923 Eng. and Construction management A2 = 5% of BM ($) = 438923 438923 438923 438923 Labor adjustment A3 = 5% of BM ($) = 438923 438923 438923 438923Contractor profit/fees
**CECC ($) =** 10,095,238 10,095,238 10,095,238 10,095,238 Cap., Eng. and management **CECC ($/kw) =** 19 19 19 19

B1 = 5% of CECC 504,762 504,762 504,762 504,762 owners cost
**TPC ($) =** 10,600,000 10,600,000 10,600,000 10,600,000 **Total project cost TPC ($/kw) =**  20 20 20 20 **It was assumed that SNCR capital cost was $20/kW per 2008 ICAC White Paper on SNCR**

**Fixed O&M Cost**
FOMO ($/kw-yr) = 0.11774 0.11774 0.11774 0.11774fixed O&M - additional labor cost FOMM ($/kw-yr) = 0.20 0.20 0.20 0.20fixed O&M - additional maintenace, mtl and labor cost
**FOM ($/kw-yr) =** 0.32 0.32 0.32 0.32**Total Fixed O&M Cost**

**Variable O&M Cost**
VOMR ($/MWhr) = 0.44 0.45 0.48 0.48Variable O&M - urea VOMM ($/MWhr) = 0.0001 0.0001 0.0001 0.0001Variable O&M - dilution water VOMP ($/MWhr)= Variable O&M Power 0.03 0.03 0.03 0.03This is not included in the S&L calculations, but should be
**VOM ($/MWhr) =** 0.47 0.48 0.51 0.51**Total Variable O&M Cost**

CR = 9.44% 9.44% 9.44% 9.44% Property Taxes and Insurance 1.20% 1.20% 1.20% 1.20%

Total Charge Rate 10.64% 10.64% 10.64% 10.64%
**Cost of control - $/Ton**

CF 88% 85% 87% 84% Control Efficiency 20% 20% 20% 20% **Uncontrolled Rate** (lb/Mbtu*Heat Input)/1000000 NOx Rate (lb/hr) 998 1018 1085 1074Lb/hr*8760*CF/2000 NOx Rate (lb/MMBtu) 0.18 0.1853 0.1965 0.1936

NOx (TPY) **3868 3789**  **4143 3972**  **Controlled Rate** NOx Rate (lb/hr) 799 814 868 859 NOx Rate (lb/MMBtu) 0.14 0.15 0.16 0.15TPC*CR+(FOM*MW)+VOM(MW*8760)*CF

NOx (TPY) 3094 3031 3314 3178
**Tons/Year Removed 774**  **758 829**  **794**
**Total Cost/year** $3,235,461 $3,193,662 $3,362,773 $3,278,694 **$/Ton** $4,182 $4,214 $4,058 $4,127 Note: Capital Cost equations were modified to be a constant $20/kWeLink to Sargent and Lundy memo **Variable Designation**  **Units Value**  **Calculation**

Unique ID 8066_BW71 8066_BW72 8066_BW73 8066_BW74 Plant Jim Bridger Jim Bridger Jim Bridger Jim Bridger Unit BW71 BW72 BW73 BW74 Unit Size A MW 530 530 530 530 Gross Heat Rate C Btu/kwhr 10463.96 10363.92 10415.53 10469.83 NOx Rate D lb/Mmbtu 0.18 0.19 0.20 0.19 CF J CF 88.5% 85.0% 87.2% 84.4% Type of Coal F prb prb prb prbblends are treated as PRB to be conservative Coal Factor G 1.05 1.05 1.05 1.05Bit=1; PRB=1.05; Lig=1.07 **Retrofit Factor B**  1.25 1.5 1.5 1.25**1 = typical retrofit** HR Factor H 1.046396 1.036392 1.041553 1.046983C/10000 Heat Input I Btu/hr 5.55E+09 5.49E+09 5.52E+09 5.55E+09A*C*1000 CF J 88.5% 85.0% 87.2% 84.4%read from Plant Data table NOx Removal Eff K % 72.2% 73.0% 74.6% 74.2%for NOx>0.5lb/Mbtu=90%; <.5 = (NOx-0.05)/NOx

NOx Removal factor L 0.90 0.91 0.93 0.93 NOx Removed M lb/hr 7.21E+02 7.43E+02 8.09E+02 7.97E+02D*I/10^6*K

Urea rate (100%) N lb/hr 504 519 565 557M*0.525*60/46 *1.01/.99 Steam Required O lb/hr 569 587 638 629N*1.13

Aux. Power P % 0.58 0.58 0.58 0.580.56*(G*H)^0.4 3 Urea Cost (50% sol) R $/ton 450 450 450 450 Catalyst Cost S $/m3 5500 5500 5500 5500 Aux Power Cost T $/kwh 0.06 0.06 0.06 0.06 Steam Cost U $/Klb 4 4 4 4 Operating Labor Rate V $/hr 60 60 60 60Total Labor Cost

**Capital Cost Calculation (includes equipment, installation, buildings, foundations,electrical, minor physical/chemical ww treatment and retrofit difficulty)**

BMR ($) = SCR 77,134,209 91,947,585 92,754,631 77,586,606 BMF ($) = base reagent preparation cost 2,124,529 2,140,712 2,186,415 2,178,343 BMA ($) = APH (SO@> 3lb/Mmbtu) BMB ($) = fans/aux power 6,887,496 8,231,715 8,248,907 6,889,118
BM ($) = Total base cost 86,146,234 102,320,012 103,189,952 86,654,067 BM ($/KW) = 163 193 195 163
**Total Project Cost** A1 = 10% of BM ($) = Eng. and Construction management 8,614,623 10,232,001 10,318,995 8,665,407 A2 = 10% of BM ($) =Labor adjustment 8,614,623 10,232,001 10,318,995 8,665,407 A3 = 10% of BM ($) =Contractor profit/fees 8,614,623 10,232,001 10,318,995 8,665,407

**CECC ($) =** Cap., Eng. and management 111,990,104 133,016,015 134,146,938 112,650,287 **CECC ($/kw) =** 211 251 253 213

B1 = 5% of CECCowners cost

- - - - B2 = 6% of CECC + B1AFUDC (2yr cycle)

- - - -

**TPC ($) = Total project cost**  111,990,104 133,016,015 134,146,938 112,650,287 **TPC ($/kw) =** $211 $251 $253 $213

**Fixed O&M Cost**
FOMO ($/kw-yr) = fixed O&M - additional labor cost 0.1 0.1 0.1 0.1 FOMM ($/kw-yr) = fixed O&M - additional maintenace, mtl and labor cost 0.6 0.6 0.6 0.6

**FOM ($/kw-yr) = Total Fixed O&M Cost**  0.68 0.68 0.68 0.68

**Variable O&M Cost**
VOMR ($/MWhr) = Variable O&M - urea 0.43 0.44 0.48 0.47 VOMW ($/MWhr) = Variable O&M - catalyst disposal 0.23 0.24 0.24 0.24See pdf pg 10/79 at http://www.epa.gov/airmarkets/progsregs/epa-ipm/docs/SuppDoc410MATS.pdf VOMP ($/MWhr)= Variable O&M Power 0.35 0.35 0.35 0.35This is not included in the S&L calculations, but should be VOMM ($/MWhr) = Variable O&M - steam 0.004 0.004 0.005 0.005
**VOM ($/MWhr) = Total Variable O&M Cost**  1.01 1.03 1.07 1.07

CR = 9.44% 9.44% 9.44% 9.44% Property Taxes and Insurance 1.20% 1.20% 1.20% 1.20%

Total Charge Rate 10.64% 10.64% 10.64% 10.64%
**Cost of control - $/Ton**CF 88% 85% 87% 84% Control Efficiency 72% 73% 75% 74% **Uncontrolled Rate** (lb/Mbtu*Heat Input)/1000000 NOx Rate (lb/hr) Lb/hr*8760*CF/2000 998 1018 1085 1074 NOx Rate (lb/MMBtu) 0.180 0.185 0.197 0.194

NOx (TPY) 3868 3789 4143 3972 **Controlled Rate** NOx Rate (lb/hr) 277.3 274.6 276.0 277.5 NOx Rate (lb/MMBtu) TPC*CR+(FOM*MW)+VOM(MW*8760)*CF 0.05 0.05 0.05 0.05

NOx (TPY) 1074 1022 1054 1026
**Tons/Year Removed 2794**  **2767 3089**  **2946**
**Total Cost/year** $16,425,339 $18,590,683 $18,968,124 $16,545,040 **$/Ton** $5,880 $6,719 $6,141 $5,616equals K/80% based upon 8/10/12 email from Sargent & Lundy, and See pdf pg 10/79 at http://www.epa.gov/airmarkets/progsregs/epa-

# 8066_BW71 **Comb Control (CC) SNCR**  **SCR CC and SNCR**  **CC and SCR**

Capital Cost, $/kW $19 $20 $211 $39 $231 Control Efficiency 54% 20% 72% 63% 87% **Uncontrolled Rate** NOx Rate (lb/hr) 2175 998 998 2175 2175 NOx Rate (lb/MMBtu) 0.39 0.18 0.18 0.39 0.39 NOx (TPY) 8426 3868 3868 8426 8426 **Controlled Rate** NOx Rate (lb/hr) 998 799 277 798.61 277.29 NOx Rate (lb/MMBtu) 0.18 0.14 0.05 0.14 0.05 NOx (TPY) 3868 3094 1074 3094.39 1074.44
Tons/Year Removed 4558 774 2794 5332.02 7351.97
Total Cost/year $1,167,297 $3,235,461 $16,425,339 $4,402,757 $17,592,636 $/Ton $256 $4,182 $5,880 $826 $2,393 $/ton Incremental $6,530 $4,182 $6,530

**8066_BW72 Comb Control (CC)**  **SNCR SCR**  **CC and SNCR CC and SCR**  Capital Cost, $/kW $19 $20 $251 $39 $270 Control Efficiency 50% 20% 73% 60% 87% **Uncontrolled Rate** NOx Rate (lb/hr) 2035 1018 1018 2035 2035 NOx Rate (lb/MMBtu) 0.37 0.19 0.19 0.37 0.37 NOx (TPY) 7577 3789 3789 7,577 7,577 **Controlled Rate** NOx Rate (lb/hr) 1018 814 275 814 275 NOx Rate (lb/MMBtu) 0.19 0.15 0.05 0.15 0.05 NOx (TPY) 3789 3031 1022 3,031 1,022
Tons/Year Removed 3787 758 2767 4,545 6,554
Total Cost/year $1,167,297 $3,193,662 $18,590,683 $4,360,958 $19,757,979 $/Ton $308 $4,214 $6,719 $959 $3,015 $/ton Incremental $7,664 $4,214 $7,664

# 8066_BW73 **Comb Control (CC) SNCR**  **SCR CC and SNCR**  **CC and SCR**

Capital Cost, $/kW $19 $20 $253 $39 $273 Control Efficiency 47% 20% 75% 58% 87% **Uncontrolled Rate** NOx Rate (lb/hr) 2056 1085 1085 2056 2056 NOx Rate (lb/MMBtu) 0.37 0.20 0.20 0.37 0.37 NOx (TPY) 7853 4143 4143 7,853 7,853 **Controlled Rate** NOx Rate (lb/hr) 1085 868 276 868 276 NOx Rate (lb/MMBtu) 0.20 0.16 0.05 0.16 0.05 NOx (TPY) 4143 3314 1054 3,314 1,054
Tons/Year Removed 3710 829 3089 4,539 6,799
Total Cost/year $1,167,297 $3,362,773 $18,968,124 $4,530,069 $20,135,420 $/Ton $315 $4,058 $6,141 $998 $2,961 $/ton Incremental $6,905 $4,058 $6,905

**8066_BW74 Comb Control (CC)**  **SNCR SCR**  **CC and SNCR CC and SCR**  Capital Cost, $/kW $19 $20 $213 $39 $232 Control Efficiency 51% 20% 74% 61% 87% **Uncontrolled Rate** NOx Rate (lb/hr) 2200 1074 1074 2200 2200 NOx Rate (lb/MMBtu) 0.40 0.19 0.19 0.40 0.40 NOx (TPY) 8133 3972 3972 8,133 8,133 **Controlled Rate** NOx Rate (lb/hr) 1074 859 277 859 277 NOx Rate (lb/MMBtu) 0.19 0.15 0.05 0.15 0.05 NOx (TPY) 3972 3178 1026 3,178 1,026
Tons/Year Removed 4161 794 2946 4,956 7,108
Total Cost/year $1,167,297 $3,278,694 $16,545,040 $4,445,990 $17,712,336 $/Ton $281 $4,127 $5,616 $897 $2,492 $/ton Incremental $6,165 $4,127 $6,165