Appendix A

Cost Estimate and Basis

This appendix is included to show the detailed costs estimate and to describe the basis of the estimate. The estimate is based on 

previous studies and cost estimates for the addition of air pollution control equipment to Unit 1 at Nebraska City. A study was 

completed in 2002 that included obtaining estimates for equipment vendors in 2002. Due to current market conditions, equipment 

vendors are unwilling to provide quotes for studies. Other than a single estimate for SDA and fabric filter equipment, the cost estimate 

was based on escalating quotes received in 2002 and developing actual estimates for installation and support costs.

OPPD BART Analysis

Cost Estimate and Basis

Page A-1

HDR Engineering, Inc.

July 2007
DETAILED COST SUMMARY, $ US 2007

OPPD -NC1

I. SDA SYSTEM SITEWORK 750,000

II. DEMOLITION FOR SDA SYSTEM 150,000

III. BURNER MODIFICATIONS 17,400,000

IV. SCR EQUIPMENT 160,880,000

V. SDA - LIME PREPARATION EQUIPMENT AND BUILDING 10,500,000

VI. SDA/FF SYSTEM 103,120,000

VII. ID BOOSTER FAN EQUIPMENT 6,600,000

VIII.OUTAGE COST 22,930,000

IX. ASH HANDLING EQUIPMENT 1,000,000

X. AIR HEATERS 8,000,000

XI. ELECTRICAL MODIFICATIONS 2,860,000

SUBTOTAL CONSTRUCTION AND EQUIPMENT 334,190,000

CONTINGENCY (25%) 83,550,000

DESIGN/ENGINEERING/CM (10%) 41,770,000

TOTAL PER UNIT CAPITAL COST 459,510,000

ANNUAL AMORTIZED CAPITAL COST (See Note 1) 36,870,000

TOTAL STATION CAPTIAL COST 459,510,000

ANNUAL AMORTIZED CAPITAL COST (See Note 1) 36,870,000

OPPD BART Analysis

NC-1 Capital Cost

Page A-2

HDR Engineering, Inc.

July 2007
Item Qnty Unit Price Item Cost

I. SDA SYSTEM SITEWORK (See Note 2)

Sitework 1 750,000 750,000

Earthwork

 General Earthwork

 Finishing Grading & Seeding

Asphalt Roadways

Site Utilities

 Fire Protection

 Water Supply

 Sewer System

 Electrical

Site Drainage

Fencing

Landscaping

Subtotal 750,000

II. DEMOLITION FOR SDA SYSTEM

Demo Ductwork 1 150,000 150,000

Subtotal 150,000

III. BURNER MODIFICATIONS

Low NOx Burner Upgrade 48 300,000 14,400,000

Over fire air Modifications 1 3,000,000 3,000,000

Subtotal 17,400,000

IV. SCR EQUIPMENT

Equipment (See Note 3)

SCR Equipment 1 70,000,000 70,000,000

Ash Handling Equipment 1 2,000,000 2,000,000

Including Structural Steel

Equipment Installation 84,072,000

Erect SCR

Install Air Heater

Install Ammonia Storage and Delivery System

Associated Mechanical

Associated Electrical

Cut over to operating unit

Start-up and Shakedown

Crane rental

Foundations (See Note 4) 60'x60'x96"

Steel reinforced concrete, $350/cy 1,067 350 373,333

Ductwork 300', 10'x20', 3/8"

Steel ductwork, 500lb/ft3, $9/lb 281,250 9 2,531,250

Insulation, 25% of ductwork 1 632,813 632,813

Ductwork support/bracing, 25% of ductwork 1 1,265,625 1,265,625

Subtotal 160,880,000

OPPD BART Analysis

NC-1 Capital Cost

Page A-3

HDR Engineering, Inc.

July 2007
V. SDA - LIME PREPARATION EQUIPMENT AND BUILDING

Lime Equipment 1 5,000,000 5,000,000

Lime Storage Silo

Feeders

Slaker

Grit screens

Slurry Tank

Slurry Pumps

Dilution water tank

Dilution Water Pumps

Air Compressors

Equipment Installation 1 3,000,000 3,000,000

Foundations

Install Lime Preparation System (included in Lime System costs)

Ductwork

Associated Mechanical

Associated Electrical

Start-up and Shakedown

Building 1 2,500,000 2,500,000

Structural Steel

Concrete Slabwork

Concrete Footings/Foundation

Overhead Doors

Building Fire Protection

Mechanical

Electrical

Subtotal 10,500,000

VI. SDA/FF SYSTEM

Equipment (See Note 5)

Scrubber 1 23,000,000 23,000,000

Filter Baghouse 1 20,000,000 20,000,000

Ash Handling Equipment 1 500,000 500,000

Equipment Installation 43,761,600

Erect SDA

Install Ash Handling System

Associated Mechanical

Associated Electrical

Cut over to operating unit

Start-up and Shakedown

Crane rental

Ductwork 1200', 10'x20', 3/8"

Steel ductwork, 500lb/ft3, $9/lb 1,125,000 9 10,125,000

Insulation, 25% of ductwork 1 2,531,250 2,531,250

Ductwork support/bracing, 25% of ductwork 1 2,531,250 2,531,250

Foundations (2) 60'x60'x96", (2) 30'x30'x96"

Steel reinforced concrete 2,667 250 666,667

Subtotal 103,120,000

OPPD BART Analysis

NC-1 Capital Cost

Page A-4

HDR Engineering, Inc.

July 2007
VII. ID BOOSTER FAN EQUIPMENT

ID Booster Fan (See Note 6) 6,600,000

Total 6,600,000

VIII.OUTAGE COST

Electrical Outage Cost $30/MWhr 7 weeks

 MWhrs = #weeks * 168 hr/wk * MW capacity 764,400 30 22,932,000

Subtotal 22,930,000

IX. ASH HANDLING EQUIPMENT

Ash Silo for SDA System 1 750,000 750,000

Ash Handling misc equipment for SDA System 1 250,000 250,000

Subtotal 1,000,000

X. AIR HEATERS

 For SCR System (See Note 7) 1 8,000,000 8,000,000

Subtotal 8,000,000

XI. ELECTRICAL MODIFICATIONS

 Cost = $200/kW upgraded service

 New switchgear/transformers for increased electrical load - SDA System 8,032 200 1,610,000

 New switchgear/transformers for Increased electrical load - SCR System 6,232 200 1,250,000

Subtotal 2,860,000

Subtotal I through X 334,190,000

Notes:

(1) Interest rate 5% and amortization period 20 years

(2) Allowance for relocation of utilities, roadways, and fencing as well as any general earthwork required.

(3)

(4)

(5)

(6)

(7) Cost to replace air heater baskets with baskets compatible with ammonia compounds.

Vendors were unwilling to provide quotes due to market conditions. Estimate was based on 2002 quotes for similar

sized units, escalated to 2007 dollars and adjusted for capacity. Equipment cost is half of total installed cost.

Escalation is approximately 68% over the time period.

Based on mat foundation under equipment footprint.

Based on Alstom quote for equipment.

ID fan sized for both SCR and SDA.

OPPD BART Analysis

NC-1 Capital Cost

Page A-5

HDR Engineering, Inc.

July 2007
BURNER MODIFICATIONS

CONCEPTUAL COST SUMMARY, 2007 $

OPPD

NC-1

Technology

NOx Control Low NOx Burners, OFA

Unit Size, kW 650,000

Capital Costs

I. SDA SYSTEM SITEWORK $0

II. DEMOLITION FOR SDA SYSTEM $0

III. BURNER MODIFICATIONS $17,400,000

IV. SCR EQUIPMENT $0

V. SDA - LIME PREPARATION EQUIPMENT AND BUILDING $0

VI. SDA/FF SYSTEM $0

VII. ID BOOSTER FAN EQUIPMENT $0

VIII. OUTAGE COST $0

IX. ASH HANDLING EQUIPMENT $0

X. AIR HEATERS $0

XI. ELECTRICAL MODIFICATIONS $0

SUBTOTAL CONSTRUCTION AND EQUIPMENT $17,400,000

CONTINGENCY (10%) $1,740,000

DESIGN/ENGINEERING/CM (10%) $1,910,000

TOTAL PER UNIT CAPITAL COST $21,050,000

ANNUAL AMORTIZED CAPITAL COST (COST X CCRF) $1,690,000

Operating Costs

I. LABOR $0

II. REAGENTS AND SUPPLIES $0

III. EQUIPMENT MAINTENANCE $0

IV. UTILITIES $0

V. ASH REVENUE AND/OR DISPOSAL COST $0

SUBTOTAL OPERATION & MAINTENANCE $0

CONTINGENCY (25%) $0

TOTAL PER UNIT ANNUAL OPERATION & MAINTENANCE COST $0

TOTAL PER UNIT LEVELIZED ANNUAL O&M COST (COST X OMLF) $0

TOTAL PER UNIT ANNUAL AMORITIZED CAPITAL AND LEVELIZED

O&M COST $1,690,000

OPPD BART Analysis

NC-1 Burner Mods Cost

Page A-6

HDR Engineering, Inc.

Ju;y 2007
SDA SCRUBBER & FILTER BAGHOUSE

CONCEPTUAL COST SUMMARY, 2007 $

OPPD

NC-1

Technology

SO2 Control SDA & New Baghouse

Unit Size, kW 650,000

Capital Costs

I. SDA SYSTEM SITEWORK $750,000

II. DEMOLITION FOR SDA SYSTEM $150,000

III. BURNER MODIFICATIONS $0

IV. SCR EQUIPMENT $0

V. SDA - LIME PREPARATION EQUIPMENT AND BUILDING $10,500,000

VI. SDA/FF SYSTEM $103,120,000

VII. ID BOOSTER FAN EQUIPMENT $6,600,000

VIII. OUTAGE COST $22,930,000

IX. ASH HANDLING EQUIPMENT $1,000,000

X. AIR HEATERS $0

XI. ELECTRICAL MODIFICATIONS $1,610,000

SUBTOTAL CONSTRUCTION AND EQUIPMENT $146,660,000

CONTINGENCY (25%) $36,670,000

DESIGN/ENGINEERING/CM (10%) $18,330,000

TOTAL PER UNIT CAPITAL COST $201,660,000

ANNUAL AMORTIZED CAPITAL COST (COST X CCRF) $16,180,000

Operating Costs

I. LABOR $420,000

II. REAGENTS AND SUPPLIES $3,310,000

III. EQUIPMENT MAINTENANCE $1,700,000

IV. UTILITIES $4,550,000

V. ASH REVENUE AND/OR DISPOSAL COST $510,000

SUBTOTAL OPERATION & MAINTENANCE $10,490,000

CONTINGENCY (25%) $2,622,500

TOTAL PER UNIT ANNUAL OPERATION & MAINTENANCE COST $13,112,500

TOTAL PER UNIT LEVELIZED ANNUAL O&M COST (COST X OMLF) $18,540,000

TOTAL PER UNIT ANNUAL AMORITIZED CAPITAL AND LEVELIZED

O&M COST $34,720,000

OPPD BART Analysis

NC-1 SDA Cost

Page A-7

HDR Engineering, Inc.

Ju;y 2007
SCR NOX REMOVAL SYSTEM

CONCEPTUAL COST SUMMARY, 2007 $

OPPD

NC-1

Technology

NOx Control Low NOx Burners, SCR

Unit Size, kW 650,000

Capital Costs

I. SDA SYSTEM SITEWORK $0

II. DEMOLITION FOR SDA SYSTEM $0

III. BURNER MODIFICATIONS $0

IV. SCR EQUIPMENT $160,880,000

V. SDA - LIME PREPARATION EQUIPMENT AND BUILDING $0

VI. SDA/FF SYSTEM $0

VII. ID BOOSTER FAN EQUIPMENT $0

VIII. OUTAGE COST $22,930,000

IX. ASH HANDLING EQUIPMENT $0

X. AIR HEATERS $8,000,000

XI. ELECTRICAL MODIFICATIONS $1,250,000

SUBTOTAL CONSTRUCTION AND EQUIPMENT $193,060,000

CONTINGENCY (25%) $48,265,000

DESIGN/ENGINEERING/CM (10%) $24,130,000

TOTAL PER UNIT CAPITAL COST $265,455,000

ANNUAL AMORTIZED CAPITAL COST (COST X CCRF) $21,300,000

Operating Costs

I. LABOR $210,000

II. REAGENTS AND SUPPLIES $2,400,000

III. EQUIPMENT MAINTENANCE $2,410,000

IV. UTILITIES $4,550,000

V. ASH REVENUE AND/OR DISPOSAL COST $0

SUBTOTAL OPERATION & MAINTENANCE $9,570,000

CONTINGENCY (25%) $2,390,000

TOTAL PER UNIT ANNUAL OPERATION & MAINTENANCE COST $11,960,000

TOTAL PER UNIT LEVELIZED ANNUAL O&M COST (COST X OMLF) $16,910,000

TOTAL PER UNIT ANNUAL AMORITIZED CAPITAL AND LEVELIZED

O&M COST $38,210,000

OPPD BART Analysis

NC-1 SCR Cost

Page A-8

HDR Engineering, Inc.

July 2007
SDA SYSTEM OPERATING COST, $ US 2007

NC1 

I. LABOR 416,00

II. REAGENTS AND SUPPLIES 3,306,00

III. EQUIPMENT MAINTENANCE 1,704,00

IV. UTILITIES 4,550,00

V. ASH REVENUE AND/OR DISPOSAL COST 509,00

SUBTOTAL OPERATION & MAINTENANCE 10,485,00CONTINGENCY (25%) 2,621,00TOTAL PER UNIT ANNUAL OPERATION & MAINTENANCE COST 13,106,00TOTAL STATION ANNUAL OPERATION & MAINTENANCE COST 13,106,00Unit Annual Operating Hours 7,88Item Qnty Units Unit Price Item Cos

OPPD BART Analysis

NC-1 SDA Ops Cost

Page A-9
I. LABOR

Operators 4

Equipment Operator 8,320 hr 50.00 416,00

Subtotal 416,00Notes: 

II. REAGENTS AND SUPPLIES

Lime 23,569 Tons 125 2,946,00

Ammonia 0 Tons 0 

SDA Filter Replacement (18,000 bags, $100/bag, once per 5 years) 0.20 LS 1,800,000 360,00

SCR Catalyst Replacement 0 LS 0 

Subtotal 3,306,00Notes: SCR catalyst replacement is based on 0.28 mils/kWh.

III. EQUIPMENT MAINTENANCE

(1.5% of cost) 1 1,704,300 1,704,30Subtotal 1,704,00

IV. UTILITIES

Electricity 51,494,862 kWh 0.03 1,545,00

Electrical Capacity 6,532 kW 460 3,005,00

Subtotal 4,550,00Notes: 

V. ASH REVENUE AND/OR DISPOSAL COST

Saleable Ash Tons 

Additional ash requiring disposal (previously saleable ash) + lost revenue 0 Tons 12 

Additional ash requiring disposal (2.4 lbs CaSO4 per lb CaO) 56,566 Tons 9 509,00

Subtotal 509,00Subtotal I through V 10,485,00

OPPD BART Analysis

NC-1 SDA Ops Cost

Page A-10
SCR SYSTEM OPERATING COST, $ US 2007

NC1 

I. LABOR 208,00

II. REAGENTS AND SUPPLIES 2,400,00

III. EQUIPMENT MAINTENANCE 2,413,00

IV. UTILITIES 4,550,00

V. ASH REVENUE AND/OR DISPOSAL COST 

SUBTOTAL OPERATION & MAINTENANCE 9,571,00CONTINGENCY (25%) 2,393,00TOTAL PER UNIT ANNUAL OPERATION & MAINTENANCE COST 11,964,00TOTAL STATION ANNUAL OPERATION & MAINTENANCE COST 11,964,00Unit Annual Operating Hours 7,88

OPPD BART Analysis

NC-1 SCR Ops Cost

Page A-11
Item Qnty Units Unit Price Item Cos

I. LABOR

Operators 2

Equipment Operator (1),(2) 4,160 hr 50.00 208,00

Subtotal 208,00Notes: 

II. REAGENTS AND SUPPLIES

Lime 0 Tons 0 

Ammonia 3,217 Tons 300 965,00

SDA Filter Replacement (18,000 bags, $100/bag, once per 5 years) 0 LS 

SCR Catalyst Replacement 1 LS 1,434,888 1,435,00

Subtotal 2,400,00SCR catalyst replacement is based on 0.28 mils/kWh.

III. EQUIPMENT MAINTENANCE

(1.5% of cost) 1 2,413,200 2,413,20Subtotal 2,413,00

IV. UTILITIES

Electricity 51,494,862 kWh 0.03 1,545,00

Electrical Capacity 6,532 kW 460 3,005,00

Subtotal 4,550,00Notes: 

V. ASH REVENUE AND/OR DISPOSAL COST

Saleable Ash Tons 

Additional ash requiring disposal (previously saleable ash) + lost revenue 0 Tons 12 

Additional ash requiring disposal (2.4 lbs CaSO4 per lb CaO) 0 Tons 9 

Subtotal Subtotal I through V 9,571,00

OPPD BART Analysis

NC-1 SCR Ops Cost

Page A-12
NCS 1

Unit(s) Size, kW 650,000

Unit(s) Heat, Btu/kWh 9,790

Flue Gas Flow, acfm 2,665,000

Additional SCR, SDA, BH and Ductwork ∆P, inwg 23.3

Lime Usage

Lime Usage, lb/hr 5,979

Annual Lime Usage, tpy (1) 23,569

Ammonia Usage

Ammonia Usage, lb/hr 816

Annual NH4 Usage, tpy (1) 3,217

Water Usage

Slaker Water, lb/hr 18,187

Dilution Water, lb/hr 239,556

Total Water Usage, lb/hr 257,743

Total Water Usage, gpm 515

Total Annual Water Usage, kgpy (1) 243,845

Power Usage

Atomizer demand, kW 740

ID booster fans demand, kW 12,183

SCR motors demand, kW 140

SDA motors demand, kW 1,200

Total demand, kW 13,063

Annual power usage, kWh/yr (1) 102,989,723

Parasitic Power, % of net 2.01%

Notes:

(1) Annual utility usage based on 8760 hr/yr and 90% unit capacity factor

OPPD BART Analysis

Utility Usage

Page A-13

HDR Engineering, Inc.

July 2007