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_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 user 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+09 A*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 60.00 Total 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 $1,167,297 TPC*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 prb PRB 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 1.046983 C/10000

Heat Input H Btu/hr 5.55E+09 5.49E+09 5.52E+09 5.55E+09 A*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 5044 L*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 60 Total Labor Cost

Includes equipment, inatallation,buildings,electrical, retrofit difficulty

BMS ($) = 8778468 8778468 8778468 8778468 SNCR

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 438923 Contractor 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 0.11774 fixed O&M - additional labor cost

FOMM ($/kw-yr) = 0.20 0.20 0.20 0.20 fixed 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 0.48 Variable O&M - urea 

VOMM ($/MWhr) = 0.0001 0.0001 0.0001 0.0001 Variable O&M - dilution water

VOMP ($/MWhr)= Variable O&M Power 0.03 0.03 0.03 0.03 This 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 1074 Lb/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 0.15 TPC*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/kWe
Link 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 prb blends are treated as PRB to be conservative

Coal Factor G 1.05 1.05 1.05 1.05 Bit=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 1.046983 C/10000

Heat Input I Btu/hr 5.55E+09 5.49E+09 5.52E+09 5.55E+09 A*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+02 D*I/10^6*K

Urea rate (100%) N lb/hr 504 519 565 557

M*0.525*60/46

*1.01/.99

Steam Required O lb/hr 569 587 638 629 N*1.13

Aux. Power P % 0.58 0.58 0.58 0.58

0.56*(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 60 Total 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 CECC owners cost - - - -

B2 = 6% of CECC + B1 AFUDC (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 0.24 See 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 0.35 This 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 $5,616

 equals 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