## SCR

Option Uncontrolled NOx (lb/MMBtu)Emissions Limit

(lb/MMBtu)% Control Baseline 0.9 0.15 83.33% Option 1 0.9 0.11 87.78% Option 2 0.9 0.08 91.11% Option 3 0.3 0.11 63.33%

SNCR
Option Uncontrolled NOx (lb/MMBtu)Emissions Limit

(lb/MMBtu)% Control Baseline 0.3 0.15 50.00% Option 1 0.3 0.15 50.00% Option 2 0.3 0.15 50.00% Option 3 0.3 0.15 50.00%

## High Sulfur MediumSulfur Low Sulfur 3.00% 1.50% 0.50% 5.11 2.57 0.93 Emissions Rate (lb/MMBtu)% ControlL/G RatioReagentEmissions Rate (lb/MMBtu)% ControlL/G RatioReagentEmissions Rate (lb/MMBtu)% ControlL/G RatioReagent 0.60 88.3%1001.05 0.60 76.7%95 1.02 0.28 69.9%95 1.020 0.21 95.9%1301.05 0.21 91.8%105 1.05 0.21 77.4%96 1.025 0.15 97.1%1401.05 0.15 94.2%115 1.05 0.15 83.9%97 1.030 0.12 97.7%1601.10 0.12 95.3%125 1.05 0.12 87.1%98 1.050

lignite lignite 1.50% 0.94% 3.97 2.51 Emissions Rate (lb/MMBtu)% ControlL/G RatioReagentEmissions Rate (lb/MMBtu)% ControlL/G RatioReagent 0.60 84.9%971.04 0.60 76.1%95 1.02 0.21 94.7%1241.05 0.21 91.6%105 1.05 0.16 96.0%1301.05 0.15 94.0%115 1.05 0.15 96.2%1311.05 0.12 95.2%125 1.05 0.12 97.0%1401.05 0.075 97.0%140 1.05

SO2 Control

L/G Ratio 70% 95 90% 100 95% 125 97% 140 98% 160

## Reverse Air ESP

Device % ReductionEmissions Rate

(lb/MMBtu)Pressure Drop

(in H2O)Gas to Cloth

Ratio Bag

MaterialsBag cost

($/ft2) Emissions Rate (lb/MMBtu)Pressure

Drop (in H2O) 99.670.030 5 2.16Fiberglass1.01 0.030 4.19 99.830.020 7 2.11Nomex 1.01 0.020 4.37 99.840.018 8 2.09Nomex 1.65 0.018 4.39 99.870.015 14 2.04Ry ton 2.02 0.015 4.46 99.900.012 18 1.97Ry ton 2.02 0.012 4.48

Pulse Jet

Device % ReductionEmissions Rate

(lb/MMBtu)Pressure Drop

(in H2O)Gas to Cloth

Ratio Bag

MaterialsBag cost

($/ft2) 99.670.030 5 3.88Fiberglass1.60 99.830.020 7 3.79Nomex 1.60 99.840.018 8 3.77Nomex 2.62 99.870.015 14 3.61Ry ton 3.20 99.900.012 18 3.40Ry ton 3.20

# CUECost **Coal Utility Environmental Cost**

**Version 1, November 25, 1998 (revised 2-9-00 as CUECost3.xls)**

Developed for EPA by Raytheon Engineers & Constructors and Eastern Research Group

**Current Date: 30-Nov-12**  

# GoTo Buttons **Print Options Inputs:** 

**Calculations and Costs:**

# APC Technology Choices **Suggested Default**  **Description Units**  **Range Values** **Input 1 Input 2** **Input 3 Input 4** **Input 5**

FGD Process Integer 1 or 2 1 1 1 1 1 1 (1 = LSFO, 2 = LSD) Particulate Control Integer 1 or 2 1 1 1 1 1 1 (1 = Fabric Filter, 2 = ESP) NOx Control Integer 1 - 4 1 1 1 1 1 1 (1 = SCR, 2 = SNCR, 3 = LNBs, 4 = NGR) **Default Values will be selected when "D" is**  **input.**



# INPUTS
**Default**

**Description Units**  **Range Values** **Input 1 Input 2** **Input 3 Input 4** **Input 5**


# General Plant Technical Inputs

Location - State Abbrev. All States PA OH OH OH OH OH MW Equivalent of Flue Gas to Control System MW 100-2000 160 500 500 500 500 500 Plant Heat Rate (w

/o Air Pollution Control) Btu/kWhr 10,5008,9798,9798,9798,9798,97938.0% Plant Capacity Factor % 40-90% 65% 85%85% 85% 85%85% Percent Excess Air in Boiler % 120%120%120%120%120%120% Air Heater Inleakage % 12% 12% 12% 12% 12% 12% Air Heater Outlet Gas Temperature °F 320 320 320 320 320 320 Inlet Air Temperature °F 80 80 80 80 80 80 Ambient Absolute Pressure In. of Hg 29.4 29.4 29.4 29.4 29.4 29.4 Pressure After Air Heater In. of H2O -12 -12 -12 -12 -12 -12 Moisture in Air lb/lb dry air 0.0130.0130.0130.0130.0130.013 Ash Split: Fly Ash % 80% 80%80% 80% 80%80% Bottom Ash % 20% 20%20% 20% 20%20%

## Seismic Zone Integer 1-5 1 1 1 1 1 1

Retrofit Factor Integer 1.0-3.0 1 1 1 1 1 1 (1.0 = new, 1.3 = medium, 1.6 = difficult) Select Coal Integer 1-8 1 8 8 8 8 8 Is Selected Coal a Powder River Basin Coal? Yes / No See Column K No No No No No No 

# Coals Available in Library Coal 1, Wyoming PRB: 8,227 Btu, 0.37% S, 5.32% ash Coal 2, Armstrong, PA: 13,100 Btu, 2.6% S, 9.1% ash Coal 3, Jefferson, OH: 11,922 Btu, 3.43% S, 13% ash Coal 4, Logan, WV: 12,058 Btu, 0.89% S, 16.6% ash Coal 5, No. 6 Illinois: 10,100 Btu, 4% S, 16% ash Coal 6, Rosebud, MT: 8,789 Btu, 0.56% S, 8.15% ash Coal 7, Lignite, ND: 7,500 Btu, 0.94% S, 5.9% ash Coal 8, "User Specified": 4,641 Btu, 0.745712155108128% S, 37.5838926174497% ash 

# Economic Inputs

Cost Basis -Year Dollars Year 199820042004 2004 20042004 Sevice Life (levelization period) Years 30 30 30 30 30 30 Inflation Rate % 3.00%3.00%3.00%3.00%3.00%3.00% After Tax Discount Rate (current $'s) % 9.20%9.20%9.20%9.20%9.20%9.20% AFDC Rate (current $'s) % 10.80%10.80%10.80%10.80%10.80%10.80% First-year Carrying Charge (current $'s) % 22.30%22.30%22.30%22.30%22.30%22.30% Levelized Carrying Charge (current $'s) % 16.90%16.90%16.90%16.90%16.90%16.90% Levelized Carrying Charge (current $'s) First-year Carrying Charge (constant $'s) % 15.70%15.70%15.70%15.70%15.70%15.70% Levelized Carrying Charge (constant $'s) % 11.70%11.70%11.70%11.70%11.70%11.70% Sales Tax % 6% 6% 6% 6% 6% 6% Escalation Rates: Consumables (O&M) % 3% 3% 3% 3% 3% 3% Capital Costs: Is Chem. Eng. Cost Index available? Yes / No Yes Yes Yes Yes Yes Yes If "Yes" input cost basis CE Plant Index.Integer 388425.20425.20425.20425.20425.20 If "No" input escalation rate. % 3% 3% 3% 3% 3% 3% Construction Labor Rate $/hr $35$70.00$70.00$70.00$70.00$70.00 Prime Contractor's Markup % 3% 3% 3% 3% 3% 3% Operating Labor Rate $/hr $30$60.00$60.00$60.00$60.00$60.00 Power Cost Mills/kWh 25$60.00$60.00$60.00$60.00$60.00 Steam Cost $/1000 lbs 3.5 $3.90$3.90$3.90$3.90$3.90


# Limestone Forced Oxidation (LSFO) Inputs

SO2 Removal Required % 90-98% 95%84.9%94.7%96.0%96.2%97.0% L/G Ratio gal / 1000 acf 95-160 125 97 124 130 131 140 Design Scrubber with Dibasic Acid Addition? Integer 1 or 2 2 2 2 2 2 2 (1 = yes, 2 = no) Adiabatic Saturation Temperature °F 100-170 127 127 127 127 127 127

## Reagent Feed Ratio Factor 1.0-2.0 1.05 1.04 1.05 1.05 1.05 1.05

(Mole CaCO3 / Mole SO2 removed) Scrubber Slurry Solids Concentration Wt. % 15% 15% 15% 15% 15% 15% Stacking, Landfill, Wallboard Integer 1,2,3 1 1 1 1 1 1 (1 = stacking, 2 = landfill, 3 = wallboard) Number of Absorbers Integer 1-6 1 2 2 2 2 2 (Max. Capacity = 700 MW per absorber) Absorber Material Integer 1 or 2 1 1 1 1 1 1 (1 = alloy, 2 = RLCS) Absorber Pressure Drop in. H2O 6 6 6 6 6 6 Reheat Required ? Integer 1 or 2 1 1 1 1 1 1 (1 = yes, 2 = no) Amount of Reheat °F 0-50 25 25 25 25 25 25 Reagent Bulk Storage Days 60 60 60 60 60 60 Reagent Cost (delivered) $/ton $15$16.20$16.20$16.20$16.20$16.20 Landfill Disposal Cost $/ton $30$12.00$12.00$12.00$12.00$12.00 Stacking Disposal Cost $/ton $6 $6.00$6.00$6.00$6.00$6.00 Credit for Gypsum Byproduct $/ton $2 $2.00$2.00$2.00$2.00$2.00 Maintenance Factors by Area (% of Installed Cost) Reagent Feed % 5% 5% 5% 5% 5% 5% SO2 Removal % 5% 5% 5% 5% 5% 5% Flue Gas Handling % 5% 5% 5% 5% 5% 5% Waste / Byproduct % 5% 5% 5% 5% 5% 5% Support Equipment % 5% 5% 5% 5% 5% 5% Contingency by Area (% of Installed Cost) Reagent Feed % 20% 20%20% 20% 20%20% SO2 Removal % 20% 20%20% 20% 20%20% Flue Gas Handling % 20% 20%20% 20% 20%20% Waste / Byproduct % 20% 20%20% 20% 20%20% Support Equipment % 20% 20%20% 20% 20%20% General Facilities by Area (% of Installed Cost) Reagent Feed % 10% 10% 10% 10% 10% 10% SO2 Removal % 10% 10% 10% 10% 10% 10% Flue Gas Handling % 10% 10% 10% 10% 10% 10% Waste / Byproduct % 10% 10% 10% 10% 10% 10% Support Equipment % 10% 10% 10% 10% 10% 10% Engineering Fees by Area (% of Installed Cost) Reagent Feed % 10% 10% 10% 10% 10% 10% SO2 Removal % 10% 10% 10% 10% 10% 10% Flue Gas Handling % 10% 10% 10% 10% 10% 10% Waste / Byproduct % 10% 10% 10% 10% 10% 10% Support Equipment % 10% 10% 10% 10% 10% 10%


# Lime Spray Dryer (LSD) Inputs

SO2 Removal Required % 90-95% 90%84.9%94.7%96.0%96.2%97.0% SO2 Removal Required

## Adiabatic Saturation Temperature °F 100-170 127 127 127 127 127 127

Flue Gas Approach to Saturation °F 10.-50 20 20 20 20 20 20 Spray Dryer Outlet Temperature °F 110-220 147 147 147 147 147 147 Reagent Feed Ratio Factor Calc. Based on %S0.90 0.92 1.02 1.04 1.04 1.05 (Mole CaO / Mole Inlet SO2) Recycle Rate Factor Calculated 30 12.5 12.5 12.5 12.5 12.5 (lb recycle / lb lime feed) Recycle Slurry Solids Concentration Wt. % 10-50 35% 35%35% 35% 35%35% Number of Absorbers Integer 1-7 2 3 3 3 3 3 (Max. Capacity = 300 MW per spray dryer) Absorber Material Integer 1 or 2 1 1 1 1 1 1 (1 = alloy, 2 = RLCS) Spray Dryer Pressure Drop in. H2O 5 5 5 5 5 5 Reagent Bulk Storage Days 60 60 60 60 60 60 Reagent Cost (delivered) $/ton $65$70.20$70.20$70.20$70.20$70.20 Dry Waste Disposal Cost $/ton $30$30.00$30.00$30.00$30.00$30.00 Maintenance Factors by Area (% of Installed Cost) Reagent Feed % 5% 5% 5% 5% 5% 5% SO2 Removal % 5% 5% 5% 5% 5% 5% Flue Gas Handling % 5% 5% 5% 5% 5% 5% Waste / Byproduct % 5% 5% 5% 5% 5% 5% Support Equipment % 5% 5% 5% 5% 5% 5% Contingency by Area (% of Installed Cost) Reagent Feed % 20% 20%20% 20% 20%20% SO2 Removal % 20% 20%20% 20% 20%20% Flue Gas Handling % 20% 20%20% 20% 20%20% Waste / Byproduct % 20% 20%20% 20% 20%20% Support Equipment % 20% 20%20% 20% 20%20% General Facilities by Area (% of Installed Cost) Reagent Feed % 10% 10% 10% 10% 10% 10% SO2 Removal % 10% 10% 10% 10% 10% 10% Flue Gas Handling % 10% 10% 10% 10% 10% 10% Waste / Byproduct % 10% 10% 10% 10% 10% 10% Support Equipment % 10% 10% 10% 10% 10% 10% Engineering Fees by Area (% of Installed Cost) Reagent Feed % 10% 10% 10% 10% 10% 10% SO2 Removal % 10% 10% 10% 10% 10% 10% Flue Gas Handling % 10% 10% 10% 10% 10% 10% Waste / Byproduct % 10% 10% 10% 10% 10% 10% Support Equipment % 10% 10% 10% 10% 10% 10%


# Particulate Control Inputs

**Outlet Particulate Em ission Lim** **it** lbs/MMBtu 0.030.01000.0300.01560.01000.00078 lbs/MWh 0.09 0.27 0.14 0.0900.0070 **Fabric Filter:**

## Pressure Drop in. H2O 6 6.00 7.57 7.57 7.57 7.57

Type (1 = Reverse Gas, 2 = Pulse Jet) Integer 2 2 2 2 2 2 Gas-to-Cloth Ratio ACFM/ft2 

## 3.5 6.00 4.00 4.00 4.00 4.00 Bag Material (RGFF fiberglass only) Integer 1 3 3 3 3 3 (1 = Fiberglass, 2 = Nomex, 3 = Ryton) Bag Diameter inches 5 - 14 6 6 6 6 6 6 Bag Length feet 15 - 35 20 20 20 20 20 20 Bag Reach 3 3 3 3 3 3 Compartments out of Service % 10% 4% 4% 4% 4% 4% Bag Life Years 1 - 10 5 5.0 5.0 5.0 5.0 5.0 Cage Life Years 10.0 10.0 10.0 10.0 10.0 Maintenance (% of installed cost) % 5% 5% 5% 5% 5% 5% Contingency (% of installed cost) % 20% 20%20% 20% 20%20% General Facilities (% of installed cost) % 10% 10% 10% 10% 10% 10% Engineering Fees (% of installed cost) % 10% 10% 10% 10% 10% 10% FF Bag cost $/bag $80 $80 $80 $80 $80 FF Cage cost $/cage $30 $30 $30 $30 $30 **ESP:** Strength of the electric field in the ESP = E kV/cm 10.0 10.0 10.0 10.0 10.0 10.0 Plate Spacing in. 12 12 12 12 12 12 Plate Height ft. 36 36 36 36 36 36 Pressure Drop in. H2O 3 4.58 4.18 4.47 4.58 4.76 Maintenance (% of installed cost) % 5% 5% 5% 5% 5% 5% Maintenance (% of installed cost) Contingency (% of installed cost) % 20% 20%20% 20% 20%20% General Facilities (% of installed cost) % 10% 10% 10% 10% 10% 10% Engineering Fees (% of installed cost) % 10% 10% 10% 10% 10% 10% Solid Waste Disposal Cost (fly ash) $/ton 17 0 0 0 0 0 Solid Waste Disposal Cost (bottom ash) $/ton 0 0 0 0 0


# NOx Control Inputs

**Selective Catalytic Reduction (SCR) Inputs**

NH3/NOX Stoichiometric Ratio NH3/NOX 0.7-1.0 0.9 1.05 1.05 1.05 1.05 1.05 NOX Reduction Efficiency Fraction 0.60-0.90 0.700.50000.63330.73330.26670.4667 Inlet NOx lbs/MMBtu 0.9 0.30 0.30 0.30 0.15 0.15 Space Velocity (Calculated if zero) 1/hr 0 D D D D D Overall Catalyst Life years 2-5 3 4 4 4 4 4 Ammonia Cost $/ton 206220.51220.51220.51220.51220.51 Catalyst Cost $/ft3 356 317 317 317 317 317 Solid Waste Disposal Cost $/ton 11.48 30 30 30 30 30 Maintenance (% of installed cost) % 1.5% D D D D D Contingency (% of installed cost) % 20% D D D D D General Facilities (% of installed cost) % 5% D D D D D Engineering Fees (% of installed cost) % 10% D D D D D

## Number of Reactors integer 2 D D D D D

Number of Air Preheaters integer 1 D D D D D
**Selective NonCatalytic Reduction (SNCR) Inputs**

Reagent integer 1:Urea 2:Ammonia1 1 1 1 1 1 Number of Injector Levels integer 3 D D D D D Number of Injectors integer 18 D D D D D Number of Lance Levels integer 0 D D D D D Number of Lances integer 0 D D D D D Steam or Air Injection for Ammonia integer 1: Steam, 2: Air 1 D D D D D NOX Reduction Efficiency fraction 0.30-0.70 0.500.50000.63330.73330.26670.4667 Inlet NOx lbs/MMBtu 0.15 0.30 0.30 0.30 0.15 0.15 NH3/NOX Stoichiometric Ratio NH3/NOX 0.8-2.0 1.2 D D D D D Urea/NOX Stoichiometric Ratio Urea/NOX 0.8-2.0 1.2 2.2 2.7 3.2 1.8 3.1 Urea Cost $/ton 225195.53195.53195.53195.53195.53 Ammonia Cost $/ton 206 D D D D D Water Cost $/1,000 gal 0.407 D D D D D Maintenance (% of installed cost) % 1.5% D D D D D Contingency (% of installed cost) % 20% D D D D D General Facilities (% of installed cost) % 5% D D D D D Engineering Fees (% of installed cost) % 10% D D D D D Engineering Fees (% of installed cost)
**Low NOX Burner Technology Inputs**
NOX Reduction Efficiency fraction 0.15-0.60 0.35 D D D D D Boiler Type T:T-fired, W:Wall T D D D D D

Retrofit Difficulty L:Low, A:Average, H:High A D D D D D Maintenance Labor (% of installed cost) % 0.8% D D D D D Maintenance Materials (% of installed cost) % 1.2% D D D D D
**Natural Gas Reburning Inputs**
NOX Reduction Efficiency fraction 0.55-0.65 0.61 D D D D D Gas Reburn Fraction fraction 0.08 - 0.20 0.15 D D D D D Waste Disposal Cost $/ton 11.48 D D D D D Natural Gas Cost $/MMBtu 2.31 D D D D D Maintenance (% of installed cost) % 1.5% D D D D D Contingency (% of installed cost) % 20% D D D D D General Facilities (% of installed cost) % 2% D D D D D Engineering Fees (% of installed cost) % 10% D D D D D

## Description of Input

**Description of Input**

Gross Plant Generation (MW) minus auxiliary power requirements. Prior to control system retrofit.

Excess O2.

## See Map.

This question is necessary for a correct SCA calculation.

Date of Startup.

The default CE Index value is the published January 1998 value.

Percent of Total Process Capital. (covers construction labor fee).

## See Source Keys @ bottom of **Constants_CC Sheet. IAPCS nam** **e Range Source** **Default Source** IAPCS Names and a list of sources are contained in columns L, M, and N. 

## NH3:NOX ratio

" n b c

" NOx

" SV i i

" N d c

" UCNH3 d a

" UCCAT d a

" UCWASTE a

" a

" f

" f

" f

## " Nr,tot

" Nt,aph

"

-- --
" NIL f

" NLL f

"

--
" n b c

" NOx

" NH3:NOX ratio Urea provides 2 moles of Ammonia for every mole of Urea. UREA:NOX ratio f c

" UCUREA g

" UCNH3 a

" UCH2O a

" a

" e

" e

" e

" n i g

"

"

" g

" g

" n i

" i

" UCWASTE a

" UCGAS a

" a

" e

" e

" e

### CUECost - Air Pollution Control Systems Economics Spreadsheet

**Fabric Filter** Case1 Case 2 Case 3 Case 4 Case 5

**Flue Gas, Upstream of Fabric Filter** Tem perature °F 320 320 320 320 320 Pressure in. H2O -12 -12 -12 -12 -12 Flow Rate SCFM 1,143,035 1,143,035 1,143,035 1,143,035 1,143,035 Flow Rate ACFM 1,798,804 1,798,804 1,798,804 1,798,804 1,798,804 CO2 lb/hr 888,923 888,923 888,923 888,923 888,923 N2 lb/hr 3,439,791 3,439,791 3,439,791 3,439,791 3,439,791 SO2 lb/hr 14,413 14,413 14,413 14,413 14,413 O2 lb/hr 280,097 280,097 280,097 280,097 280,097 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 940 940 940 940 940 H2O lb/hr 516,971 516,971 516,971 516,971 516,971 Fly Ash lb/hr 291,831 291,831 291,831 291,831 291,831 Total (gas only) lb/hr 5,141,135 5,141,135 5,141,135 5,141,135 5,141,135

**Total Net Fabric Required** Ft2 299,801 449,701 449,701 449,701 449,701

**Surface Area per Bag** Ft2 31.4 31.4 31.4 31.4 31.4

**Required No. of Bags (no spare compartments)** 9,543 14,314 14,314 14,314 14,314

**Final No. of Bags** 9,925 14,887 14,887 14,887 14,887

**No. of Casings** 1 1 1 1 1

**Fabric Filter Dimensions (per Casing)** Ft2 9,744 14,615 14,615 14,615 14,615 Length Ft 140 171 171 171 171 Width Ft 70 85 85 85 85

**Capital Cost** Case1 Case 2 Case 3 Case 4 Case 5 **Cost Basis (Year) 2004**  **2004 2004**  **2004 2004** 

Total Gross Fabric Required Ft2 311,793 467,689 467,689 467,689 467,689 Number of Baghouses (Reverse Air) 0.57 0.85 0.85 0.85 0.85 Number of Baghouses (Reverse Air, Rounded) 1.0 1.0 1.0 1.0 1.0 Number of Baghouses (Pulse Jet) 13.0 19.5 19.5 19.5 19.5 Number of Baghouses (Pulse Jet, Rounded) 13.0 20.0 20.0 20.0 20.0 Fabric Filter $ $3,799,011 $5,705,189 $5,705,189 $5,705,189 $5,705,189 Fabric Filter $3,799,011 $5,705,189 $5,705,189 $5,705,189 $5,705,189 Bags $ $793,972 $1,674,327 $1,674,327 $1,674,327 $1,674,327 Cages for IPM costs $297,739 Auxiliary Costs $ $1,997,374 $1,997,374 $1,997,374 $1,997,374 $1,997,374 Equipm

ent Cost Subtotal $ $6,888,096 $9,376,889 $9,376,889 $9,376,889 $9,376,889 Instrum

ents & Controls $ $688,810 $937,689 $937,689 $937,689 $937,689 Taxes $ $206,643 $281,307 $281,307 $281,307 $281,307 Freight $ $344,405 $468,844 $468,844 $468,844 $468,844 Purchased Equipm

ent Cost Subtotal $ $8,127,953 $11,064,729 $11,064,729 $11,064,729 $11,064,729 Installation $ $6,014,685 $8,187,900 $8,187,900 $8,187,900 $8,187,900 **Total Direct Cost** $ $14,142,638 $19,252,629 $19,252,629 $19,252,629 $19,252,629

Total Direct Cost with Retrofit Factor $ $14,142,638 $19,252,629 $19,252,629 $19,252,629 $19,252,629 General Facilities $ $812,795 $1,106,473 $1,106,473 $1,106,473 $1,106,473 Engineering Fees $ $812,795 $1,106,473 $1,106,473 $1,106,473 $1,106,473 Contingency $ $1,625,591 $2,212,946 $2,212,946 $2,212,946 $2,212,946 **Total Plant Cost (TPC)** $ $17,393,819 $23,678,521 $23,678,521 $23,678,521 $23,678,521

**Total Capital Requirement (TCR)** $ $20,436,367 $27,820,397 $27,820,397 $27,820,397 $27,820,397 $/kW $40.9 $55.6 $55.6 $55.6 $55.6 Owners Costs = $1,021,818 $1,391,020 $1,391,020 $1,391,020 $1,391,020 Total Project Costs including owner's costs = $21,458,186 $29,211,416 $29,211,416 $29,211,416 $29,211,416 Allowable Funds Use During Construction (AFUDC) = $1,287,491 $1,752,685 $1,752,685 $1,752,685 $1,752,685 TPC ($) - Includes Owner's Costs and AFUDC = **$22,745,677 $30,964,101**  **$30,964,101 $30,964,101**  **$30,964,101**

**O&M Data and Costs** Case1 Case 2 Case 3 Case 4 Case 5 **Cost Basis (Year) 2004**  **2004 2004**  **2004 2004** 
Power Required System Fan(s) $/yr $872,746 $1,100,679 $1,100,679 $1,100,679 $1,100,679 Bag Cleaning $/yr $257,163 $257,163 $257,163 $257,163 $257,163 Parasitic Power % 0.51% 0.61% 0.61% 0.61% 0.61% Power Cost ** $/yr $1,129,909 $1,357,841 $1,357,841 $1,357,841 $1,357,841 Maintenance Costs $/yr $1,606,930 $2,309,680 $2,309,680 $2,309,680 $2,309,680 Periodic Replacem

ent Items (cages) $50,222 Periodic Replacem

ent Items (bags) $/yr $224,342 $463,834 $463,834 $463,834 $463,834

090000648117af4f.xlsx, FF ESP Cost & Tech. Results 

### 1 11/30/2012, 1:03 PM

### CUECost - Air Pollution Control Systems Economics Spreadsheet

First Year Cost. Bags Replaced Every 5 Years 5 Years 5 Years 5 Years 5 Years ** These costs assume inputs are in current dollars (no escalation included). Capial Recovery $1,842,221 $2,446,531 $2,446,531 $2,446,531 $2,446,531 Waste Disposal $0 $0 $0 $0 $0 Total Annual Costs w/o waste $4,853,625 $6,577,886 $6,577,886 $6,577,886 $6,577,886 Total Annual Costs w/ waste $4,853,625 $6,577,886 $6,577,886 $6,577,886 $6,577,886 Cost ratio to IPM costing analysis 127%

**ESP** Case1 Case 2 Case 3 Case 4 Case 5

**Flue Gas, Upstream of ESP** Tem perature °F 320 320 320 320 320 Pressure in. H2O -12 -12 -12 -12 -12 Flow Rate SCFM 1,143,035 1,143,035 1,143,035 1,143,035 1,143,035 Flow Rate ACFM 1,798,804 1,798,804 1,798,804 1,798,804 1,798,804 CO2 lb/hr 888,923 888,923 888,923 888,923 888,923 N2 lb/hr 3,439,791 3,439,791 3,439,791 3,439,791 3,439,791 SO2 lb/hr 14,413 14,413 14,413 14,413 14,413 O2 lb/hr 280,097 280,097 280,097 280,097 280,097 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 940 940 940 940 940 H2O lb/hr 516,971 516,971 516,971 516,971 516,971 Fly Ash lb/hr 291,831 291,831 291,831 291,831 291,831 Total (gas only) lb/hr 5,141,135 5,141,135 5,141,135 5,141,135 5,141,135
**Inlet Particulate Loading** lb/hr 291,831 291,831 291,831 291,831 291,831 gr/ft3 18.93 18.93 18.93 18.93 18.93
**Overall PM Collection Efficiency** % h 99.98% 99.95% 99.98% 99.98% 100.00%

**ESP Requirements**k dimensionless 0.452 0.452 0.452 0.452 0.452 E kV/cm 10.0 10.0 10.0 10.0 10.0
**Ash Composition**Na2O wt% in Ash 0.59 0.59 0.59 0.59 0.59

Fe wt% in Ash 3 3 3.00 3.00 3.00 MgO wt% in Ash 4.20 4.20 4.20 4.20 4.20 CaO wt% in Ash 0.00 0.00 0.00 0.00 0.00
**Flue Gas Composition**H2O Vol% 15.88 15.88 15.88 15.88 15.88

SO2 ppm 1245 1245 1245 1245 1245 SO3 ppm 0 9.2 9.2 9.2 9.2 9.2

**Flue Gas Temperature**TF °F 320 320 320 320 320

TC °C 160 160 160 160 160 TK Kelvin 433 433 433 433 433
**Resistivity Calculations** Volume Resistivityrv1 Log10(ohm-cm) 9.19 9.19 9.19 9.19 9.19

rv2 Log10(ohm-cm) 8.95 8.95 8.95 8.95 8.95 iv Log10(ohm-cm) 2.02 2.02 2.02 2.02 2.02

rv Log10(ohm-cm) 12.02 12.02 12.02 12.02 12.02 rv(TK=1000/2.4) Log10(ohm-cm) 12.42 12.42 12.42 12.42 12.42 Volume Resistivity ohm-cm 1.0585E+12 1.0585E+12 1.0585E+12 1.0585E+12 1.0585E+12
Surface Resistivityrs1 Log10(ohm-cm) 11.29 11.29 11.29 11.29 11.29

rs2 Log10(ohm-cm) 10.40 10.40 10.40 10.40 10.40 rs3 Log10(ohm-cm) 4.20 4.20 4.20 4.20 4.20 rs4 Log10(ohm-cm) 3.96 3.96 3.96 3.96 3.96 rs4(with E=12) Log10(ohm-cm) 3.90 3.90 3.90 3.90 3.90 rs0 Log10(ohm-cm) 5.92 5.92 5.92 5.92 5.92

rs Log10(ohm-cm) 4.88 4.88 4.88 4.88 4.88 Surface Resistivity ohm-cm 7.6150E+04 7.6150E+04 7.6150E+04 7.6150E+04 7.6150E+04

rvs1 ohm-cm 7.6150E+04 7.6150E+04 7.6150E+04 7.6150E+04 7.6150E+04 rs2(with H2O=10) Log10(ohm-cm) 1.12E+01 1.12E+01 1.12E+01 1.12E+01 1.12E+01 rs3(with H2O=10) Log10(ohm-cm) 4.20 4.20 4.20 4.20 4.20 rs4(with H2O = 10) Log10(ohm-cm) 3.96 3.96 3.96 3.96 3.96 rs4(with H2O = 10, E = 12) Log10(ohm-cm) 3.90 3.90 3.90 3.90 3.90 rs0(with H2O = 10) Log10(ohm-cm) 5.17 5.17 5.17 5.17 5.17 rs(with H2O = 10, TK = 1000/2.4) Log10(ohm-cm) 4.36 4.36 4.36 4.36 4.36

090000648117af4f.xlsx, FF ESP Cost & Tech. Results 

### 2 11/30/2012, 1:03 PM

### CUECost - Air Pollution Control Systems Economics Spreadsheet

rvs1(with H2O=10, TK = 1000/2.4) ohm-cm 2.3166E+04 2.3166E+04 2.3166E+04 2.3166E+04 2.3166E+04

rvs2 Log10(ohm-cm) 4.60 4.60 4.60 4.60 4.60
Acid Resistivity ia1 Log10(ohm-cm) 0.29 0.29 0.29 0.29 0.29

ra1 Log10(ohm-cm) 3.82 3.82 3.82 3.82 3.82

sa -5.00 -5.00 -5.00 -5.00 -5.00 ia2 Log10(ohm-cm) 6.83 6.83 6.83 6.83 6.83 ra2 Log10(ohm-cm) 2.01 2.01 2.01 2.01 2.01
acid_v index value 3 3 3 3 3 atom_v index value 3 3 3 3 3 sa1 -10.59 -10.59 -10.59 -10.59 -10.59 ia3 Log10(ohm-cm) 27.43 27.43 27.43 27.43 27.43 ra3 Log10(ohm-cm) 2.98 2.98 2.98 2.98 2.98

ra Log10(ohm-cm) 4.21 4.21 4.21 4.21 4.21 Acid Resistivity ohm-cm 1.6340E+04 1.6340E+04 1.6340E+04 1.6340E+04 1.6340E+04
**Total Resistivity**

rvsa ohm-cm 1.3454E+04 1.3454E+04 1.3454E+04 1.3454E+04 1.3454E+04
**Migration Velocity**

wk 1000ft/minute 0.092 0.092 0.092 0.092 0.092

**Specific Collection Area**

SCA ft2/1000acfm **1335.9 993.8**  **1190.9 1335.91**  **2349.45**

**Total Collector Plate Area** ft2 2,403,033 1,787,625 2,142,212 2,403,033 4,226,209 **ESP Footprint Area** ft2 66,751 49,656 59,506 66,751 117,395

**COHPAC** ESP Purchase price (All Options, mid 1987 $) = 20,110,934 $ 20,110,934

$ 15,671,404

$ 18,254,244

$ 20,110,934

$ 32,370,763

$ ESP Purchase price (Basic, m id 1987 $) = 13,869,858 $ 13,869,858

$ 10,808,058

$ 12,589,359

$ 13,869,858

$ 22,325,064

$ Material = 1.0 1.0 1.0 1.0 1.0 1.0 Retrofit = 1.0 1.0 1.0 1.0 1.0 1.0 Auxillary Equipment = 1,436,707 $ 1,436,707

$ 1,436,707

$ 1,436,707

$ 1,436,707

$ 1,436,707

$ Escalation factor = 1.35 1.35 1.35 1.35 1.35 1.35

**Direct Costs** ESP + Auxillary Equipment = 29,096,285 $ 29,096,285

$ 23,101,484

$ 26,589,153

$ 29,096,285

$ 45,651,019

$ Instruments = 2,909,629 $ 2,909,629

$ 2,310,148

$ 2,658,915

$ 2,909,629

$ 4,565,102

$ Sales Taxes = 872,889 $ 872,889

$ 693,045

$ 797,675

$ 872,889

$ 1,369,531

$ Sales Taxes = 872,889 $ 872,889

$ 693,045

$ 797,675

$ 872,889

$ 1,369,531

$ Freight = 1,454,814 $ 1,454,814

$ 1,155,074

$ 1,329,458

$ 1,454,814

$ 2,282,551

$ Total Purchased Equipment Costs = 34,333,616 $ 34,333,616

$ 27,259,751

$ 31,375,201

$ 34,333,616

$ 53,868,203

$

**Direct Installation Costs** Foundation and Support = 1,373,345 $ 1,373,345

$ 1,090,390

$ 1,255,008

$ 1,373,345

$ 2,154,728

$ Handling and Erection = 17,166,808 $ 17,166,808

$ 13,629,875

$ 15,687,600

$ 17,166,808

$ 26,934,101

$ Electrical = 2,746,689 $ 2,746,689

$ 2,180,780

$ 2,510,016

$ 2,746,689

$ 4,309,456

$ Piping =

- $ 343,336

$ 272,598

$ 313,752

$ 343,336

$ 538,682

$ Insulation for Ductwork =

- $ 686,672

$ 545,195

$ 627,504

$ 686,672

$ 1,077,364

$ Painting = 686,672 $ 686,672

$ 545,195

$ 627,504

$ 686,672

$ 1,077,364

$ Direct Installation Costs = 21,973,515 $ 23,003,523

$ 18,264,033

$ 21,021,384

$ 23,003,523

$ 36,091,696

$
Site Preparation =

- $

-

$

-

$

-

$

-

$

-

$ Buildings =

- $

-

$

-

$

-

$

-

$

-

$

Total Direct Costs = 56,307,131 $ 57,337,139

$ 45,523,784

$ 52,396,585

$ 57,337,139

$ 89,959,899

$

**Indirect Costs (installation)** Engineering =

- $ 6,866,723

$ 5,451,950

$ 6,275,040

$ 6,866,723

$ 10,773,641

$ Construction and Field Expense = 6,866,723 $ 6,866,723

$ 5,451,950

$ 6,275,040

$ 6,866,723

$ 10,773,641

$ Contractor Fees = 3,433,362 $ 3,433,362

$ 2,725,975

$ 3,137,520

$ 3,433,362

$ 5,386,820

$ Start-up Fee =

- $ 343,336

$ 272,598

$ 313,752

$ 343,336

$ 538,682

$ Performance Test =

- $ 343,336

$ 272,598

$ 313,752

$ 343,336

$ 538,682

$ Model Study = 686,672 $ 686,672

$ 545,195

$ 627,504

$ 686,672

$ 1,077,364

$ Contingencies = 1,030,008 $ 1,030,008

$ 817,793

$ 941,256

$ 1,030,008

$ 1,616,046

$ Total Indirect Costs = 12,016,766 $ 19,570,161

$ 15,538,058

$ 17,883,864

$ 19,570,161

$ 30,704,876

$
Total Capital Costs = 68,323,897 $ 76,907,301

$ 61,061,842

$ 70,280,450

$ 76,907,301

$ 120,664,774

$ Owners Costs = 3,416,195 $ 3,845,365

$ 3,053,092

$ 3,514,022

$ 3,845,365

$ 6,033,239

$ Total Project Costs including owner's costs = 71,740,092 $ 80,752,666

$ 64,114,934

$ 73,794,472

$ 80,752,666

$ 126,698,013

$ Allowable Funds Use During Construction (AFUDC) = 4,304,405 $ 4,845,160

$ 3,846,896

$ 4,427,668

$ 4,845,160

$ 7,601,881

$ TPC ($) - Includes Owner's Costs and AFUDC = **76,044,497 $**  **85,597,826**

**$ 67,961,830** 

**$ 78,222,140** 

**$ 85,597,826** 

**$ 134,299,894** 

**$**

Pressure Drop = 4.58 4.58 4.18 4.47 4.58 4.76

090000648117af4f.xlsx, FF ESP Cost & Tech. Results 

### 3 11/30/2012, 1:03 PM

### CUECost - Air Pollution Control Systems Economics Spreadsheet

**Annual Costs Direct Annual Costs**  Operating Labor Operator $/hr = $60.00 $60.00 $60.00 $60.00 $60.00 $60.00 Operator hr/day = 3.0 3.0 3.0 3.0 3.0 3.0 Operator day/yr = 360 360 360 360 360 360 Operator =

- $ 64,800

$ 64,800

$ 64,800

$ 64,800

$ 64,800

$ Supervisor =

- $ 9,720

$ 9,720

$ 9,720

$ 9,720

$ 9,720

$ Coordinator =

- $ 21,600

$ 21,600

$ 21,600

$ 21,600

$ 21,600

$ Operating Materials =

- $

-

$

-

$

-

$

-

$

-

$ Maintenance Labor = 400,624 $ 400,624

$ 298,026

$ 357,141

$ 400,624

$ 704,577

$ Maintenance $/ft2 = 0.167 $ 0.167

$ 0.167

$ 0.167

$ 0.167

$ 0.167

$ Material = 343,336 $ 343,336

$ 272,598

$ 313,752

$ 343,336

$ 538,682

$ Utilities Cost per kilowatt hour ($/kWh) = 0.060 $ 0.060

$ 0.060

$ 0.060

$ 0.060

$ 0.060

$ Hours per year operation (hr/yr) = 7,446 7,446 7,446 7,446 7,446 7,446 Electricity - Fan = 666,196 $ 666,196

$ 608,013

$ 649,928

$ 666,196

$ 693,020

$ Electricity - Operating = 2,082,743 $ 2,082,743

$ 1,549,360

$ 1,856,686

$ 2,082,743

$ 3,662,916

$ Total Electricity (MWh) = 45,816 Fly Ash (tons) = 1,086,321 1,086,321 1,085,986 1,086,227 1,086,321 1,086,475 Incremental Reduction (tons) -334 241 93 154 Cost per ton of Waste = $17.00 $0.00 $0.00 $0.00 $0.00 $0.00 Waste Disposal =

- $

-

$

-

$

-

$

-

$

-

$ Conditioning Costs = 0

- $

-

$

-

$

-

$

-

$

-

$ Total Direct Annual Costs = 3,492,900 $ 3,589,020

$ 2,824,117

$ 3,273,627

$ 3,589,020

$ 5,695,314

$ Total Direct Annual Costs w/o operator = 3,492,900 $ 3,492,900

$ Total Direct Annual Costs w/o operator or waste = 3,492,900 $ 3,492,900

$

**Indirect Annual Costs** Overhead = 446,376 $ 504,048

$ 400,046

$ 460,208

$ 504,048

$ 803,627

$ Administrative Charges = 1,366,478 $ 1,538,146

$ 1,221,237

$ 1,405,609

$ 1,538,146

$ 2,413,295

$ Property Tax = 683,239 $ 769,073

$ 610,618

$ 702,804

$ 769,073

$ 1,206,648

$ Insurance = 683,239 $ 769,073

$ 610,618

$ 702,804

$ 769,073

$ 1,206,648

$ Capital Recovery = 7,178,063 $ 8,079,829

$ 6,415,116

$ 7,383,617

$ 8,079,829

$ 12,676,960

$ Total Indirect Annual Costs = 10,357,395 $ 11,660,169

$ 9,257,636

$ 10,655,042

$ 11,660,169

$ 18,307,178

$

Total Annual Costs = 13,850,294 $ **15,249,189**

**$ 12,081,752** 

**$ 13,928,670** 

**$ 15,249,189** 

**$ 24,002,492** 

**$** Total Annual Costs w/o operator = **13,850,294 $**  **15,153,069**

**$** Total Annual Costs w/o operator or waste = **13,850,294 $**  **15,153,069**

**$** Total Annual Costs w/o operator or waste & 10% increase= **15,235,324 $**  **16,668,376**

**$** Incremental Cost Effectiveness ($/ton) = **15,153,069 $**  **9,475**

**$ 7,669** 

**$ 14,128** 

**$ 56,798** 

**$** Com pare Estim

ated COHPAC to standalone ESP or FF (3,167,437) $ COHPAC FF TCR = 20,436,367.15 $ (37,707.58)

$ COHPAC ESP TCR = 76,907,300.82 $ COHPAC TCR = 97,343,667.97 $ COHPAC FF TAC = 4,853,624.65 $ 6,577,886.32 $ 6,577,886.32

$ COHPAC ESP TAC = 15,249,189.20 $ 12,081,752.08

$ COHPAC TAC = 20,102,813.84 $

090000648117af4f.xlsx, FF ESP Cost & Tech. Results 

### 4 11/30/2012, 1:03 PM

# Electric Generating Unit (EGU) Operating Parameters

**Parameter Designation**  **Units** Unit Size A MW Retrofit Factor B Gross Heat Rate C Btu/kWh Coal Ty pe D FF Air-to-Cloth-Ratio (ACR) E

Heat Input F Btu/h Flue Gas Rate G
acfm

Auxiliary Power H % Pressure Drop Ha inches H2O Auxiliary Power Cost I $/kWh FF Bag Cost J $/bag Bag Life Ja years FF Cage Cost K $/cage Cage Life Ka years Operating Labor Rate L $/hr EGU Capacity

Factor M % Interest Rate N % FF Service Life O years Particulate Matter Emission Rate (uncontrolled) P lb/MMBtu Particulate Matter Emission Rate (controlled) Pa lb/MMBtu Particulate Matter Emission Rate (controlled) Pb lb/MWh Overall PM Control Efficiency Q % EGU Gross Efficiency R % EGU Uncontrolled PM emissions S lb/h EGU Controlled PM emissions T lb/h 

# Pulse-Jet Fabric Filter (FF) Cost Model **(Version 1.0, Prepared August 8, 2012)** (a) Cost Model adapted from "IPM Model - Revisions to Cost and Performance for APC Technologies, Particulate Control Cost Development Methodology" prepared by Sargent & Lundy for Systems Research and Application Corporation, March, 2011. (b) Costs based on 2009 U.S. dollars.

# Disposal Costs (fly ash) V $/ton Disposal Costs (bottom ash) Va $/ton Percent Bottom Ash Y % Cost of bag material Z $/ft2


# Capital Cost Calculation (Includes - equipment, installation, buildings, foundations, electrical, and retrofit difficulty)

BM per kW ($/kW) =


# Total Project Cost (TPC) A1 = 10% of BM A2 = 5% of BM A3 = 5% of BM
CECC per kW ($/kW) = CECC/A*1000

B1 = 5% of CECC

B2 = 6% of CECC **Total Project Cost (TPC) ($) = CECC + B1 + B2** TPC per kW ($/kW) = TPC/(A*1000)


# Fixed O&M Cost (FOM) FOMO ($/kW y

r) = 2080*L/(A*1000)] x [# of additional operators] = 0 FOMM ($/kW y

r) = BM*0.005/(A*B*1000) FOMA ($/kW y

r) = 0.03*(FOMO+0.4*FOMM) **FOM ($/kW yr) = FOMO + FOMM + FOMA**


# Variable O&M Cost (VOMB)

Annual Auxillary

Power Costs **VOM per MWh ($/MWh) = VOMB**



# Total Annual Cost Capital Recovery

Factor (CRF) = Annualized Capital Costs (ACC) = TPC*CFR Annual Fixed O&M Costs (AFOMC) = FOM*A*1000*M Annual Variable Costs (AVC) = VOMB*A*8760*M **Total Annual Cost (TAC) ($/yr) = ACC + AFOMC + AVC** TAC per kW ($/kW) = TAC/(A*1000) Ash disposal costs Base Module (BM) Cost ($) = (584-27*E)*B*G^0.81

**Capital, Engineering and Construction Cost (CECC) ($) = BM + A1 + A2 + A3**

VOMB ($/MWh) =For 6.0 Air-to-Cloth Ratio VOM = 0.004*(J/3+K/9) = For 4..0 Air-to-Cloth Ratio VOM = 0.005*(J/3+K/9)

# Total Annual Cost including ash ($/y r)


# Environmental and Energy Impacts Annual PM Uncontrolled Emissions (ton/y r) = S*8760*M/2000 Annual PM Controlled Emissions (ton/y r) = T*8760*M/2000 Cost Effectiveness ($/ton) = TPC/(Uncontrolled PM - Controlled PM)
FF Annual Electricity

Use (MWh/y

r) = A*H*8760*M

Annual Make-up Electricity Air Emissions = Annual Electric Use * Pollutant Emission Factor PM (ton/y

r) = SO2

# (ton/y

r) = NOX

# (ton/y

r) = CO (ton/y r) = Hg (lb/y r) = CO2

# (ton/y

r) =

# Value

**500 0.77**  **8,979 "User Specified"**  **6.0**

**4,489,500,000 1,798,804** 

**0.51% 10.6**  **$0.06 $80**  **5 $30**  **10 $60.00**  **85% 7.0%**  **20 81.0**  **0.010 0.090**  **99.99% 38.0%**  **363,570 44.9**  

# Pulse-Jet Fabric Filter (FF) Cost Model **(Version 1.0, Prepared August 8, 2012)** (a) Cost Model adapted from "IPM Model - Revisions to Cost and Performance for APC Technologies, Particulate Control Cost Development Methodology" prepared by Sargent & Lundy for Systems Research and Application Corporation, March, 2011.

# 0

**0 20%**  **$2.55**


# Capital Cost Calculation (Includes - equipment, installation, buildings, foundations, electrical, and retrofit difficulty) **$37,873,909 $76** 

**$3,787,391 $0**  **$1,893,695 $43,554,996**  **$87.11**

**$2,177,750**

**$2,613,300 $48,346,045**  **$96.69**

**$0.49 $0.01**  **$0.50**

**$0.07**

**$0.30 $0.38** 

**0.09439 $4,563,525**  **$211,553 $1,404,473**  **$6,179,551 $12.36**  **$0**

# $6,179,551

**1,353,572 167**  **$5**

**18,832**
Annual Make-up Electricity Air Emissions = Annual Electric Use * Pollutant Emission Factor **0.85 9.4**  **6.6 3.8**  **0.00009 9,416** 

# Comment

<---User Input <---User Input (An "average" retrofit has a factor = 1.0)(0.77 for new facility ) <---User Input <---User Input(Used CueCost coals) <---User Input If FF is used as sole PM control device, then ACR of 4.0 should be used If FF is installed for retrofit application following another PM control device (e.g. ESP) with activated carbon injection for Hg removal then ACR of 6.0 should be used. A*C*1000 Downstream of an air preheater(Used CueCost Calculations) For Bituminous G = A*C*0.435 For Subbituminous (PRB) G = A*C*0.400 For Lignite G = A*C*0.362

<---User Input (0.6 default value should be used for model input)(From CueCost) 1.518*E+1.495;use 6 inches of H2O for polishing scrubber <---User Input <---User Input <---User Input (default is 3 y rs for A/C of 6 and 5 for A/C of 4) <---User Input <---User Input (default is 9 y rs for A/C of 6 and 10 for A/C of 4) <---User Input (Labor cost including all benefits) <---User Input <---User Input <---User Input <---User Input(Used CueCost value) <---User Input W*3.412/R

3412/C [1 kWh = 3,412 Btu] P*F/1,000,000 A*Pb 

# Pulse-Jet Fabric Filter (FF) Cost Model**a,b** 

# (Version 1.0, Prepared August 8, 2012) (a) Cost Model adapted from "IPM Model - Revisions to Cost and Performance for APC Technologies, Particulate Control Cost Development Methodology" prepared by Sargent & Lundy for Systems Research and Application Corporation, March, 2011.

# Selling price = $20/ton; Disposal costs < $20/ton; Contaminated Fly Ash (Trona, etc.) = $50/ton; Polishing Scrubber = $100/ton

<---User Input



# Capital Cost Calculation (Includes - equipment, installation, buildings, foundations, electrical, and retrofit difficulty) Total base module(linear fit of IPM cost data)

Engineering and Construction Management costs Labor adjustment for 6 x 10 hour shift premium, per diem, etc.(Zero for NSPS) Contractor profit and fees CECC subtotal (excludes owner's costs)

Owners costs including all "home office" costs (owners engineering, management, and procurement activities) Allowance for Funds Used During Construction (AFUDC)
Total project cost per kW

Fixed O&M additional operating labor costs Fixed O&M additional maintenance material and labor costs Fixed O&M additional administrative labor costs Total fixed O&M costs

Variable O&M costs for bags and cages(Calculated using CueCost - based on bag and cage life) From CueCost - use lower pressure for polishing scrubber

Multiply total annual costs by

90% for polishing scrubber - duplicative equipment

# $6,180

# $5,561,596

# Displaced Power Air Emission Factors

PM (lb/MWh) = 0.090 SO2

# (lb/MWh) = 1.0 NOX

# (lb/MWh) = 0.70 CO (lb/MWh) = 0.40 Hg (lb/GWh) = 0.000010 CO2

# (lb/MWh) = 1,000

## Specific Collection Area (ft2/1000acfm) 1,336

Total Annual Costs = $15,249,189 Total Electricity (MWh) = 45,816

### CUECost - Air Pollution Control Systems Economics Spreadsheet



# SUMMARY OF COSTS

**Description Units**  **Input 1 Input 2**  **Input 3 Input 4**  **Input 5**


## APC Technologies NOx Control SCR SCR SCR SCR SCR Particulate Control PJFF PJFF PJFF PJFF PJFF SO2 Control LSFO LSFO LSFO LSFO LSFO



## SO2 Control Costs LSFO LSFO LSFO LSFO LSFO **Total Capital Requirement (TCR)** $ $84,684,162$85,294,380$85,389,499$85,404,669$85,838,662 $/kW $169 $171 $171 $171 $172 **First Year Costs** Fixed O&M $ $8,742,876$8,771,085$8,775,571$8,776,288$8,798,070 $/kW-Yr 17.49 17.54 17.55 17.55 17.60 Mills/kWH 2.35 2.36 2.36 2.36 2.36 $/ton SO2 removed$191.9 $172.6 $170.4 $170.0 $169.0 Variable O&M $ $7,208,195$7,462,713$7,494,276$7,499,132$7,518,555 $/kW-Yr 14.42 14.93 14.99 15.00 15.04 Mills/kWH 1.94 2.00 2.01 2.01 2.02 $/ton SO2 removed$158.2 $146.9 $145.5 $145.3 $144.5 Fixed Charges $ $18,884,568$19,020,647$19,041,858$19,045,241$19,142,022 $/kW-Yr 37.77 38.04 38.08 38.09 38.28 Mills/kWH 5.07 5.11 5.11 5.12 5.14 $/ton SO2 removed$414.5 $374.3 $369.7 $369.0 $367.8 TOTAL $ $34,835,639$35,254,444$35,311,705$35,320,661$35,458,647 $/kW-Yr 69.67 70.51 70.62 70.64 70.92 Mills/kWH 9.36 9.47 9.48 9.49 9.52 $/ton SO2 removed$765 $694 $686 $684 $681 **Levelized Current Dollars** Fixed O&M $/kW-Yr 23.79 23.87 23.88 23.89 23.95 Mills/kWH 3.20 3.21 3.21 3.21 3.22 $/ton SO2 removed$261.2 $234.9 $231.8 $231.4 $230.0 Variable O&M $/kW-Yr 19.62 20.31 20.40 20.41 20.46 Mills/kWH 2.63 2.73 2.74 2.74 2.75 $/ton SO2 removed$215.3 $199.9 $198.0 $197.7 $196.6 Fixed Charges $/kW-Yr 28.62 28.83 28.86 28.87 29.01 Fixed Charges $/kW-Yr Mills/kWH 3.84 3.87 3.88 3.88 3.90 $/ton SO2 removed$314.2 $283.7 $280.1 $279.6 $278.7 TOTAL $/kW-Yr 72.04 73.01 73.14 73.16 73.42 Mills/kWH 9.67 9.81 9.82 9.83 9.86 $/ton SO2 removed$790.6 $718.4 $709.9 $708.7 $705.3 **Levelized Constant Dollars** Fixed O&M $/kW-Yr 17.49 17.54 17.55 17.55 17.60 Mills/kWH 2.35 2.36 2.36 2.36 2.36 $/ton SO2 removed$191.9 $172.6 $170.4 $170.0 $169.0 Variable O&M $/kW-Yr 14.42 14.93 14.99 15.00 15.04 Mills/kWH 1.94 2.00 2.01 2.01 2.02 $/ton SO2 removed$158.2 $146.9 $145.5 $145.3 $144.5 Fixed Charges $/kW-Yr 19.82 19.96 19.98 19.98 20.09 Mills/kWH 3.78 3.81 3.81 3.81 3.83 $/ton SO2 removed$308.9 $278.9 $275.5 $275.0 $274.1 TOTAL $/kW-Yr 51.72 52.43 52.52 52.54 52.72 Mills/kWH 8.06 8.17 8.18 8.18 8.21 $/ton SO2 removed$659.1 $598.4 $591.3 $590.2 $587.6

090000648117af4f.xlsx, Input & Calculation Summary 

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# LSFO Material Balance - Preliminary Case1 Case 2 Case 3 Case 4 Case 5


### Flue Gas, Downstream of ID Fans Temperature °F 315 315 315 315 315 Pressure in. H2O 10 10 10 10 10 Flow Rate SCFM 1,143,035 1,143,035 1,143,035 1,143,035 1,143,035 Flow Rate ACFM 1,691,437 1,691,437 1,691,437 1,691,437 1,691,437 CO2 lb/hr 888,923 888,923 888,923 888,923 888,923 N2 lb/hr 3,439,791 3,439,791 3,439,791 3,439,791 3,439,791 SO2 lb/hr 14,413 14,413 14,413 14,413 14,413 O2 lb/hr 280,097 280,097 280,097 280,097 280,097 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 940 940 940 940 940 H2O lb/hr 516,971 516,971 516,971 516,971 516,971 Fly Ash lb/hr 45 135 70 45 4 Total (gas only

) lb/hr 5,141,135 5,141,135 5,141,135 5,141,135 5,141,135


### Flue Gas, to Absorber Temperature °F 315 315 315 315 315 Pressure in. H2O 10 10 10 10 10 Flow Rate SCFM 571,518 571,518 571,518 571,518 571,518 Flow Rate ACFM 845,718 845,718 845,718 845,718 845,718 CO2 lb/hr 444,462 444,462 444,462 444,462 444,462 N2 lb/hr 1,719,895 1,719,895 1,719,895 1,719,895 1,719,895 SO2 lb/hr 7,206 7,206 7,206 7,206 7,206 O2 lb/hr 140,048 140,048 140,048 140,048 140,048 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 470 470 470 470 470 H2O lb/hr 258,486 258,486 258,486 258,486 258,486 Fly Ash lb/hr 22 67 35 22 2 Total (gas only

) lb/hr 2,570,567 2,570,567 2,570,567 2,570,567 2,570,567 

### Flue Gas, from Absorbers (total) Temperature °F 127 127 127 127 127 Pressure in. H2O 4 4 4 4 4 Flow Rate SCFM 569,256 570,522 570,690 570,716 570,819 Flow Rate ACFM 647,498 648,938 649,129 649,158 649,275 CO2 lb/hr 452,868 453,838 453,967 453,987 454,066 N2 lb/hr 1,760,429 1,765,108 1,765,729 1,765,824 1,766,206 SO2 lb/hr -5,030 -6,442 -6,630 -6,659 -6,774 SO2 O2 lb/hr 149,216 150,275 150,415 150,437 150,523 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 470 470 470 470 470 H2O lb/hr 220,726 220,726 220,726 220,726 220,726 Fly Ash lb/hr 22 67 35 22 2 Total (gas only

) lb/hr 2,578,679 2,583,974 2,584,676 2,584,784 2,585,217 **Heat Capacities** O2 Btu/lbmol°F 7.213 7.213 7.213 7.213 7.213 CO2 Btu/lbmol°F 9.354 9.354 9.354 9.354 9.354 N2 Btu/lbmol°F 6.999 6.999 6.999 6.999 6.999 H2O Btu/lbmol°F 8.069 8.069 8.069 8.069 8.069 NO Btu/lbmol°F 7.164 7.164 7.164 7.164 7.164 SO2 Btu/lbmol°F 9.830 9.830 9.830 9.830 9.830 HCl Btu/lbmol°F 6.951 6.951 6.951 6.951 6.951 O2 Btu/lb°F 0.225 0.225 0.225 0.225 0.225 CO2 Btu/lb°F 0.213 0.213 0.213 0.213 0.213 N2 Btu/lb°F 0.250 0.250 0.250 0.250 0.250 H2O Btu/lb°F 0.448 0.448 0.448 0.448 0.448 NO Btu/lb°F 0.239 0.239 0.239 0.239 0.239 SO2 Btu/lb°F 0.153 0.153 0.153 0.153 0.153 HCl Btu/lb°F 0.191 0.191 0.191 0.191 0.191 Reheated Gas Temperature: °C 66.7 66.7 66.7 66.7 66.7 K 339.7 339.7 339.7 339.7 339.7 FGD Outlet Temperature: °C 52.8 52.8 52.8 52.8 52.8 K 325.8 325.8 325.8 325.8 325.8 Total Btu/hr Btu/hr 16,695,651 16,730,570 16,735,202 16,735,915 16,738,765



### Hot Reheat Air Temperature °F 440 440 440 440 440 Pressure in. H2O 1 1 1 1 1 Flow Rate SCFM 51,258 51,366 51,380 51,382 51,391 Flow Rate ACFM 90,060 90,249 90,274 90,278 90,293 N2 lb/hr 175,867 176,235 176,284 176,291 176,321 O2 lb/hr 53,037 53,148 53,163 53,165 53,174

090000648117af4f.xlsx, LSFO Cost & Tech. Results 

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### CUECost - Air Pollution Control Systems Economics Spreadsheet

H2O lb/hr 3,015 3,021 3,022 3,022 3,023 Total lb/hr 231,919 232,404 232,468 232,478 232,518 **Heat Capacities of Hot Reheat Air** O2 Btu/lbmol°F 7.332 7.332 7.332 7.332 7.332 N2 Btu/lbmol°F 7.113 7.113 7.113 7.113 7.113 H2O Btu/lbmol°F 8.338 8.338 8.338 8.338 8.338 O2 Btu/lb°F 0.229 0.229 0.229 0.229 0.229 N2 Btu/lb°F 0.254 0.254 0.254 0.254 0.254 H2O Btu/lb°F 0.463 0.463 0.463 0.463 0.463 Heated Temperature: °C 226.7 226.7 226.7 226.7 226.7 K 499.7 499.7 499.7 499.7 499.7 FGD Outlet Temperature: °C 66.7 66.7 66.7 66.7 66.7 K 339.7 339.7 339.7 339.7 339.7 **Heat Capacities of Inlet Reheat Air** O2 Btu/lbmol°F 7.304 7.304 7.304 7.304 7.304 N2 Btu/lbmol°F 7.087 7.087 7.087 7.087 7.087 H2O Btu/lbmol°F 8.276 8.276 8.276 8.276 8.276 O2 Btu/lb°F 0.228 0.228 0.228 0.228 0.228 N2 Btu/lb°F 0.253 0.253 0.253 0.253 0.253 H2O Btu/lb°F 0.459 0.459 0.459 0.459 0.459 Heated Temperature: °C 226.7 226.7 226.7 226.7 226.7 K 499.7 499.7 499.7 499.7 499.7 Inlet Air Temperature: °C 26.7 26.7 26.7 26.7 26.7 K 299.7 299.7 299.7 299.7 299.7 **Required Heat** Btu/hr 20,869,564 20,913,212 20,919,002 20,919,893 20,923,456


### Oxidation Air (total) Temperature °F 60 60 60 60 60 Pressure in. H2O 0 0 0 0 0 Flow Rate SCFM 11,811 13,174 13,355 13,383 13,494 Flow Rate ACFM 12,020 13,407 13,591 13,619 13,733 N2 lb/hr 40,534 45,212 45,833 45,929 46,311 O2 lb/hr 12,224 13,635 13,822 13,851 13,966 H2O lb/hr 686 765 776 777 784 Total (gas only

) lb/hr 53,443 59,612 60,431 60,557 61,060



### Limestone to Ball Mill Temperature °F 80 80 80 80 80 Wt.% Solids wt. % 100% 100% 100% 100% 100% Inerts lb/hr 981 1,104 1,119 1,122 1,131 CaCO3 lb/hr 19,882 22,391 22,698 22,745 22,934 Total lb/hr 20,863 23,495 23,817 23,867 24,066 

### Limestone Slurry to Limestone Slurry Tank Temperature °F 90 90 90 90 90 Flow Rate GPM 74.5 83.8 85.0 85.2 85.9 Wt.% Solids wt. % 40% 40% 40% 40% 40% Inerts lb/hr 981 1,104 1,119 1,122 1,131 CaCO3 lb/hr 19,882 22,391 22,698 22,745 22,934 H2O lb/hr 31,294 35,242 35,726 35,801 36,098 Total lb/hr 52,157 58,737 59,544 59,668 60,164 

### Limestone Slurry to Reaction Mix Tank (total) Temperature °F 68 68 68 68 68 Flow Rate GPM 173.7 195.6 198.3 198.7 200.4 Wt.% Solids wt. % 20% 20% 20% 20% 20% Inerts lb/hr 981 1,104 1,119 1,122 1,131 CaCO3 lb/hr 19,882 22,391 22,698 22,745 22,934 H2O lb/hr 83,452 93,980 95,270 95,468 96,262 Total lb/hr 104,315 117,475 119,087 119,335 120,328 

### Slurry to Absorber Temperature °F 126 126 126 126 126 Flow Rate GPM 62,040 79,485 83,356 84,001 89,788 Wt.% Solids wt. % 15% 15% 15% 15% 15% CaSO3*1/2H2O lb/hr 0 0 0 0 0 CaSO4*2H2O lb/hr 5,085,350 6,477,791 6,793,231 6,845,797 7,317,443 Inerts lb/hr 151,630 195,005 204,501 206,083 220,282 CaCl2 lb/hr 0 0 0 0 0 CaCO3 lb/hr 118,251 188,288 197,456 198,984 212,693 H2O lb/hr 30,346,306 38,879,475 40,772,736 41,088,232 43,919,038 Total lb/hr 35,701,537 45,740,559 47,967,924 48,339,096 51,669,456 

### Slurry from Rxn Tank to Thickener Temperature °F 126 126 126 126 126

090000648117af4f.xlsx, LSFO Cost & Tech. Results 

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### CUECost - Air Pollution Control Systems Economics Spreadsheet

Flow Rate GPM 401.2 450.1 456.3 457.2 461.0 Wt.% Solids wt. % 15% 15% 15% 15% 15% CaSO3*1/2H2O lb/hr 0 0 0 0 0 CaSO4*2H2O lb/hr 32,886 36,682 37,186 37,263 37,573 Inerts lb/hr 981 1,104 1,119 1,122 1,131 CaCl2 lb/hr 0 0 0 0 0 CaCO3 lb/hr 765 1,066 1,081 1,083 1,092 H2O lb/hr 196,244 220,164 223,186 223,651 225,511 Total lb/hr 230,875 259,017 262,572 263,119 265,307



# LSFO Equipment Capital Costs Case1 Case 2 Case 3 Case 4 Case 5 **Cost Basis (Year) 2004**  **2004 2004**  **2004 2004**  Sizing Criteria 

### Reagent Feed System $kpph Reag.$9,143,850 $9,285,759 $9,302,771 $9,305,382 $9,315,803 

### Ball Mill & Hydroclone System $TPH Reag.$2,292,872 $2,326,246 $2,330,344 $2,330,975 $2,333,498 

### DBA Acid Tank (pump, heater, agitator) $gpm DBA $0 $0 $0 $0 $0 

### SO2 Removal System $ kpph SO2$2,597,780 $2,597,780 $2,597,780 $2,597,780 $2,597,780 

### Absorber Tower $ kACFM$22,542,915$22,542,915$22,542,915$22,542,915$22,542,915 

### Spray Pumps $slurry gpm$943,109 $1,093,039 $1,124,424 $1,129,597 $1,384,835 

### Flue Gas Handling System $ * $5,566,519 $5,567,415 $5,567,534 $5,567,553 $5,567,626 

### ID Fans $ ACFM$2,359,180 $2,359,180 $2,359,180 $2,359,180 $2,359,180 

### Waste / Byproduct Handling System $ kpph SO2$115,754 $115,754 $115,754 $115,754 $115,754 

### Thickener System $TPH solids$296,683 $317,543 $320,178 $320,584 $322,206 

### Support Equipment $ MW $2,131,917 $2,131,917 $2,131,917 $2,131,917 $2,131,917 

### Chimney $ ACFM$3,841,019 $3,843,869 $3,844,246 $3,844,305 $3,844,537



### TOTAL $ $51,831,598$52,181,417$52,237,046$52,245,941$52,516,051 * Based on flue gas flow

and reheat temperature. 

### Capital Costs with Retrofit Factors Reagent Feed System $ $9,143,850 $9,285,759 $9,302,771 $9,305,382 $9,315,803 

### Ball Mill & Hydroclone System $ $2,292,872 $2,326,246 $2,330,344 $2,330,975 $2,333,498 

### DBA Acid Tank (pump, heater, agitator) $ $0 $0 $0 $0 $0 

### SO2 Removal System $ $2,597,780 $2,597,780 $2,597,780 $2,597,780 $2,597,780 

### Absorber Tower $ $22,542,915$22,542,915$22,542,915$22,542,915$22,542,915 

### Spray Pumps $ $943,109 $1,093,039 $1,124,424 $1,129,597 $1,384,835 

### Flue Gas Handling System $ $5,566,519 $5,567,415 $5,567,534 $5,567,553 $5,567,626 

### ID Fans $ $2,359,180 $2,359,180 $2,359,180 $2,359,180 $2,359,180 

### Waste / Byproduct Handling System $ $115,754 $115,754 $115,754 $115,754 $115,754 

### Thickener System $ $296,683 $317,543 $320,178 $320,584 $322,206 

### Support Equipment $ $2,131,917 $2,131,917 $2,131,917 $2,131,917 $2,131,917 

### Chimney $ $3,841,019 $3,843,869 $3,844,246 $3,844,305 $3,844,537



### TOTAL $ $51,831,598$52,181,417$52,237,046$52,245,941$52,516,051



### General Facilities Reagent Feed System $ $914,385 $928,576 $930,277 $930,538 $931,580 

### Ball Mill & Hydroclone System $ $229,287 $232,625 $233,034 $233,097 $233,350 

### DBA Acid Tank (pump, heater, agitator) $ $0 $0 $0 $0 $0 

### SO2 Removal System $ $259,778 $259,778 $259,778 $259,778 $259,778 

### Absorber Tower $ $2,254,291 $2,254,291 $2,254,291 $2,254,291 $2,254,291 

### Spray Pumps $ $94,311 $109,304 $112,442 $112,960 $138,484 

### Flue Gas Handling System $ $556,652 $556,742 $556,753 $556,755 $556,763 

### ID Fans $ $235,918 $235,918 $235,918 $235,918 $235,918 

### Waste / Byproduct Handling System $ $11,575 $11,575 $11,575 $11,575 $11,575 

### Thickener System $ $29,668 $31,754 $32,018 $32,058 $32,221 

### Support Equipment $ $213,192 $213,192 $213,192 $213,192 $213,192 

### Chimney $ $384,102 $384,387 $384,425 $384,430 $384,454



### TOTAL $ $5,183,160 $5,218,142 $5,223,705 $5,224,594 $5,251,605


### Engineering Fees Reagent Feed System $ $914,385 $928,576 $930,277 $930,538 $931,580 

### Ball Mill & Hydroclone System $ $229,287 $232,625 $233,034 $233,097 $233,350 

### DBA Acid Tank (pump, heater, agitator) $ $0 $0 $0 $0 $0 

### SO2 Removal System $ $259,778 $259,778 $259,778 $259,778 $259,778 

### Absorber Tower $ $2,254,291 $2,254,291 $2,254,291 $2,254,291 $2,254,291

090000648117af4f.xlsx, LSFO Cost & Tech. Results 

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Spray Pumps $ $94,311 $109,304 $112,442 $112,960 $138,484 

### Flue Gas Handling System $ $556,652 $556,742 $556,753 $556,755 $556,763 

### ID Fans $ $235,918 $235,918 $235,918 $235,918 $235,918 TPC ($) - Includes Owner's Costs and AF UDC = $ **0 792569.9564** **792659.5877 792671.4759** **792673.3048 792680.6204**  

### Support Equipment $ $213,192 $213,192 $213,192 $213,192 $213,192 

### Chimney $ $384,102 $384,387 $384,425 $384,430 $384,454



### TOTAL $ $5,934,486 $5,967,472 $5,972,783 $5,973,634 $6,000,490


### Contingency Reagent Feed System $ $1,828,770 $1,857,152 $1,860,554 $1,861,076 $1,863,161 

### Ball Mill & Hydroclone System $ $458,574 $465,249 $466,069 $466,195 $466,700 

### DBA Acid Tank (pump, heater, agitator) $ $0 $0 $0 $0 $0 

### SO2 Removal System $ $519,556 $519,556 $519,556 $519,556 $519,556 

### Absorber Tower $ $4,508,583 $4,508,583 $4,508,583 $4,508,583 $4,508,583 

### Spray Pumps $ $188,622 $218,608 $224,885 $225,919 $276,967 

### Flue Gas Handling System $ $1,113,304 $1,113,483 $1,113,507 $1,113,511 $1,113,525 

### ID Fans $ $471,836 $471,836 $471,836 $471,836 $471,836 

### Waste / Byproduct Handling System $ $23,151 $23,151 $23,151 $23,151 $23,151 

### Thickener System $ $59,337 $63,509 $64,036 $64,117 $64,441 

### Support Equipment $ $426,383 $426,383 $426,383 $426,383 $426,383 

### Chimney $ $768,204 $768,774 $768,849 $768,861 $768,907



### TOTAL $ $10,366,320$10,436,283$10,447,409$10,449,188$10,503,210


### Total Plant Cost (TPC) $ $73,315,563$73,803,313$73,880,942$73,893,356$74,271,356 **Total Plant Cost (TPC) w/ Prime Contractor's Markup**$ $75,515,030$76,017,413$76,097,370$76,110,157$76,499,497 

### Total Cash Expended (TCE) $ $73,336,917$73,824,809$73,902,461$73,914,879$74,292,989


### Allow. for Funds During Constr. (AFDC) $ $8,041,080 $8,094,575 $8,103,090 $8,104,451 $8,145,909


### Total Plant Investment (TPI) $ $81,377,998$81,919,385$82,005,550$82,019,330$82,438,898


### Preproduction Costs $ $3,062,819 $3,100,950 $3,106,142 $3,106,953 $3,119,064 

### Inventory Capital $ $243,346 $274,045 $277,807 $278,386 $280,701


### Total Capital Requirement (TCR) $ 

### $84,684,162$85,294,380$85,389,499$85,404,669$85,838,662 $/kW $169 $171 $171 $171 $172 

### Total annual cost (TAC), $/y $27,676,284$28,041,796$28,090,829$28,098,474$28,200,092 **Total annual cost (TAC), $/y** $27,676,284$28,041,796$28,090,829$28,098,474$28,200,092 

# Maintenance Cost by Area Case1 Case 2 Case 3 Case 4 Case 5

**TPC w/o Retrofit Factor** Reagent Feed System $ $13,167,144$13,371,492$13,395,991$13,399,750$13,414,756 

### Ball Mill & Hydroclone System $ $3,301,735 $3,349,794 $3,355,696 $3,356,604 $3,360,237 

### DBA Acid Tank (pump, heater, agitator) $ $0 $0 $0 $0 $0 

### SO2 Removal System $ $3,740,804 $3,740,804 $3,740,804 $3,740,804 $3,740,804 

### Absorber Tower $ $32,461,797$32,461,797$32,461,797$32,461,797$32,461,797 

### Spray Pumps $ $1,358,077 $1,573,976 $1,619,171 $1,626,619 $1,994,163 

### Flue Gas Handling System $ $8,015,788 $8,017,078 $8,017,249 $8,017,276 $8,017,381 

### ID Fans $ $3,397,220 $3,397,220 $3,397,220 $3,397,220 $3,397,220 

### Waste / Byproduct Handling System $ $166,686 $166,686 $166,686 $166,686 $166,686 

### Thickener System $ $427,223 $457,262 $461,057 $461,641 $463,976 

### Support Equipment $ $3,069,960 $3,069,960 $3,069,960 $3,069,960 $3,069,960 

### Chimney $ $5,531,067 $5,535,171 $5,535,715 $5,535,798 $5,536,133



### TOTAL $ $74,637,501$75,141,240$75,221,346$75,234,154$75,623,114



### First Year Maintenance Costs Reagent Feed System $ $658,357 $668,575 $669,800 $669,987 $670,738 

### Ball Mill & Hydroclone System $ $165,087 $167,490 $167,785 $167,830 $168,012 

### DBA Acid Tank (pump, heater, agitator) $ $0 $0 $0 $0 $0 

### SO2 Removal System $ $187,040 $187,040 $187,040 $187,040 $187,040 

### Absorber Tower $ $1,623,090 $1,623,090 $1,623,090 $1,623,090 $1,623,090 

### Spray Pumps $ $67,904 $78,699 $80,959 $81,331 $99,708 

### Flue Gas Handling System $ $400,789 $400,854 $400,862 $400,864 $400,869 

### ID Fans $ $169,861 $169,861 $169,861 $169,861 $169,861 

### Waste / Byproduct Handling System $ $8,334 $8,334 $8,334 $8,334 $8,334 

### Thickener System $ $21,361 $22,863 $23,053 $23,082 $23,199

090000648117af4f.xlsx, LSFO Cost & Tech. Results 

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### CUECost - Air Pollution Control Systems Economics Spreadsheet

Support Equipment $ $153,498 $153,498 $153,498 $153,498 $153,498 

### Chimney $ $276,553 $276,759 $276,786 $276,790 $276,807



### TOTAL $ $3,731,875 $3,757,062 $3,761,067 $3,761,708 $3,781,156



# LSFO O&M Data and Costs Case1 Case 2 Case 3 Case 4 Case 5 **Cost Basis (Year) 2004**  **2004 2004**  **2004 2004**  

### Parameters Reagent Required lbs/hr 20,863 23,495 23,817 23,867 24,066 lbs/MMBtu 4.647 5.233 5.305 5.316 5.360 

### DBA Required lbs/hr 0.0 0.0 0.0 0.0 0.0 

### Percent SO2 Removal % 85% 95% 96% 96% 97% 

### FGD Sludge to Disposal lbs/hr, dry 34,631 38,853 39,386 39,468 39,796 

### Steam to FGD System lbs/hr 24,405 24,456 24,463 24,464 24,468 

### Total FGD Power Consumption kW 10,000 10,000 10,000 10,000 10,000 

### FGD By

product lbs/hr 0 0 0 0 0



### Fixed O&M Costs Number of Operators 28 28 28 28 28 

### (40 hrs/week) Operating Labor Cost ** $/yr $3,510,135 $3,510,135 $3,510,135 $3,510,135 $3,510,135 

### Maint. Labor & Matls. Cost $/yr $3,731,875 $3,757,062 $3,761,067 $3,761,708 $3,781,156 

### Admin. & Support Labor $/yr $1,500,866 $1,503,888 $1,504,369 $1,504,445 $1,506,779 

### TOTAL $/yr $8,742,876 $8,771,085 $8,775,571 $8,776,288 $8,798,070



### Variable Operating Costs ** Reagent Costs $/yr $1,258,300 $1,417,041 $1,436,494 $1,439,486 $1,451,457 

### DBA Costs $/yr $0 $0 $0 $0 $0 

### Disposal Costs $/yr $773,593 $867,887 $879,801 $881,634 $888,966 

### Credit for By

product $/yr $0 $0 $0 $0 $0 

### Steam Costs $/yr $708,702 $710,184 $710,381 $710,411 $710,532 

### Power Costs $/yr $4,467,600 $4,467,600 $4,467,600 $4,467,600 $4,467,600 

### TOTAL $/yr $7,208,195 $7,462,713 $7,494,276 $7,499,132 $7,518,555

** These costs assume inputs are in current dollars (no escalation included).



# Intermediate Material Balance Calcs. Case1 Case 2 Case 3 Case 4 Case 5

**Sulfite Reaction** SO2 lbmole/hr 191.01 213.05 215.98 216.43 218.23 CaCO3 lbmole/hr 191.01 213.05 215.98 216.43 218.23 H2O lbmole/hr 95.50 106.53 107.99 108.21 109.11 CaSO3*1/2H2O lbmole/hr 191.01 213.05 215.98 216.43 218.23 CO2 lbmole/hr 191.01 213.05 215.98 216.43 218.23 SO2 lb/hr 12,236 13,649 13,836 13,865 13,980 CaCO3 lb/hr 19,118 21,324 21,617 21,662 21,842 H2O lb/hr 1,721 1,919 1,945 1,950 1,966 CaSO3*1/2H2O lb/hr 24,668 27,516 27,894 27,952 28,184 CO2 lb/hr 8,406 9,377 9,505 9,525 9,604 

### Sulfate Reaction CaSO3*1/2H2O lbmole/hr 191.01 213.05 215.98 216.43 218.23 O2 lbmole/hr 95.50 106.53 107.99 108.21 109.11 H2O lbmole/hr 286.51 319.58 323.97 324.64 327.34 CaSO4*2H2O lbmole/hr 191.01 213.05 215.98 216.43 218.23 CaSO3*1/2H2O lb/hr 24,668 27,516 27,894 27,952 28,184 O2 lb/hr 3,056 3,409 3,456 3,463 3,492 H2O lb/hr 5,162 5,757 5,836 5,849 5,897 CaSO4*2H2O lb/hr 32,886 36,682 37,186 37,263 37,573



### Water in Absorber Mole Fraction H2O in Absorber % 0.1389 0.1389 0.1389 0.1389 0.1389 Moles H2O in Absorber lbmole 12,252.10 12,252.10 12,252.10 12,252.10 12,252.10



### DBA Feed Calculations SO2 Removed lbs/hr 12,236 13,649 13,836 13,865 13,980 DBA Added lbs/hr 0.00 0.00 0.00 0.00 0.00

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DBA Added GPM 0.00 0.00 0.00 0.00 0.00

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# LSD Material Balance - Preliminary Case1 Case 2 Case 3 Case 4 Case 5


### Flue Gas, Downstream of Air Heater Temperature °F 320 320 320 320 320 Pressure in. H2O -12 -12 -12 -12 -12 Flow Rate SCFM 1,143,035 1,143,035 1,143,035 1,143,035 1,143,035 Flow Rate ACFM 1,798,804 1,798,804 1,798,804 1,798,804 1,798,804 CO2 lb/hr 888,923 888,923 888,923 888,923 888,923 N2 lb/hr 3,439,791 3,439,791 3,439,791 3,439,791 3,439,791 SO2 lb/hr 14,413 14,413 14,413 14,413 14,413 O2 lb/hr 280,097 280,097 280,097 280,097 280,097 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 940 940 940 940 940 H2O lb/hr 516,971 516,971 516,971 516,971 516,971 Fly Ash lb/hr 291,831 291,831 291,831 291,831 291,831 Total (gas only

) lb/hr 5,141,135 5,141,135 5,141,135 5,141,135 5,141,135 

### Flue Gas, to Spray Dryer Temperature °F 320 320 320 320 320 Pressure in. H2O -12 -12 -12 -12 -12 Flow Rate SCFM 381,012 381,012 381,012 381,012 381,012 Flow Rate ACFM 599,601 599,601 599,601 599,601 599,601 CO2 lb/hr 296,308 296,308 296,308 296,308 296,308 N2 lb/hr 1,146,597 1,146,597 1,146,597 1,146,597 1,146,597 SO2 lb/hr 4,804 4,804 4,804 4,804 4,804 O2 lb/hr 93,366 93,366 93,366 93,366 93,366 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 313 313 313 313 313 H2O lb/hr 172,324 172,324 172,324 172,324 172,324 Fly Ash lb/hr 97,277 97,277 97,277 97,277 97,277 Total (gas only

) lb/hr 1,713,712 1,713,712 1,713,712 1,713,712 1,713,712 

### Flue Gas, from Spray Dryers (total) Temperature °F 147 147 147 147 147 Pressure in. H2O -17 -17 -17 -17 -17 Flow Rate SCFM 1,287,665 1,300,919 1,302,677 1,302,947 1,304,029 Flow Rate ACFM 1,597,534 1,613,977 1,616,159 1,616,494 1,617,837 CO2 lb/hr 888,923 888,923 888,923 888,923 888,923 N2 lb/hr 3,439,791 3,439,791 3,439,791 3,439,791 3,439,791 SO2 lb/hr 4,624 3,494 3,344 3,321 3,228 SO2 O2 lb/hr 279,486 279,415 279,406 279,404 279,398 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 940 940 940 940 940 H2O lb/hr 931,676 969,772 974,825 975,602 978,712 Fly Ash lb/hr 428,194 447,303 449,838 450,228 451,788 Total (gas only

) lb/hr 5,545,439 5,582,334 5,587,228 5,587,981 5,590,993 

### Flue Gas Downstream of Particulate Control Device Temperature °F 147 147 147 147 147 Pressure in. H2O -23 -25 -25 -25 -25 Flow Rate SCFM 1,284,336 1,297,424 1,299,159 1,299,426 1,300,494 Flow Rate ACFM 1,618,745 1,642,060 1,644,257 1,644,595 1,645,946 CO2 lb/hr 888,923 888,923 888,923 888,923 888,923 N2 lb/hr 3,439,791 3,439,791 3,439,791 3,439,791 3,439,791 SO2 lb/hr 2,176 764 577 548 432 O2 lb/hr 279,333 279,245 279,233 279,231 279,224 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 940 940 940 940 940 H2O lb/hr 922,973 960,684 965,685 966,454 969,532 Fly Ash lb/hr 45 135 70 45 4 Total (gas only

) lb/hr 5,534,136 5,570,347 5,575,149 5,575,887 5,578,842 

### Flue Gas Downstream of ID Fans Temperature °F 152 152 152 152 152 Pressure in. H2O 1 1 1 1 1 Flow Rate SCFM 1,284,336 1,297,424 1,299,159 1,299,426 1,300,494 Flow Rate ACFM 1,534,467 1,550,103 1,552,177 1,552,496 1,553,772 CO2 lb/hr 888,923 888,923 888,923 888,923 888,923 N2 lb/hr 3,439,791 3,439,791 3,439,791 3,439,791 3,439,791 SO2 lb/hr 2,176 764 577 548 432 O2 lb/hr 279,333 279,245 279,233 279,231 279,224 HCl lb/hr 0 0 0 0 0 Other Gases lb/hr 940 940 940 940 940 H2O lb/hr 922,973 960,684 965,685 966,454 969,532

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Fly Ash lb/hr 45 135 70 45 4 Total (gas only

) lb/hr 5,534,136 5,570,347 5,575,149 5,575,887 5,578,842



### Lime to Ball Mill Temperature °F 60 60 60 60 60 Wt.% Solids wt. % 100% 100% 100% 100% 100% Inerts lb/hr 1,284 1,433 1,452 1,455 1,467 CaO lb/hr 11,559 12,893 13,070 13,097 13,206 Total lb/hr 12,843 14,326 14,522 14,552 14,673



### Water to Ball Mill Temperature °F 60 60 60 60 60 Flow Rate GPM 85 94 96 96 97 Wt.% Solids wt. % 0% 0% 0% 0% 0% H2O lb/hr 42,344 47,232 47,881 47,980 48,379 Total lb/hr 42,344 47,232 47,881 47,980 48,379 

### Lime Slurry to Head Tanks (Total) Temperature °F 110 110 110 110 110 Flow Rate GPM 85 95 96 96 97 Wt.% Solids wt. % 30% 30% 30% 30% 30% Ca(OH)2 lb/hr 15,272 17,035 17,269 17,305 17,449 Inerts lb/hr 1,284 1,433 1,452 1,455 1,467 H2O lb/hr 38,631 43,090 43,682 43,773 44,137 Total lb/hr 55,187 61,558 62,403 62,533 63,053 

### Lime Slurry from Head Tank Temperature °F 110 110 110 110 110 Flow Rate GPM 251 280 284 284 287 Wt.% Solids wt. % 35% 35% 35% 35% 35% CaSO3*1/2H2O lb/hr 2,891 3,576 3,672 3,686 3,746 CaSO4*2H2O lb/hr 1,285 1,589 1,632 1,638 1,665 Flyash / Inerts lb/hr 48,406 53,466 54,130 54,232 54,639 Ca(OH)2 lb/hr 5,379 6,021 6,106 6,119 6,172 CaCl2 lb/hr 937 1,186 1,221 1,226 1,248 H2O lb/hr 110,270 122,999 124,687 124,947 125,986 Total lb/hr 169,168 188,836 191,447 191,848 193,455 

### Lime Slurry to Atomizer Temperature °F 104 104 104 104 104 Flow Rate GPM 305 334 338 338 341 low Rate Wt.% Solids wt. % 30% 30% 30% 30% 30% CaSO3*1/2H2O lb/hr 2,891 3,576 3,672 3,686 3,746 CaSO4*2H2O lb/hr 1,285 1,589 1,632 1,638 1,665 Flyash / Inerts lb/hr 48,406 53,466 54,130 54,232 54,639 Ca(OH)2 lb/hr 5,379 6,021 6,106 6,119 6,172 CaCl2 lb/hr 937 1,186 1,221 1,226 1,248 H2O lb/hr 139,091 151,820 153,508 153,768 154,807 Total lb/hr 197,990 217,657 220,268 220,670 222,277 

### Solids from Spray Dryers (Total) Temperature °F 150 150 150 150 150 Wt.% Solids wt. % 98% 98% 98% 98% 98% CaSO3*1/2H2O lb/hr 2,348 2,724 2,775 2,783 2,815 CaSO4*2H2O lb/hr 1,043 1,210 1,233 1,237 1,251 Flyash / Inerts lb/hr 43,705 45,223 45,422 45,453 45,575 Ca(OH)2 lb/hr 481 543 552 553 558 CaCl2 lb/hr 0 0 0 0 0 H2O lb/hr 971 1,014 1,020 1,021 1,024 Total lb/hr 48,548 50,715 51,002 51,046 51,223 

### Baghouse/ESP Solids to Recycle Particulate Removal Efficiency % 99.99% 99.97% 99.98% 99.99% 100.00% Temperature °F 150 150 150 150 150 Wt.% Solids wt. % 98% 98% 98% 98% 98% CaSO3*1/2H2O lb/hr 6,327 8,004 8,240 8,276 8,423 CaSO4*2H2O lb/hr 2,811 3,557 3,662 3,678 3,743 Flyash / Inerts lb/hr 100,230 113,742 115,515 115,787 116,875 Ca(OH)2 lb/hr 383 484 499 501 510 CaCl2 lb/hr 2,811 3,557 3,662 3,678 3,743 H2O lb/hr 2,240 2,567 2,611 2,617 2,644 Total lb/hr 111,990 128,354 130,525 130,859 132,195 

### Recycle Solids to Slurry Tank Temperature °F 150 150 150 150 150

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Wt.% Solids wt. % 98% 98% 98% 98% 98% CaSO3*1/2H2O lb/hr 8,674 10,728 11,015 11,059 11,238 CaSO4*2H2O lb/hr 3,855 4,767 4,895 4,914 4,994 Flyash / Inerts lb/hr 143,935 158,965 160,937 161,240 162,450 Ca(OH)2 lb/hr 864 1,028 1,050 1,054 1,068 CaCl2 lb/hr 2,811 3,557 3,662 3,678 3,743 H2O lb/hr 3,211 3,581 3,631 3,638 3,668 Total lb/hr 163,349 182,626 185,189 185,583 187,161 

### Blowdown Water to Recycle Solids Tank Temperature °F 60 60 60 60 60 Flow Rate GPM 577 644 653 654 660 Wt.% Solids wt. % 0% 0% 0% 0% 0% H2O lb/hr 288,969 322,324 326,749 327,430 330,152 Total lb/hr 288,969 322,324 326,749 327,430 330,152 

### Recycle Slurry to Head Tanks (Total) Temperature °F 110 110 110 110 110 Flow Rate GPM 670 747 758 759 766 Wt.% Solids wt. % 35% 35% 35% 35% 35% CaSO3*1/2H2O lb/hr 8,674 10,728 11,015 11,059 11,238 CaSO4*2H2O lb/hr 3,855 4,767 4,895 4,914 4,994 Flyash / Inerts lb/hr 143,935 158,965 160,937 161,240 162,450 Ca(OH)2 lb/hr 864 1,028 1,050 1,054 1,068 CaCl2 lb/hr 2,811 3,557 3,662 3,678 3,743 H2O lb/hr 292,179 325,906 330,379 331,068 333,821 Total lb/hr 452,318 504,950 511,938 513,013 517,314 

### Dry Solids Temperature °F 100 100 100 100 100 Wt.% Solids wt. % 98% 98% 98% 98% 98% CaSO3*1/2H2O lb/hr 18,499 20,628 20,915 20,961 21,138 CaSO4*2H2O lb/hr 8,221 9,167 9,294 9,314 9,393 Flyash / Inerts lb/hr 293,074 293,141 293,220 293,246 293,296 Ca(OH)2 lb/hr 1,119 1,248 1,266 1,268 1,279 CaCl2 lb/hr 0 0 0 0 0 H2O lb/hr 6,549 6,616 6,626 6,628 6,635 Total lb/hr 327,462 330,800 331,322 331,418 331,740 

### Solids to Landfill Temperature °F 100 100 100 100 100 Temperature Wt.% Solids wt. % 80% 80% 80% 80% 80% CaSO3*1/2H2O lb/hr 18,499 20,628 20,915 20,961 21,138 CaSO4*2H2O lb/hr 8,221 9,167 9,294 9,314 9,393 Flyash / Inerts lb/hr 293,074 293,141 293,220 293,246 293,296 Ca(OH)2 lb/hr 1,119 1,248 1,266 1,268 1,279 CaCl2 lb/hr 0 0 0 0 0 H2O lb/hr 80,228 81,046 81,174 81,197 81,276 Total lb/hr 401,141 405,230 405,869 405,987 406,382



# LSD Equipment Capital Costs Case1 Case 2 Case 3 Case 4 Case 5 **Cost Basis (Year) 2004**  **2004 2004**  **2004 2004**  Sizing Criteria 

### Reagent Feed System $ * $6,846,092 $7,133,947 $7,172,069 $7,177,933 $7,201,385 

### SO2 Removal System $ Wt. % S$1,849,817 $1,849,817 $1,849,817 $1,849,817 $1,849,817 

### Spray Dryers $ kACFM$22,537,063 $22,537,063 $22,537,063 $22,537,063 $22,537,063 

### Flue Gas Handling System $ kACFM$5,504,887 $5,529,175 $5,532,335 $5,532,821 $5,534,765 

### ID Fans $ ACFM$1,771,196 $1,788,612 $1,790,248 $1,790,500 $1,791,507 

### Waste / Byproduct Handling System $kpph SO2$1,238,140 $1,238,140 $1,238,140 $1,238,140 $1,238,140 

### Support Equipment $ MW $2,634,559 $2,634,559 $2,634,559 $2,634,559 $2,634,559 

### Chimney $ ACFM$5,123,482 $5,140,856 $5,143,151 $5,143,504 $5,144,915



### TOTAL $ $47,505,236 $47,852,168 $47,897,383 $47,904,337 $47,932,151 * Based on lbs/hr of lime feed and GPM of lime slurry. 

### Capital Costs with Retrofit Factors Reagent Feed System $ $6,846,092 $7,133,947 $7,172,069 $7,177,933 $7,201,385 

### SO2 Removal System $ $1,849,817 $1,849,817 $1,849,817 $1,849,817 $1,849,817 

### Spray Dryers $ $22,537,063 $22,537,063 $22,537,063 $22,537,063 $22,537,063 TPC ($) - Includes Owner's Costs and AF UDC =$ **0 24386879.92**  **24386879.92 24386879.92**  **24386879.92 24386879.92**  

### Waste / Byproduct Handling System $ $1,238,140 $1,238,140 $1,238,140 $1,238,140 $1,238,140

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Support Equipment $ $2,634,559 $2,634,559 $2,634,559 $2,634,559 $2,634,559 

### Chimney $ $5,123,482 $5,140,856 $5,143,151 $5,143,504 $5,144,915



### TOTAL $ $64,616,033 $64,921,262 $64,961,679 $64,967,896 $64,992,759



### General Facilities Reagent Feed System $ $684,609 $713,395 $717,207 $717,793 $720,138 

### SO2 Removal System $ $184,982 $184,982 $184,982 $184,982 $184,982 

### Spray Dryers $ $2,253,706 $2,253,706 $2,253,706 $2,253,706 $2,253,706 

### Flue Gas Handling System $ $2,438,688 $2,438,688 $2,438,688 $2,438,688 $2,438,688 

### ID Fans $ #REF! #REF! #REF! #REF! #REF! 

### Waste / Byproduct Handling System $ $123,814 $123,814 $123,814 $123,814 $123,814 

### Support Equipment $ $263,456 $263,456 $263,456 $263,456 $263,456 

### Chimney $ $512,348 $514,086 $514,315 $514,350 $514,491



### TOTAL $ #REF! #REF! #REF! #REF! #REF! 

### Engineering Fees Reagent Feed System $ $684,609 $713,395 $717,207 $717,793 $720,138 

### SO2 Removal System $ $184,982 $184,982 $184,982 $184,982 $184,982 

### Spray Dryers $ $2,253,706 $2,253,706 $2,253,706 $2,253,706 $2,253,706 

### Flue Gas Handling System $ $2,438,688 $2,438,688 $2,438,688 $2,438,688 $2,438,688 

### ID Fans $ #REF! #REF! #REF! #REF! #REF! 

### Waste / Byproduct Handling System $ $123,814 $123,814 $123,814 $123,814 $123,814 

### Support Equipment $ $263,456 $263,456 $263,456 $263,456 $263,456 

### Chimney $ $512,348 $514,086 $514,315 $514,350 $514,491



### TOTAL $ #REF! #REF! #REF! #REF! #REF! 

### Contingency Reagent Feed System $ $1,369,218 $1,426,789 $1,434,414 $1,435,587 $1,440,277 

### SO2 Removal System $ $369,963 $369,963 $369,963 $369,963 $369,963 

### Spray Dryers $ $4,507,413 $4,507,413 $4,507,413 $4,507,413 $4,507,413 

### Flue Gas Handling System $ $4,877,376 $4,877,376 $4,877,376 $4,877,376 $4,877,376 

### ID Fans $ #REF! #REF! #REF! #REF! #REF! 

### Waste / Byproduct Handling System $ $247,628 $247,628 $247,628 $247,628 $247,628 

### Support Equipment $ $526,912 $526,912 $526,912 $526,912 $526,912 

### Chimney $ $1,024,696 $1,028,171 $1,028,630 $1,028,701 $1,028,983



### TOTAL $ #REF! #REF! #REF! #REF! #REF!


### Total Plant Cost (TPC) $ #REF! #REF! #REF! #REF! #REF! **Total Plant Cost (TPC) w/ Prime Contractor's Markup**$ #REF! #REF! #REF! #REF! #REF! 

### Total Cash Expended (TCE) $ #REF! #REF! #REF! #REF! #REF!


### Allow. for Funds During Constr. (AFDC)$ #REF! #REF! #REF! #REF! #REF!


### Total Plant Investment (TPI) $ #REF! #REF! #REF! #REF! #REF!


### Preproduction Costs $ #REF! #REF! #REF! #REF! #REF! 

### Inventory Capital $ $649,139 $724,069 $734,009 $735,538 $741,655


### Total Capital Requirement (TCR) $ 

### #REF! #REF! #REF! #REF! #REF! $/kW #REF! #REF! #REF! #REF! #REF! 

### Total annual cost (TAC), $/y #REF! #REF! #REF! #REF! #REF! 

# Maintenance Cost by Area Case1 Case 2 Case 3 Case 4 Case 5

**TPC w/o Retrofit Factor** Reagent Feed System $ $9,858,372 $10,272,884 $10,327,780 $10,336,224 $10,369,994 

### SO2 Removal System $ $2,663,737 $2,663,737 $2,663,737 $2,663,737 $2,663,737 

### Spray Dryers $ $32,453,370 $32,453,370 $32,453,370 $32,453,370 $32,453,370 

### Flue Gas Handling System $ $7,927,037 $7,962,012 $7,966,563 $7,967,263 $7,970,062 

### ID Fans $ $2,550,523 $2,575,601 $2,577,957 $2,578,320 $2,579,770 

### Waste / Byproduct Handling System $ $1,782,922 $1,782,922 $1,782,922 $1,782,922 $1,782,922 

### Support Equipment $ $3,793,765 $3,793,765 $3,793,765 $3,793,765 $3,793,765 

### Chimney $ $7,377,814 $7,402,832 $7,406,137 $7,406,645 $7,408,677



### TOTAL $ $68,407,539 $68,907,122 $68,972,231 $68,982,245 $69,022,297



### First Year Maintenance Costs

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Reagent Feed System $ $492,919 $513,644 $516,389 $516,811 $518,500 

### SO2 Removal System $ $133,187 $133,187 $133,187 $133,187 $133,187 

### Spray Dryers $ $1,622,669 $1,622,669 $1,622,669 $1,622,669 $1,622,669 

### Flue Gas Handling System $ $396,352 $398,101 $398,328 $398,363 $398,503 

### ID Fans $ $127,526 $128,780 $128,898 $128,916 $128,988 

### Waste / Byproduct Handling System $ $89,146 $89,146 $89,146 $89,146 $89,146 

### Support Equipment $ $189,688 $189,688 $189,688 $189,688 $189,688 

### Chimney $ $368,891 $370,142 $370,307 $370,332 $370,434



### TOTAL $ $3,420,377 $3,445,356 $3,448,612 $3,449,112 $3,451,115



# LSD O&M Data and Costs Case1 Case 2 Case 3 Case 4 Case 5 **Cost Basis (Year) 2004**  **2004 2004**  **2004 2004**  

### Parameters Reagent Required lbs/hr 12,843 14,326 14,522 14,552 14,673 lbs/MMBtu 2.861 3.191 3.235 3.241 3.268 

### Percent SO2 Removal % 85% 95% 96% 96% 97% 

### FGD Solids - dry lbs/hr 320,913 324,184 324,695 324,789 325,105 

### - wetted lbs/hr 401,141 405,230 405,869 405,987 406,382 

### Fresh Water to FGD gpm 85 94 96 96 97 

### Blowdown Water to FGD gpm 782 850 860 861 867 

### Total FGD Power Consumption kW 3,500 3,500 3,500 3,500 3,500



### Fixed O&M Costs Number of Operators 20 20 20 20 20 

### (40 hrs/week) Operating Labor Cost ** $/yr $2,554,109 $2,554,109 $2,554,109 $2,554,109 $2,554,109 

### Maint. Labor & Matls. Cost $/yr $3,420,377 $3,445,356 $3,448,612 $3,449,112 $3,451,115 

### Admin. & Support Labor $/yr $1,176,677.81 $1,179,675 $1,180,066 $1,180,126 $1,180,366 

### TOTAL $/yr $7,151,163 $7,179,140 $7,182,786 $7,183,347 $7,185,590



### Variable Operating Costs ** Reagent Costs $/yr $3,356,589 $3,744,040 $3,795,436 $3,803,343 $3,834,972 

### Disposal Costs $/yr $35,842,729 $36,208,145 $36,265,227 $36,275,712 $36,311,019 

### Credit for By

product $/yr $0 $0 $0 $0 $0 

### Credit for By

product Steam Costs $/yr $0 $0 $0 $0 $0 

### Fresh Water Costs $/yr $22,683 $25,302 $25,649 $25,702 $25,916 

### Power Costs $/yr $1,563,660 $1,563,660 $1,563,660 $1,563,660 $1,563,660 

### TOTAL $/yr $40,785,661 $41,541,146 $41,649,972 $41,668,418 $41,735,567 ** These costs assume inputs are in current dollars (no escalation included). Total annual cost (TAC), $/y (jht) #REF! #REF! #REF! #REF! #REF! Direct annual costs, $/y

(jht) $47,066,503 $47,858,158 $47,971,698 $47,990,869 $48,060,918 Indirect annual cost, $/y

(jht) #REF! #REF! #REF! #REF! #REF! Capital recovery

cost, $/y (jht) #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

090000648117af4f.xlsx, LSD Cost & Tech. Results 

### 5 11/30/2012, 1:03 PMCUECost - Air Pollution Control Systems Economics Spreadsheet



## SCR Capital Costs Case1 Case2 Case3 Case4 Case5 **Cost Basis (Year) 2004**  **2004 2004**  **2004 2004** 
Allowable NH3 slip, ppm 2 2 2 2 2 SCR inlet temp, oF 700 700 700 700 700 Gas flow rate, acfm 2,675,145 2,675,145 2,675,145 2,675,145 2,675,145

**Reactor Calcualtions** Catalyst volume, ft3 11,705 13,728 15,246 7,750 10,631 Cat cross-section, ft2 2,787 2,787 2,787 2,787 2,787 SCR cross section, ft2 3,205 3,205 3,205 3,205 3,205 Length of reactor, ft2 57 57 57 57 57 Width of reactor, ft2 57 57 57 57 57 Catalyst layers, no. 2 2 2 1 2 Check cat height, ft 3 3 4 4 3 Should be 2.5 to 5 ft. 3.1 3.5 3.7 3.8 2.9 **READ THIS CELL!**SHOULD START WITH ALL ZEROS, but If see "Too tall" above. Add 1 or more to this row; if "Too short, subtract 1 or more. 0 0 0 -1 0 Total catalyst layers, no. 3 3 3 2 3 SCR height ft. 29.2 29.9 30.5 19.8 28.8

**Reagent Calculations** MW NH3 17.03 17.03 17.03 17.03 17.03 MW NO2 46.01 46.01 46.01 46.01 46.01
Reagent mass flow, lb/h 262 331 384 70 122 NH3Solution flow, lb/h 902 1,143 1,324 241 421 Solution flow, gph 121 153 177 32 56 Tank volume, gal 40,509 51,309 59,411 10,804 18,906
**Capital Costs** Direct costs height adj., $/MMBtu -9 -5 -1 -67 -12 NH3 adj., $/MMBtu -23 -17 -12 -41 -36 New boiler? 0, else 1 0 0 0 0 0 Adj., $/MM Btu -728 -728 -728 -728 -728 Add bypass? 0, else 1 1 1 1 1 1 Adj., $/MM Btu 0 0 0 0 0 Catalyst cost, $ 2,809,139 3,294,709 3,658,978 1,859,914 2,551,496 Direct capital cost, $ 13,587,812 14,117,950 14,515,654 12,329,085 13,267,889

Indirect costs General facilities, $ 679,391 705,898 725,783 616,454 663,394 Engineering etc. fees, $ 1,358,781 1,411,795 1,451,565 1,232,908 1,326,789 Process contingencies, $ 679,391 705,898 725,783 616,454 663,394 Indirect capital cost, $ 2,717,562 2,823,590 2,903,131 2,465,817 2,653,578
Project contingencies, $ 2,445,806 2,541,231 2,612,818 2,219,235 2,388,220
Total plant cost, $ 18,751,180 19,482,771 20,031,602 17,014,137 18,309,687
Preproduction cost, $ 375,024 389,655 400,632 340,283 366,194 Inventory capital. $ 30,626 38,791 44,917 8,168 14,293
Total capital Investment (TCI), 1998 $ 19,156,830 19,911,218 20,477,150 17,362,588 18,690,174 C. E. cost index, chosen year 425.2 425.2 425.2 425.2 425.2 **TCI in chosen year $**  

### 20,912,66821,736,20022,354,00418,953,97320,403,240

**Annual Cost** Maintenance, $/y 313,690 326,043 335,310 284,310 306,049 Power, kW 1,249 1,268 1,282 962 1,211 Power cost, $/y 558,094 566,516 572,834 429,628 541,247 NH3 cost, $/y 740,908 938,434 1,086,616 197,600 345,782 Future Worth Factor 0.225 0.225 0.225 0.225 0.225 Cat replace cost, $/y 835,687 980,139 1,088,505 553,304 759,042 Total varible costs, $/y 2,134,690 2,485,089 2,747,955 1,180,532 1,646,070 Total direct annual cost, $/y 2,448,380 2,811,132 3,083,265 1,464,842 1,952,119 Indirect cost, $/y 1,808,269 1,879,478 1,932,898 1,638,905 1,764,220

Total Annual cost TAC, $/Y 

### 4,256,6494,690,6105,016,1633,103,7473,716,339



## SNCR Capital Costs Case1 Case2 Case3 Case4 Case5 **Cost Basis (Year) 2004**  **2004 2004**  **2004 2004** 
SNCR inlet temp,oF 575 575 575 575 575

**Reagent Calculations** MW urea 60.06 60.06 60.06 60.06 60.06 MW NO2 46.01 46.01 46.01 46.01 46.01 Reagent density, lb/cuft 71 71 71 71 71

090000648117af4f.xlsx, NOX Cost & Tech. Results 1 11/30/2012, 1:03 PMCUECost - Air Pollution Control Systems Economics Spreadsheet

Reagent mass flow, lb/h 952 1,528 2,048 208 638 Urea Solution flow, lb/h 1,905 3,056 4,097 417 1,276 Solution flow, gph 201 322 432 44 134 Tank volume, gal 67,430 108,177 145,037 14,758 45,191
**Capital Costs** Direct capital cost, $ 3,204,727 3,539,392 3,790,453 2,619,000 3,121,123

Indirect costs General facilities, $ 160,236 176,970 189,523 130,950 156,056 Engineering etc. fees, $ 320,473 353,939 379,045 261,900 312,112 Process contingencies, $ 160,236 176,970 189,523 130,950 156,056 Indirect capital cost, $ 640,945 707,878 758,091 523,800 624,225
Project contingencies, $ 576,851 637,091 682,282 471,420 561,802
Total plant cost, $ 4,422,523 4,884,361 5,230,825 3,614,220 4,307,150
Preproduction cost, $ 88,450 97,687 104,617 72,284 86,143 Inventory capital. $ 57,317 91,952 123,283 12,544 38,413
Total capital Investment (TCI), 1998 $ 4,568,290 5,073,999 5,458,725 3,699,049 4,431,705 C. E. cost index, chosen year 425.2 425.2 425.2 425.2 425.2 **TCI in chosen year $** 

### 4,987,0015,539,0625,959,0504,038,0894,837,898

**Annual Cost** Maintenance, $/y 74,805 83,086 89,386 60,571 72,568 Power, kW 144 183 212 59 104 Power cost, $/y 64,500 81,696 94,596 26,465 46,311 Urea cost, $/y 1,386,596 2,224,483 2,982,452 303,468 929,271 q watercost, $/y 2,767 4,439 5,951 606 1,854 Delta coal usage, MMBtu/hr 15.43 24.75 33.18 3.38 10.34 Delta coal cost, $/y 172,311 276,435 370,627 37,712 115,480 Delta ash, lb/h 1,249 2,004 2,687 273 837 Delta ash cost, $/y 139,542 223,863 300,142 30,540 93,518 Total varible costs, $/y 1,765,716 2,810,915 3,753,768 398,790 1,186,434 Total direct annual cost, $/y 1,840,521 2,894,001 3,843,154 459,361 1,259,003 Indirect cost, $/y 470,723 522,832 562,475 381,155 456,649

**Total Annual cost TAC, $/Y** 

### 2,311,2443,416,8334,405,628 840,5161,715,652


## Low NOX Burner Technology Capital Costs Case1 Case2 Case3 Case4 Case5

**Cost Basis (Year) 2004**  **2004 2004**  **2004 2004** 

Total Capital Requirement with Retrofit (TCR) **$ $10,540,338**  **$10,540,338 $10,540,338**  **$10,540,338 $10,540,338**  $/kW $21.1 $21.1 $21.1 $21.1 $21.1



## Low NOX Burner Technology O&M Costs Case1 Case2 Case3 Case4 Case5

**Cost Basis (Year) 2004**  **2004 2004**  **2004 2004**  Maintenance Labor $/yr 84,323 84,323 84,323 84,323 84,323 Maintenance Materials $/yr 126,484 126,484 126,484 126,484 126,484 Control, Administration, Overhead $/yr 25,297 25,297 25,297 25,297 25,297 **Total O&M Costs** $/yr **236,104 236,104**  **236,104 236,104**  **236,104**



## Natural Gas Reburning - Preliminary Case1 Case2 Case3 Case4 Case5

Fraction of heat input as reburn fuel fraction 0.15 0.15 0.15 0.15 0.15

Bottom Ash Rate tons/yr 13536 13536 13536 13536 13536



## Natural Gas Reburning Capital Costs Case1 Case2 Case3 Case4 Case5

**Cost Basis (Year) 2004**  **2004 2004**  **2004 2004** 

Gas Pipeline from Fenceline to Boiler $ $1,472,052 $1,472,052 $1,472,052 $1,472,052 $1,472,052 Fuel Injectors, Overfire Air Ports and Associated Piping, Valves, Windbox and Control Dampers $ $3,713,964 $3,713,964 $3,713,964 $3,713,964 $3,713,964

090000648117af4f.xlsx, NOX Cost & Tech. Results 2 11/30/2012, 1:03 PMCUECost - Air Pollution Control Systems Economics Spreadsheet

**Total Direct Cost** $ $5,186,016 $5,186,016 $5,186,016 $5,186,016 $5,186,016

**Total Direct Cost with Retrofit Factor** $ $5,186,016 $5,186,016 $5,186,016 $5,186,016 $5,186,016 General Facilities $ #REF! #REF! #REF! #REF! #REF! Engineering Fees $ $518,602 $518,602 $518,602 $518,602 $518,602 Contingency $ $12,057,487 $12,057,487 $12,057,487 $12,057,487 $12,057,487 **Total Plant Cost (TPC)** $ #REF! #REF! #REF! #REF! #REF! **Total Plant Cost (TPC) w/ Prime Contractor's Markup** $ #REF! #REF! #REF! #REF! #REF!

**Total Cash Expended (TCE)** $ #REF! #REF! #REF! #REF! #REF!

**Allow. for Funds During Constr. (AFDC)** $ #REF! #REF! #REF! #REF! #REF!

**Total Plant Investment (TPI)** $ #REF! #REF! #REF! #REF! #REF! Preproduction Costs $ #REF! #REF! #REF! #REF! #REF! Inventory Capital $ $0 $0 $0 $0 $0

**Total Capital Requirement (TCR)** $ **#REF! #REF!**  **#REF! #REF!**  **#REF!** $/kW #REF! #REF! #REF! #REF! #REF!



## Natural Gas Reburning O&M Costs Case1 Case2 Case3 Case4 Case5 **Cost Basis (Year) 2004**  **2004 2004**  **2004 2004** 

Electrical Consumption Savings $/yr (703,766) (703,766) (703,766) (703,766) (703,766)

Maintenance $/yr #REF! #REF! #REF! #REF! #REF!

Waste Disposal Savings $/yr (23,309) (23,309) (23,309) (23,309) (23,309)

Natural Gas Consumption $/yr 4,061,601 4,061,601 4,061,601 4,061,601 4,061,601 **Total O&M Costs #REF!**  **#REF! #REF!**  **#REF! #REF!** 

090000648117af4f.xlsx, NOX Cost & Tech. Results 3 11/30/2012, 1:03 PM

### CUECost - Air Pollution Control Systems Economics Spreadsheet

**COAL ANALYSIS LIBRARY**

Index Number 1 2 3 4 5 6 7 8

Coal Name Wyoming PRBArmstrong, PAJefferson, OH Logan, WV No. 6 Illinois Rosebud, MT Lignite, ND"User Specified" Coal Cost $/MMBtu 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 PROXIMATE ANALYSIS (ASTM, as rec'd) **Moisture - Enter below in Ultimate Analysis** Volatile Matter wt% **31.39 36.20**  **37.20 35.40**  **33.00 36.40**  **42.00** 23.5 Fixed Carbon wt% **33.05 48.70**  **44.80 43.00**  **39.00 30.30**  **20.10** 13.5 **Ash - Enter below in Ultimate Analysis** 100.00 100.00 100.00 100.00 100.00 100.05 100.00 100
COAL ULTIMATE ANALYSIS (ASTM, as rec'd) Moisture wt% **30.24 6.00**  **5.00 5.00**  **12.00 25.20**  **32.00** 25.4 Carbon wt% **48.18 71.55**  **65.72 65.99**  **55.35 51.52**  **45.06** 25.2 Hydrogen wt% **3.31 4.88**  **4.53 4.75**  **4.00 3.29**  **2.80** 2.5 Nitrogen wt% **0.70 1.40**  **1.21 0.70**  **1.08 0.69**  **1.50** 0.3 Chlorine wt% **0.01 0.00**  **0.10 0.10**  **0.10 0.10**  **0.10** 0.0 Sulfur wt% **0.37 2.60**  **3.43 0.89**  **4.00 0.56**  **0.94** 0.7 Ash wt% **5.32 9.10**  **13.00 16.60**  **16.00 8.15**  **5.90** 37.6 Oxygen wt% **11.87 4.47**  **7.01 5.97**  **7.47 10.49**  **11.70** 8.3 TOTAL wt% 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100
Modified Mott Spooner HHV (Btu/lb) -**calc** Btu/lb 8,227 13,100 11,922 12,058 10,100 8,789 7,500 4,641
COAL ASH ANALYSIS (ASTM, as rec'd) SiO2 wt% **35.51 46.92**  **51.35 50.68**  **50.82 27.00**  **29.80** 62.4 Al2O3 wt% **17.11 21.00**  **30.00 29.00**  **19.06 19.00**  **10.00** 21.5 TiO2 wt% **1.26 2.40**  **1.80 1.70**  **0.83 1.08**  **0.40** 0.5 Fe2O3 wt% **6.07 20.20**  **9.00 9.00**  **20.00 9.00**  **9.00** 3 CaO wt% **26.67 3.25**  **4.50 5.50**  **3.43 18.50**  **21.40** 3 MgO wt% **5.30 2.65**  **2.00 1.00**  **3.07 2.40**  **10.50** 1.2 Na2O wt% **1.68 0.90**  **0.40 0.40**  **0.60 2.80**  **4.40** 0.59 K2O wt% **2.87 0.30**  **0.20 0.90**  **0.37 0.45**  **0.49** 0.92 P2O5 wt% **0.97 0.00**  **0.16 0.60**  **0.17 0.42**  **0.00** 0 SO3 wt% **1.56 1.38**  **0.59 1.22**  **1.22 18.85**  **14.01** 3.5 Other Unaccounted for wt% **1.00 1.00**  **0.00 0.00**  **0.43 0.50**  **0.00** 3.39 TOTAL wt% 100.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00

090000648117af4f.xlsx, Constants_CC 

### 1 11/30/2012, 1:03 PM