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 Medium Sulfur Low Sulfur

3.00% 1.50% 0.50%

5.11 2.57 0.93

Emissions Rate 

(lb/MMBtu) % Control L/G Ratio Reagent

Emissions Rate 

(lb/MMBtu) % Control L/G Ratio Reagent

Emissions Rate 

(lb/MMBtu) % Control L/G Ratio Reagent

0.60 88.3% 100 1.05 0.60 76.7% 95 1.02 0.28 69.9% 95 1.020

0.21 95.9% 130 1.05 0.21 91.8% 105 1.05 0.21 77.4% 96 1.025

0.15 97.1% 140 1.05 0.15 94.2% 115 1.05 0.15 83.9% 97 1.030

0.12 97.7% 160 1.10 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) % Control L/G Ratio Reagent

Emissions Rate 

(lb/MMBtu) % Control L/G Ratio Reagent

0.60 84.9% 97 1.04 0.60 76.1% 95 1.02

0.21 94.7% 124 1.05 0.21 91.6% 105 1.05

0.16 96.0% 130 1.05 0.15 94.0% 115 1.05

0.15 96.2% 131 1.05 0.12 95.2% 125 1.05

0.12 97.0% 140 1.05 0.075 97.0% 140 1.05

SO2 ControlL/G Ratio

70% 95

90% 100

95% 125

97% 140

98% 160
Reverse Air ESP

Device % 

Reduction

Emissions Rate 

(lb/MMBtu)

Pressure Drop 

(in H2O)

Gas to Cloth 

Ratio

Bag 

Materials

Bag cost 

($/ft2)

Emissions Rate 

(lb/MMBtu)

Pressure 

Drop (in H2O)

99.67 0.030 5 2.16 Fiberglass 1.01 0.030 4.19

99.83 0.020 7 2.11 Nomex 1.01 0.020 4.37

99.84 0.018 8 2.09 Nomex 1.65 0.018 4.39

99.87 0.015 14 2.04 Ryton 2.02 0.015 4.46

99.90 0.012 18 1.97 Ryton 2.02 0.012 4.48

Pulse Jet

Device % 

Reduction

Emissions Rate 

(lb/MMBtu)

Pressure Drop 

(in H2O)

Gas to Cloth 

Ratio

Bag 

Materials

Bag cost 

($/ft2)

99.67 0.030 5 3.88 Fiberglass 1.60

99.83 0.020 7 3.79 Nomex 1.60

99.84 0.018 8 3.77 Nomex 2.62

99.87 0.015 14 3.61 Ryton 3.20

99.90 0.012 18 3.40 Ryton 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 10,500 8,979 8,979 8,979 8,979 8,979 38.0%

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 0.013 0.013 0.013 0.013 0.013 0.013

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 1998 2004 2004 2004 2004 2004

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) Levelized Carrying Charge (current $'s) % 16.90% 16.90% 16.90% 16.90% 16.90% 16.90%

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 388 425.20 425.20 425.20 425.20 425.20

 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 1,2,3111111

 (1 = stacking, 2 = landfill, 3 = wallboard)

Number of Absorbers Integer 1-6122222

 (Max. Capacity = 700 MW per absorber)

Absorber Material Integer 1 or 2111111

 (1 = alloy, 2 = RLCS)

Absorber Pressure Drop in. H2O666666

Reheat Required ? Integer 1 or 2111111

 (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 SO2 Removal Required% 90-95% 90% 84.9% 94.7% 96.0% 96.2% 97.0%
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 %S 0.90 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 Emission Limit lbs/MMBtu 0.03 0.0100 0.030 0.0156 0.0100 0.00078

lbs/MWh 0.09 0.27 0.14 0.090 0.0070

Fabric Filter:
 Pressure Drop in. H2O

6 6.00 7.57 7.57 7.57 7.57

 Type (1 = Reverse Gas, 2 = Pulse Jet) Integer222222

 Gas-to-Cloth Ratio ACFM/ft

2

3.5 6.00 4.00 4.00 4.00 4.00

 Bag Material (RGFF fiberglass only) Integer133333

 (1 = Fiberglass, 2 = Nomex, 3 = Ryton)

 Bag Diameter inches 5 - 14666666

 Bag Length feet 15 - 35 20 20 20 20 20 20

 Bag Reach333333

 Compartments out of Service% 10% 4% 4% 4% 4% 4%

 Bag Life Years 1 - 105 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. H2O3 4.58 4.18 4.47 4.58 4.76

 Maintenance (% of installed cost) 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%

Solid Waste Disposal Cost (fly ash) $/ton 1700000

Solid Waste Disposal Cost (bottom ash) $/ton00000

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 0.70 0.5000 0.6333 0.7333 0.2667 0.4667

Inlet NOx lbs/MMBtu 0.9 0.30 0.30 0.30 0.15 0.15

Space Velocity (Calculated if zero) 1/hr0DDDDD

Overall Catalyst Life years 2-5344444

Ammonia Cost $/ton 206 220.51 220.51 220.51 220.51 220.51

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%DDDDD

Contingency (% of installed cost)% 20%DDDDD

General Facilities (% of installed cost)% 5%DDDDD

Engineering Fees (% of installed cost)% 10%DDDDD
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:Ammonia 1 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 0.50 0.5000 0.6333 0.7333 0.2667 0.4667

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 225 195.53 195.53 195.53 195.53 195.53

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) Engineering Fees (% of installed cost) % 10% D D D D D

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 name 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

 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

Total Net Fabric Required Ft2299,801 449,701 449,701 449,701 449,701

Surface Area per Bag Ft231.4 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) Ft29,744 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 Ft2311,793 467,689 467,689 467,689 467,689

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 Fabric Filter $ $3,799,011 $3,799,011 $5,705,189 $5,705,189 $5,705,189 $5,705,189 $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

 Equipment Cost Subtotal $ $6,888,096 $9,376,889 $9,376,889 $9,376,889 $9,376,889

 Instruments & 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 Equipment 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 Replacement Items (cages) $50,222

 Periodic Replacement 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

 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

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 Resistivity

rv1 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 Resistivity

rs1 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 ft22,403,033 1,787,625 2,142,212 2,403,033 4,226,209

 ESP Footprint Area ft266,751 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, mid 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 = Sales Taxes = $ $ 872,889 872,889 $ $ 872,889 872,889 $ $ 693,045 693,045 $ $ 797,675 797,675 $ $ 872,889 872,889 $ $ 1,369,531 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

Compare Estimated 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 Type 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) Co

(Version 1.0, Prepared Augus

(a) Cost Model adapted from "IPM Model - Revisions to Cost and Performance for APC Techn

 prepared by Sargent & Lundy for Systems Research and Application Corporation, March, 20

(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

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 yr) = 2080*L/(A*1000)] x [# of additional operators] =0

FOMM ($/kW yr) = BM*0.005/(A*B*1000)

FOMA ($/kW yr) = 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 ($/yr)

Environmental and Energy Impacts

Annual PM Uncontrolled Emissions (ton/yr) = S*8760*M/2000

Annual PM Controlled Emissions (ton/yr) = T*8760*M/2000

Cost Effectiveness ($/ton) = TPC/(Uncontrolled PM - Controlled PM)

FF Annual Electricity Use (MWh/yr) = A*H*8760*M

Annual Make-up Electricity Air Emissions = Annual Electric Use * Pollutant Emission Factor

PM (ton/yr) =

SO2 (ton/yr) =

NOX (ton/yr) =

CO (ton/yr) =

Hg (lb/yr) =

CO2 (ton/yr) =
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

-Jet Fabric Filter (FF) Cost Model

rsion 1.0, Prepared August 8, 2012)

nd Performance for APC Technologies, Particulate Control Cost Development Methodology"

plication Corporation, March, 2011.
0

0

20%

$2.55

ldings, 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

nt 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 yrs for A/C of 6 and 5 for A/C of 4)

<---User Input

<---User Input (default is 9 yrs 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

 (FF) Cost Modela,b

d August 8, 2012)

APC Technologies, Particulate Control Cost Development Methodology"

 March, 2011.
Selling price = $20/ton; Disposal costs < $20/ton; Contaminated Fly Ash (Trona, 

etc.) = $50/ton; Polishing Scrubber = $100/ton

<---User Input

 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 Fixed Charges $/kW-Yr $/kW-Yr 28.62 28.83 28.86 28.87 29.01

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 1 11/30/2012, 1:03 PM
CUECost - Air Pollution Control Systems Economics Spreadsheet

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 SO2 lb/hr -5,030 -6,442 -6,630 -6,659 -6,774

 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 1 11/30/2012, 1:03 PM
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 2 11/30/2012, 1:03 PM
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 3 11/30/2012, 1:03 PM
CUECost - Air Pollution Control Systems Economics Spreadsheet

 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 AFUDC = $ 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 Total annual cost (TAC), $/y $27,676,284 $27,676,284 $28,041,796 $28,041,796 $28,090,829 $28,090,829 $28,098,474 $28,098,474 $28,200,092 $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 4 11/30/2012, 1:03 PM
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 Byproduct 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 Byproduct $/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

090000648117af4f.xlsx, LSFO Cost & Tech. Results 5 11/30/2012, 1:03 PM
CUECost - Air Pollution Control Systems Economics Spreadsheet

 DBA Added GPM 0.00 0.00 0.00 0.00 0.00

090000648117af4f.xlsx, LSFO Cost & Tech. Results 6 11/30/2012, 1:03 PM
CUECost - Air Pollution Control Systems Economics Spreadsheet

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 SO2 lb/hr 4,624 3,494 3,344 3,321 3,228

 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

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

 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 low Rate GPM 305 334 338 338 341

 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

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

 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 Temperature °F 100 100 100 100 100

 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 AFUDC = $ 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

090000648117af4f.xlsx, LSD Cost & Tech. Results 3 11/30/2012, 1:03 PM
CUECost - Air Pollution Control Systems Economics Spreadsheet

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

090000648117af4f.xlsx, LSD Cost & Tech. Results 4 11/30/2012, 1:03 PM
CUECost - Air Pollution Control Systems Economics Spreadsheet

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 Credit for Byproduct product $/yr $0 $0 $0 $0 $0

 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 PM
CUECost - 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, ft311,705 13,728 15,246 7,750 10,631

 Cat cross-section, ft22,787 2,787 2,787 2,787 2,787

 SCR cross section, ft23,205 3,205 3,205 3,205 3,205

 Length of reactor, ft257 57 57 57 57

 Width of reactor, ft257 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

 NH3 Solution 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 $ 20,912,668 21,736,200 22,354,004 18,953,973 20,403,240

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 4,256,649 4,690,610 5,016,163 3,103,747 3,716,339

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 PM
CUECost - 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 $ 4,987,001 5,539,062 5,959,050 4,038,089 4,837,898

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 2,311,244 3,416,833 4,405,628 840,516 1,715,652

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 PM
CUECost - 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 PRB Armstrong, PA Jefferson, 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