## Development of Chemical Precipitation Purchased Equipment Costs: **Filter Presses**

Purchased Equipment Costs are the sum of the following cost elements: (1) Pump Costs (2) Tank Costs (3) Chemical Feed Sy stem Costs (4) Mixer Costs (5) Clarifier Costs (6) Filter Press Costs (7) Sand Filter Costs

This Excel workbook consists of the following worksheets:

Unit Cost

Sizing Tool Each cost component includes the cost of freight and associated ancillary equipm ent such as piping, valves, and controllers.
This Excel workbook supports EPA's derivation of cost element (6) using information provided in response to the Steam Electric Survey

and vendor data.

The following worksheets support EPA's development of filter press cost equations used in the Steam Electric Cost Model. For wastewater flow rates <350gpm, EPA costed 2 filter presses each with 100% capacity . For wastewater flow rates >350 gpm , EPA costed 3 filter presses each with 50% capacity

.

Relates the unit cost per filter press to filter press size based on data provided by the vendor. See DCN SE01825.A35 as the source of data used on this analy sis. A tool to calculate the minimum required filter press size based on wastewater flow rate and filter press percent capacity . Assumptions, conversion factors, and vendor provided data are used to calculate the values. This sheet is used to quickly calculate the filter press size needed for a particular wastewater flow rate and desired capacity , and vice versa. This tab is used to develop the subsequent tabs.2FP, 100%

3FP, 50%

Freight Develops a freight factor using filter press unit cost and estimated freight cost. Develops a relationship between filter press unit cost and sludge flow, assuming 2 filter presses each with 100% capacity are used. The unit cost equation developed in the the Unit Cost tab was used to calculate wastewater flow rate.

Develops a relationship between filter press unit cost and sludge flow, assuming 3 filter presses each with 50% capacity are used.**Filter press size, cu ft Cost, $**  330 525,000 $ 250 405,000 $ 25 205,000 $

y = 1014.3x + 173777 R2 = 0.9846

$- $100,000 $200,000 $300,000 $400,000 $500,000 $600,000

0 50 100 150 200 250 300 350**C o** **s t** **, $** 

**Filter press size, cu ft** 

# Filt **er Pr ess Unit Cost vs. Siz**  **e**Enter a flow rate and capacity to calculate the minimum required filter press size

Flow rate 702 gpm **Variables/Assumptions** Sludge flow rate 280.8 gpm Sludge factor 0.4 Sludge flow rate 2341.872 lb/min Assumed % solids in clarifier underflow sludge 11% Solids flow rate 257.6059 lb/min % solids filter cake 50% Solids flow rate 370952.5 lb/day Cake density 75 lb/ft^3 Cake weight 741905 lb/day FP Cycles per day 15 Cake volume 9892.067 cu ft/day FP Cycle length 1.5 hrs Cake per cycle 659.4712 cu ft/cycle FP hours per day 22.5 Min FP size 329.7356 cu ft Capacity of FPs 50%**Conversion factors** FP size (cu ft) Cost per FP ($)

8.34 lb/gal water 330 525,000 1440 min/day 250 405,000 25 205,000 Note: FP cost includes cost of associated feed pump

y = 1014.3x + 173777 R2 = 0.9846

0 100,000 200,000 300,000 400,000 500,000 600,000

0 50 100 150 200 250 300 350**C o** **s t** **P e** **r F** **P (** **$ )** 

**FP Size (cu ft) Wastewater Flow, GPM**  **Sludge Flow, GPM FP Size (cu ft)**  **Qty Unit Cost, $**  **Total Cost, $** 50 20 46.97088 2 $221,420 $442,839 75 30 70.45632 2 $245,241 $490,482 100 40 93.94176 2 $269,062 $538,124 150 60 140.91264 2 $316,705 $633,409 200 80 187.88352 2 $364,347 $728,695 250 100 234.8544 2 $411,990 $823,980 300 120 281.82528 2 $459,632 $919,265 350 140 328.79616 2 $507,275 $1,014,550

**2 at 100%**

y = 2382.1x + 173777 R2 = 1

$0 $100,000 $200,000 $300,000 $400,000 $500,000 $600,000

0 20 40 60 80 100 120 140 160**U n** **i t** **C o** **s t** **, $** 

**Sludge Flow, GPM** 

# Filt **er Pr ess Unit Cost vs. Sludg**  **e Flow** Recommendation for costing 3 50% filter presses for round 2.

Assume 15 cycles per day. 3 filter presses each handling 50% of the sludge volume Using the filter press sizing tool, calculate the maximum sludge flow rate that can be accommodated by each FP size:
**Filter press size, cu ft Total Cake volume, cu ft**  **Volume per day, cu ft Sludge Flow, gpm**  **Wastewater Flow, gpm Cost per FP, $** 

330 660 9900 280.8 702 525,000 $ 250 500 7500 212.8 532 405,000 $ 25 50 750 21.2 53 205,000 $
Total Cake Volume, cu ft =Filter press size x 2, since each press is designed to handle 50% of the sludge flow Volume per day, cu ft =Cake Volume x Cycle per day Sludge Flow, gpm =Wastewater Flow x Sludge Factor Wastewater Flow, gpm Calculated by entering filter press size and capacity into sizing tool

y = 2.7768x 2 + 394.06x + 195398

R2 = 1

$- $100,000 $200,000 $300,000 $400,000 $500,000 $600,000

0 50 100 150 200 250 300**C o** **s t** **p e** **r F** **P ,** **$**

**Sludge Flow, gpm**



# FP cost vs. sludg **e gpm** **Filter press size, cu ft Cost per FP, $**  **Approx Weight, lbs # of trucks required**  **Shipping cost, $** 330 525000 71507 2 2800 250 405000 61066 2 2800 25 205000 11279 1 1400

Assume one truck can hold 45000 lbs Assume the cost to ship one truck 500 miles is 1400 dollars
Revised Freight factor 1.01**Freight/FP cost**

0.5% 0.7% 0.7%
*Based on information from FreightCenter.com (see DCN SE01825.A1) *Based on information from FreightCenter.com (see DCN SE01825.A1)