# DSI Capital Costs

Description Formula Value

Boiler Size (MMBtu/hr) Q B 

# 1941

SO2 Removal Efficiency (%) η NOx 

# 50.0%

Cost Year 2010

Capital Costs ($)



# Base DSI module includes all equipment from unloading

to injection BM 

# $8,966,549

Total Project Costs ($)



# Engineering and construction management costs A1 = 5% of BM $448,327

Labor adjustment for 6 x 10 hour shift premium, per

diem, etc.. A1 = 5% of BM $448,327

Contractor profit and fees A1 = 5% of BM $448,327

Total Capital Investment (TCI) ($) BM+A1+A2+A3 

# $10,311,531

Total Capital Investment (TCI) ($) Per kW $64

DSI Annual Costs

Direct Annnual Costs

Fixed O&M costs for operations staff 

# $124,800

Fixed O&M costs for maintenance labor and materi als 

# $84,961

Fixed O&M costs for adminstrative labor 

# $4,764

Variable O&M costs for trona reagent $1,494,517

Variable O&M costs for waste disposal $2,205,561

Variable O&M costs for additional auxillary power

required including additional fan power $123,684

Lost Ash Sales Revenue $352,200

Total Direct Annual Costs DAC 

# $4,390,487

Indirect Annual Costs IDAC = TCI x CRF 

# $973,409

Total Annual Costs TAC = DAC + IAC 

# $5,363,896

Cost Effectivness

DSI SO2 Removed (tons/yr) 

# 1,361

DSI Cost Effectiveness ($/ton removed) 

# $3,940 Corette BART Cost Analysis - DSI

(2010 Dollars)DSI Capital Cost Estimate WorksheetVariable Designation Units ValueCalculationUnit Size (Gross) A (MW) 162 Input (Greater than 50 MW)Retrofit Factor B1 Input (An "average" retrofit has a factor = 1.0)Gross Heat Rate C (Btu/kWh) 11982 InputSO2RateD (lb/MMBtu) 0.461 InputType of Coal EInputParticulate Capture FMilled Trona GRemoval Target H50Maximum Removal Targets:Unmilled Trona with an ESP = 65%Milled Trona with an ESP = 80%Unmilled Trona with a BGH = 80%Milled Trona with a BGH = 90%Heat Input J (Btu/hr) 1.94E+09 A*C*1000NSR K1.43Unmilled Trona with an ESP = If(H<40.0,0.0350*H,0.352e(0.0345*H))Milled Trona with an ESP = If(H<40.0,0.0270*H,0.353e(0.0280*H))Unmilled Trona with an BGH = If(H<40.0,0.0215*H,0.295e(0.0267*H))Milled Trona with an BGH = IF(H<40.0,0.0160*H,0.208e(0.0281*H))Trona Feed Rate M (ton/hr) 1.54 (1.2011*10-6)*K*A*C*DSorbent Waste Rate N (ton/hr) 1.04(0.7035-0.00073696*H/K)*M; Based on a final reaction product of NA2SO4andunreacted drysorbent as NA2CO3Fly Ash Waste Rate P (ton/hr) 5.55(A*C)*Ash in Coal*(1-Boiler Ash Removal)/(2*HHV)For Bituminous Coal: Ash in Coal = 0.012; Boiler Ash Removal = 0.2; HHV= 11000For PRB Coal: Ash in Coal = 0.06; Boiler Ash Removal = 0.2; HHV= 8400For Lignite Coal: Ash in Coal = 0.08; Boiler Ash Removal = 0.2 HHV= 7200Aux Power Q (%) 0.19 If Milled Trona M*20/A, else M*18/ATrona Cost R ($/ton) 145.00Waste Disposal Cost S ($/ton) 50.00Aux Power Cost T ($/kWh) 0.06Operating Labor Rate U ($/hr) 60 Labor cost including all benefitsCosts are all based on 2009 dollarsCapital Cost CalculationInclude: equipment, installation, buildings, foundations, electrical, and retrofit difficulty.$8,496,082 Base DSI module includes all equipment from unloading to injectionBM ($/kW)$52 Base module cost per kWTotal Project CostA1 = 5% of BM$424,804 Engineering and construction management costsA2 = 5% of BM$424,804 Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 5% of BM$424,804 Contractor profit and feesCECC($) - excludes owner's costs = BM+A1+A2+A3$9,770,494Capital, engineering and construction cost subtotalCECC($/kW) - excludes owner's costs =$60Capital, engineering and construction cost subtotal per kWB1 = %5 of CECC$488,525 Owners costs including "home office" costs (owner engineering, management, and procurement activities)TPC ($) - includes owner's costs = CECC + B1$10,259,019Total project cost without AFUDCTPC ($/kw) - includes owner's costs =$63Total project cost per kW without AFUDCB2 = 0% of (CECC + B1)$0 AFUDC (based on 3 year enginering and construction cycle)TPC ($) - includes owner's costs and AFUDC = CECC + B1 + B2 $10,259,019Total project costTPC ($/kw) - includes owner's costs and AFUDC ($/kW) =$63Total project cost per kWPRBESPTRUEBM ($) = Unmilled Trona, If(M>25 then (682,000*B*M) else (6,833,000*B*M0.284)Milled Trona, If(M>25 then (750,000*B*M) else (7,516,000*B*M0.284)DSI Capital Cost Estimate WorksheetVariableDesignationUnitsValueCalculationUnit Size (Gross)A(MW)162Input (Greater than 50 MW)Retrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Gross Heat RateC(Btu/kWh)11982InputSO2RateD (lb/MMBtu) 0.461 InputType of CoalEInputParticulate CaptureFMilled TronaGRemoval Target H50Maximum Removal Targets:Unmilled Trona with an ESP = 65%Milled Trona with an ESP = 80%Unmilled Trona with a BGH = 80%Milled Trona with a BGH = 90%Heat InputJ(Btu/hr)1.94E+09A*C*1000NSR K1.43Unmilled Trona with an ESP = If(H<40.0,0.0350*H,0.352e(0.0345*H))Milled Trona with an ESP = If(H<40.0,0.0270*H,0.353e(0.0280*H))Unmilled Trona with an BGH = If(H<40.0,0.0215*H,0.295e(0.0267*H))Milled Trona with an BGH = IF(H<40.0,0.0160*H,0.208e(0.0281*H))Trona Feed Rate M (ton/hr) 1.54(1.2011*10-6)*K*A*C*DSorbent Waste Rate N (ton/hr) 1.04(0.7035-0.00073696*H/K)*M; Based on a final reaction product of NA2SO4andunreacted drysorbent as NA2CO3Fly Ash Waste Rate P (ton/hr) 5.55(A*C)*Ash in Coal*(1-Boiler Ash Removal)/(2*HHV)For Bituminous Coal: Ash in Coal = 0.012; Boiler Ash Removal = 0.2; HHV= 11000For PRB Coal: Ash in Coal = 0.06; Boiler Ash Removal = 0.2; HHV= 8400For Lignite Coal: Ash in Coal = 0.08; Boiler Ash Removal = 0.2 HHV= 7200Aux Power Q (%) 0.19If Milled Trona M*20/A, else M*18/ATrona CostR($/ton)145.00Waste Disposal CostS($/ton)50.00Aux Power CostT($/kWh)0.06Operating Labor RateU($/hr)60Labor cost including all benefitsCosts are all based on 2009 dollarsFixed O&M CostFOMO ($/kW yr) = (1 additional operator)*2080*U/(A*1000)$0.770Fixed O&M additional operating labor costsFOMM ($/kW yr) = BM*0.01/(B*A*1000)$0.524Fixed O&M maintenance material and labor costsFOMA ($/kW yr) = 0.03*(FOMO+0.4*FOMM)$0.029Fixed O&M additional addministrative labor costsFOM ($/kW yr) = FOMO + FOMM$1.324Total Fixed O&M costsVariable O&MVOMR ($/MWh) = M*R/A$1.378Variable O&M costs for trona reagentVOMW ($/MWh)= (N+P)*S/A$2.034Variable O&M costs for waste disposal that includes both the sorbent and the fly ash wasteVOMP ($/MWh) = Q*T*10$0.114Variable O&M costs for additional auxillary power requiredVOM ($/MWh) = VOMR + VOMW + VOMP + VOMM$3.526Total variable O&M costsBituminousESPTRUESTATEFACILITY_NAMEORISPLCODE UNIT ID OP YEARSUM OPTIMENUMMONTHSREPORTEDGROSSLOAD(MWh)SO2 MASS SO2 RATE NOX RATENOXMASSHEAT INPUT(MMBtu)HEATINPUT(MMBtu/hr)MTJ E Corette2187220087,314121,086,4772,8170.4720.2781,65811,925,7341,631MTJ E Corette2187220097,824121,141,2922,8320.4550.2611,64112,445,1521,591MTJ E Corette2187220107,401121,025,5972,5190.4570.2821,57511,037,7061,491Averages7,5131,084,4552,7230.4610.2741,62511,802,8641,571