NPPD - Gerald Gentleman Units #1+#2

Given/Assumptions

New or Retrofit? Retrofit

Generation capacity (MW) 665

SCR bypass included? No

Fuel High Heating Value (Btu/lb) 8,576

Maximum Fuel Consumption Rate (lb/hr) 6.5E+05

Average Annual Fuel Consumption (lb) 5.71E+09

Number of SCR Operating Days 365

Plant Capacity Factor 69%

Uncontrolled NOx Concentration (lb/mmBtu) 0.46

Uncontrolled NOx Emissions (tpy) 15,122

LNB + OFA Total Capital Cost $ 18,465,000

LNB + OFA Total Annual Cost $ 1,480,000

LNB outlet = SCR inlet NOx Concentration (lb/mmBtu) 0.23

Required Controlled NOx Concentration (lb/mmBtu) 0.05

Acceptable Ammonia Slip (ppm) 2.0

Fuel Volume Flow Rate (ft3/min/mmBtu/hr) 547

Fuel Heating Value (Btu/lb) 8,576

Fuel Sulfur Content 0.30%

Fuel Ash Content 4.69%

Number of SCR reactor chambers 1

ASR 1.05

Stored Ammonia Concentration 29%

Reagent Molecular Weight (g/mole) 17.03

Reagent Density (lb/ft3 @ 60F) 56.0

Reagent Specific Volume (gal/ft3) 7.481

NOx Molecular Weight (g/mole) 46.01

Number of Days of Storage for Ammonia 14

Pressure Drop for SCR Ductwork H2O") 3

Pressure Drop for each Catalyst Layer (H2O") 1

Temperature at SCR Inlet (degrees F) 650

Equipment Life (years) 20

Annual Interest Rate 7%

Inflation Since 1998 1.28

Catalyst Cost, Initial ($/ft3) 240

Catalyst Cost, Replacement ($/ft3) 290

Electrical Power Cost ($/kWh) 0.05

29% Ammonia Solution Cost ($/lb) 0.101

Operating Life of Catalyst (hours) 24,000
from EIA 2001

NPS estimate

from EIA 2001

Cost Tool

annual average from CAM data

company report

company report

company report

presumptive BART

NPS estimate

OAQPS Control Cost Manual

OAQPS Control Cost Manual

from EIA 2001

from EIA 2001

from EIA 2001

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

CPI

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual

OAQPS Control Cost Manual
Uncontrolled NOx emissions (tpy) 15,122

LNB Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc

( 0.46 - 0.23 )/

Boiler Calculations

2.3 QB = HVm-dotfuel

QB = 8576 Btu/lb * 651,484 lb/hr

QB = 5,587 mmBtu/hr

2.7 CFPlant = actual mfuel/maximum mfuel

CFPlant = 5.71E+09 lb/yr / 8760 hr/yr / 651,484 lb/hr

CFPlant = 100%

2.8 CFSCR = tSCR/365 days

CFSCR = 365 days/ 365 days

CFSCR = 100%

CFTotal = CFPlant x CFSCR

CFTotal = 100% * 100%

CFTotal = 69% from Given/Assume

2.12 qfluegas = qfuelQB(460+T)/(460+700o

F)nSCR

qfluegas = 547 ft3/min/(mmBtu/hr)* 5587 mmBtu/hr*( 460 +

qfluegas = 2,924,427 acfm

2.9 ηNOx = (NOxin – NOxout) / NOxin

ηNOx = ( 0.23 lb/mmBtu - 0.05 lb/mmBtu)/ 0.23

ηNOx = 78% Modern NOx controls can achieve 90% NOx reduction.

Overall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc

( 0.46 - 0.05 )/

NOx removed = 13,489 tpy

Controlled NOx emissions (tpy) = 1,633 tpy
0.46 = 50%

650 )/( 460 + 700 )* 1

lb/mmBtu

ieve 90% NOx reduction.

0.46 = 89%
SCR Reactor Calculations

2.19 Volcatalyst = 2.81 x QB x ηadj x Slipadj x NOxadj x Sadj x Tadj/NSCR

Volcatalyst = 2.81 * 5587 = 15700

2.2 ηadj = 0.2869 + (1.058 x η)

ηadj = 0.2869 +( 1.058 * 0.78 )

ηadj = 1.115

2.22 Slipadj = 1.2835 – (0.0567 x Slip)

Slipadj = 1.2835 - ( 0.057 * 2 )

Slipadj = 1.170

2.21 NOxadj = 0.8524 + (0.3208 x NOxin)

NOxadj = 0.8524 + ( 0.321 * 0.23 )

NOxadj = 0.926

2.23 Sadj = 0.9636 + (0.0455 x S)

Sadj = 0.9636 + ( 0.046 * 0.3 )

Sadj = 0.977

2.24 Tadj = 15.16 – (0.03937 x T) + (2.74 x 10-5 x T2

)

Tadj = 15.16 - ( 0.039 * 650 ) + 2.74E-05 *

Tadj = 1.146

Volcatalyst = 21,244 ft3

2.25 Acatalyst = qfluegas/(16 ft/sec x 60 sec/min)

Acatalyst = 2924427 /( 16 * 60 )

Acatalyst = 3046 ft2

2.26 ASCR = 1.15 x Acatalyst

ASCR = 1.15 * 3046

ASCR = 3503 ft2

2.27 l = w = ASCR

1/2

l = w = 59.2 ft

2.28 nlayer = Volcatalyst/(h’layer x Acatalyst)

nlayer = 21244 /( 3.1 * 3046 )

nlayer = 2.0

2.29 hlayer = [Volcatalyst/(nlayer x Acatalyst)] + 1

hlayer = 21244 /( 3 * 3046 ) + 1

hlayer = 3.3

2.3 ntotal = nlayer + nempty

ntotal = 2 + 1

ntotal = 3

2.31 hSCR = ntotal(c1

 + hlayer) + c2
hSCR =

3 * (7+ 3.3 ) +9

hSCR = 40 ft
422500
Reagent Calculations

2.32 m-dotreagent = NOxinQBASRηNOxMreagent/MNOx

m-dotreagent = 0.23 * 5587 * 1.05 * 78% * 17.03

m-dotreagent = 391 lb/hr

2.33 m-dotsol = m-dotreagent/Csol

m-dotsol = 391 / 0.29

m-dotsol = 1348 lb/hr

2.34 qsol = (m-dotvol/ρsol)Vsol

qsol = 1348 * 7.481 / 56

qsol = 180 gph

2.35 Tank Volume = qsolt

Tank Volume = 180 * 14 * 24

Tank Volume = 60,496 gal
/ 46.01
Direct Capital Cost

2.36 DC = QB[($3380/MMBtu/hr) + f(hSCR) +f(NH3

rate) + f(new) + f(bypass)](3500/Q

DC = 5587 (( $ 3,380 +

2.37 f(hSCR) = {[$612/(ft-mmBtu/hr)]hSCR} - $187.9/(mmBtu/hr)

f(hSCR) = 6.12 * 40 - 187.9

f(hSCR) = $ 57 /mmBtu/hr

2.38 f(NH3

rate) = [($411/lb/hr)(m-dotreagent/QB)] - $473/(mmBtu/hr)

f(NH3rate) = 411 * 391 / 5587 -

f(NH3rate) = $ (19) /mmBtu/hr

2.39 f(new) = $0/(mmBtu/hr) for retrofit

f(new) = $ -

2.41 f(bypass) = $0/(mmBtu/hr) for no bypass

f(bypass) = $ - /mmBtu/hr

2.43 f(Volcatalyst) = VolcatalystCCinitial

f(Volcatalyst) = 21244 * 240

f(Volcatalyst) = $ 5,098,619

DC = 5587 * ( $ 3,380 + $ 57 + $ (19)

DC = $ 34,706,599

Inflation Adjustment = 1.28

DC = $ 44,424,446
bypass)](3500/QB)

0.35 + f(Volcatalyst)

/(mmBtu/hr)

473/(mmBtu/hr)

47.3

+ $ - + $ - )*( 3500 / 1000 )^ 0.35 + $ 5,098,619
Indirect Capital Costs

Total Direct Capital Costs, A

Indirect Installation Costs 

General Facilities 0.05

Engineering and Home Office Fees 0.10

Process Contingencies 0.05

Total Indirect Installation Costs, B 0.20

Project Contingency, C = 0.15

Total Plant Cost D =

Allowance for Funds During Construction, E = 0

Royalty Allowance, F = 0

Preproduction Cost, G = 0.02

Inventory Capital, H = 0.101 /lb * 1348 lb/r * 24 hr/day *

Initial Catalyst and Chemicals, I =

Total Capital Investment TCI = D+G+H

Total Capital Investment TCI including LNB + OFA =
$ 44,424,446

A $2,221,222

A $4,442,445

A $2,221,222

A $8,884,889

(A+B) $7,996,400

A+B+C $61,305,736

$0

$0

(D+E) $1,226,115

14 days = $45,738

$ -

+D+E+F+G+H+I $62,577,589

$81,042,589
Annual Costs

2.45 DAC = Annual Maintenance Cost + Annual Reagent Cost + Annual Electricity Cost + Ann

2.46 Annual Maintenance Cost = 0.015 TCI

Annual Maintenance Cost = 0.015 * $ 62,577,589

Annual Maintenance Cost = $ 938,664

2.47 Annual Reagent Cost = qreagentCostreagenttop

2.47a top = CFtotal8760hr/yr

top = 69% * 8760

top = 6044

Annual Reagent Cost = 1348 * 6044 * 0.101

Annual Reagent Cost = $ 822,791

2.49 Annual Electricity Cost = Power (Costelect)top

2.48 Power = 0.105QB[NOxinηNOxCFtotal + 0.5(ΔPduct

Power = 0.105 * 5587 *( 0.463 *

Power = 1613 kW

Annual Electricity Cost = 1613 * 6044 * 0.05

Annual Electricity Cost = $ 487,570

2.51 Annual Catalyst Replacement Cost = (Catalyst Replacement Cost)FW

2.5 Catalyst Replacement Cost = nSCRVolcatalystCCreplace/R

Catalyst Replacement Cost = 1 * 21244 * 290 /

Catalyst Replacement Cost = $ 3,080,416

2.52 FWF = i{1/[(1+i)Y

-1]}

2.53 Y = hcatalyst/hyear

Y = 24000 / 6044

Y = 4

FWF = 0.07 *( 1 /( 1 +

FWF = 0.23

Annual Catalyst Cost = $ 693,796

DAC = $ 2,942,821

2.55 CRF = i(1+i)n

/[(1+i)

n

-1]

CRF = 0.07 *( 1 + 0.07 )^

CRF = 0.0944

Indirect Annual Cost = CFR * TCI

Indirect Annual Cost = 0.0944 * $ 81,042,589

Indirect Annual Cost = $ 7,649,847

2.56 Total Annual Cost = Direct Annual Cost + Indirect Annual Cost

Total Annual Cost = $ 2,942,821 + $ 7,649,847

Total Annual Cost = $ 10,592,668 + $ 1,480,000 for LNB+OFA

Total Annual Cost = $ 12,072,668

2.57 NOx Removed = NOxinηNOxQBtop

NOx Removed = 0.46 * 89% * 5587 *
NOx Removed = 13,489 data from CAM

2.58 Cost effectiveness = TAC/NOx removed

Cost effectiveness = $ 895 / ton

Cost effectiveness = / dv
nual Electricity Cost + Annual Water Cost + Annual Catalyst Cost

SRP estimate frm table E-1 $ 936,000

duct + ntotalΔPcatalyst)]

78% * 69% + 0.5 * ( 3 + 2 * 1 ))

talyst Replacement Cost)FWF

/Rlayer

2

0.07 )^ 4.00 - 1 )

20 /(( 1 + 0.07 )^ 20 - 1 )

+ Indirect Annual Cost

6044 / 2000