DSI Capital Costs

Description Formula Value

Boiler Size (MMBtu/hr) QB 1941

SO2 Removal Efficiency (%) ηNOx 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 materials $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 Worksheet

Variable Designation Units Value Calculation

Unit Size (Gross) A (MW) 162 Input (Greater than 50 MW)Retrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Gross Heat Rate C (Btu/kWh) 11982 InputSO2 Rate D (lb/MMBtu) 0.461 Input

Type of Coal E Input

Particulate Capture FMilled Trona GRemoval Target H 50

Maximum 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 K 1.43

Unmilled 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*D

Sorbent Waste Rate N (ton/hr) 1.04

(0.7035-0.00073696*H/K)*M; Based on a final reaction product of NA2SO4 and 

unreacted drysorbent as NA2CO3

Fly 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= 7200

Aux 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 benefits

Costs are all based on 2009 dollars

Capital Cost Calculation Include: equipment, installation, buildings, foundations, electrical, and retrofit difficulty.

$8,496,082 Base DSI module includes all equipment from unloading to injection

 BM ($/kW) $52 Base module cost per kWTotal Project Cost A1 = 5% of BM $424,804 Engineering and construction management costs A2 = 5% of BM $424,804 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 5% of BM $424,804 Contractor profit and fees CECC($) - excludes owner's costs = BM+A1+A2+A3 $9,770,494 Capital, engineering and construction cost subtotal

 CECC($/kW) - excludes owner's costs = $60 Capital, engineering and construction cost subtotal per kW

 B1 = %5 of CECC $488,525 Owners costs including "home office" costs (owner engineering, management, and procurement activities) TPC ($) - includes owner's costs = CECC + B1 $10,259,019 Total project cost without AFUDC

 TPC ($/kw) - includes owner's costs = $63 Total project cost per kW without AFUDC

 B2 = 0% of (CECC + B1) $0 AFUDC (based on 3 year enginering and construction cycle) TPC ($) - includes owner's costs and AFUDC = CECC + B1 + B2 $10,259,019 Total project cost TPC ($/kw) - includes owner's costs and AFUDC ($/kW) = $63 Total project cost per kW

PRB

ESP

TRUE

 BM ($) = 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 Worksheet

Variable Designation Units Value Calculation

Unit Size (Gross) A (MW) 162 Input (Greater than 50 MW)Retrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Gross Heat Rate C (Btu/kWh) 11982 InputSO2 Rate D (lb/MMBtu) 0.461 InputType of Coal E InputParticulate Capture FMilled Trona GRemoval Target H 50

Maximum 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 K 1.43

Unmilled 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*D

Sorbent Waste Rate N (ton/hr) 1.04

(0.7035-0.00073696*H/K)*M; Based on a final reaction product of NA2SO4 a

unreacted drysorbent as NA2CO3

Fly 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= 1For 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= 7200

Aux Power Q (%) 0.19 If Milled Trona M*20/A, else M*18/A

Trona 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 benefits

Costs are all based on 2009 dollars

Fixed O&M Cost FOMO ($/kW yr) = (1 additional operator)*2080*U/(A*1000) $0.770 Fixed O&M additional operating labor costs FOMM ($/kW yr) = BM*0.01/(B*A*1000) $0.524 Fixed O&M maintenance material and labor costs FOMA ($/kW yr) = 0.03*(FOMO+0.4*FOMM) $0.029 Fixed O&M additional addministrative labor costs FOM ($/kW yr) = FOMO + FOMM $1.324 Total Fixed O&M costsVariable O&M VOMR ($/MWh) = M*R/A $1.378 Variable O&M costs for trona reagent VOMW ($/MWh)= (N+P)*S/A $2.034 Variable O&M costs for waste disposal that includes both the sorbent and th VOMP ($/MWh) = Q*T*10 $0.114 Variable O&M costs for additional auxillary power required VOM ($/MWh) = VOMR + VOMW + VOMP + VOMM $3.526 Total variable O&M costs

Bituminous

ESP

TRUE
STATE

FACILITY_

NAME

ORISPL 

CODE UNIT ID OP YEAR

SUM OP 

TIME

NUM 

MONTHS 

REPORTED

GROSS 

LOAD 

(MWh) SO2 MASS SO2 RATE NOX RATE

NOX 

MASS

MT J E Corette 2187 2 2008 7,314 12 1,086,477 2,817 0.472 0.278 1,6MT J E Corette 2187 2 2009 7,824 12 1,141,292 2,832 0.455 0.261 1,6MT J E Corette 2187 2 2010 7,401 12 1,025,597 2,519 0.457 0.282 1,5

Averages 7,513 1,084,455 2,723 0.461 0.274 1,6