**NPPD - Gerald Gentleman Unit #2**
**Given/Assumptions**

New or Retrofit? Retrofit Generation capacity (MW ) 700 SCR bypass included? No Fuel High Heating Value (Btu/lb) **8,576** Maximum Fuel Consumption Rate (lb/hr) 6.5E+05 Av erage Annual Fuel Consumption (lb) **5.71E+09** Number of SCR Operating Days 365 Plant Capacity Factor 62% Uncontrolled NOx Concentration (lb/mmBtu) **0.32** Uncontrolled NOx Emissions (tpy) **15,122** LNB + OFA Total Capital Cost **18,465,000 $**  LNB + OFA Total Annual Cost **1,480,000 $**  SCR inlet NOx Concentration (lb/mmBtu) **0.23** Required Controlled NOx Concentration (lb/mmBtu) **0.05** Acceptable Ammonia Slip (ppm) 2.0 Fuel Volume Flow Rate (ft3/min/mmBtu/hr) 547 Fuel Heating Value (Btu/lb) **8,576** Fuel Sulfur Content **0.30%** Fuel Ash Content **4.69%** Number of SCR reactor chambers **1** ASR 1.05 Stored Ammonia Concentration 29% Reagent Molecular W eight (g/mole) 17.03 Reagent Density (lb/ft3 @ 60F) 56.0 Reagent Specific Volume (gal/ft3) 7.481 NOx Molecular W eight (g/mole) 46.01 Number of Days of Storage for Ammonia 14 Pressure Drop for SCR Ductwork H2O") 3 Pressure Drop for each Catalyst Layer (H2O") 1 Temperature at SCR Inlet (degrees F) 650 Equipment Life (years) 20 Annual Interest Rate 7% Inflation Since 1998 1.28 Catalyst Cost, Initial ($/ft3) 240 Catalyst Cost, Replacement ($/ft3) 290 Electrical Power Cost ($/kW h) 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** ( 0.32

- 0.23 )/

**Boiler Calculations**



### 2.3 Q B 

### = HVm-dot fuel QB = 8576 Btu/lb * 651,484 lb/hr QB = **5,587** mmB tu/hr



### 2.7 CF Plant 

### = actual m fuel

### /maximum m fuel CFPlant = 5.71E+09 lb/y r / 8760 hr/y r / 651,484 lb/hr CFPlant = 100%



### 2.8 CF SCR 

### = t SCR



### /365 day s CFSCR = 365 days/ 365 days CFSCR = 100%



### CF Total 

### = CF Plant 

### x CF SCR CFTotal = 100% * 100% **CFTotal = 62%**  **from Given/A ssume** 



### 2.12 q fluegas 

### = q fuel 

### Q B 

### (460+T)/(460+700 o 

### F)n SCR qfluegas = 547 ft3/min/(mmBtu/hr)* 5587 mmB tu/hr*( 460 + qfluegas = 2,924,427 acfm



### 2.9 η NOx

### = (NOx in

### – NOx out 

### ) / NOx in ηNOx = ( 0.23 lb/m mB tu - 0.05 lb/m mB tu)/ 0.23 ηNOx = **78% Modern NOx controls can achieve 90% NOx reduction.** 

**Overall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc** ( 0.32

- 0.05 )/

**NOx removed =** 12,764 tpy
**Controlled NOx emissions (tpy) =** 2,358 tpy0.32 = 28%

650 )/( 460 + 700 )* 1

lb/m mB tu **Modern NOx controls can achieve 90% NOx reduction.**

0.32 = 84%**SCR Reactor Calculations**



### 2.19 Vol catalyst

### = 2.81 x Q B 

### x η adj 

### x Slip adj 

### x NOx adj 

### x S adj 

### x T adj 

### /N SCR Volcatalyst = 2.81 * 5587 = 15700



### 2.2 η adj 

### = 0.2869 + (1.058 x η) ηadj = 0.2869 +( 1.058 * 0.78 ) ηadj = 1.115 

### 2.22 Slip adj 

### = 1.2835 – (0.0567 x Slip) Slipadj = 1.2835 - ( 0.057 * 2 ) Slipadj = 1.170 

### 2.21 NOx adj 

### = 0.8524 + (0.3208 x NOx in 

### ) NOxadj = 0.8524 + ( 0.321 * 0.23 ) NOxadj = 0.926 

### 2.23 S adj 

### = 0.9636 + (0.0455 x S) Sadj = 0.9636 + ( 0.046 * 0.3 ) Sadj = 0.977 

### 2.24 T adj 

### = 15.16 – (0.03937 x T) + (2.74 x 10 -5 

### x T 2 

### ) Tadj = 15.16 - ( 0.039 * 650 ) + 2.74E-05 * Tadj = 1.146 Volcatalyst = 21,244 ft3



### 2.25 A catalyst

### = q fluegas 

### /(16 ft/sec x 60 sec/min) Acatalyst = 2924427 /( 16 * 60 ) Acatalyst = 3046 ft2



### 2.26 A SCR



### = 1.15 x A catalyst ASCR = 1.15 * 3046 ASCR = 3503 ft2



### 2.27 l = w = A SCR 1/2
l = w = 59.2 ft



### 2.28 n layer 

### = Vol catalyst

### /(h’ layer



### x A catalyst 

### ) nlayer = 21244 /( 3.1 * 3046 ) nlayer = 2.0



### 2.29 h layer 

### = [Vol catalyst

### /(n layer



### x A catalyst 

### )] + 1 hlayer = 21244 /( 3 * 3046 ) + 1 hlayer = 3.3



### 2.3 ntotal

### = n layer



### + n empty ntotal = 2 + 1 ntotal = 3



### 2.31 h SCR 

### = ntotal 

### (c 1 

### + h laye

### r) + c 2hSCR = 3 * ( 7 + 3.3 ) + 9 hSCR = 40 ft422500**Reagent Calculations**



### 2.32 m- dot reagent



### = NOxin 

### Q B 

### ASR

**η NOx** 

### M reagent



### /MNOx m-dotreagent = 0.23 * 5587 * 1.05 * **78%** * 17.03 m-dotreagent = 391 lb/hr



### 2.33 m- dot sol

### = m-dot reagent 

### /C sol m-dotsol = 391 / 0.29 m-dotsol = 1348 lb/hr



### 2.34 q sol

### = (m-dot vol

### /ρ sol 

### )V sol qsol = 1348 * 7.481 / 56 qsol = 180 gph



### 2.35 Tank Volume = q sol

### t Tank Volume = 180 * 14 * 24 Tank Volume = 60,496 gal/ 46.01**Direct Capital Cost**



### 2.36 DC = Q B 

### [($3380/MMBtu/hr) + f(h SCR

### ) +f(NH 3 

### rate) + f(new) + f(bypass)](3500/Q DC = 5587 (( 3,380 $ + 

### 2.37 f(h SCR

### ) = {[$612/(ft-m mBt u/hr)]h SCR 

### } - $187.9/(m mBt u/hr) f(hSCR) = 6.12 * 40

- 187.9 

### f(hSCR) = 57

$ /mmBtu/hr



### 2.38 f(NH 3 

### rate) = [($411/l b/hr)(m-dot reagent



### /Q B 

### )] - $473/(m

mBt u/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

### ) = Volcatalyst 

### CCinit ial 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 $

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

### ) 0.35 

### + f(Volcatalyst

### )
} - $187.9/(m

mBt u/hr)

)] - $473/(m

mBt u/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 Hom e 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 + Annual Water Cost + Annual Catalyst Cost 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 = qreagent 

### Cost reagent

### t op 

### 2.47a **t op**  

### = CF **total** 

### 8760hr/yr top = **62%** * 8760 

### top = **5431** Annual Reagent Cost = 1348 * **5431** * 0.101 Annual Reagent Cost = 739,319 $ 

### 2.49 Annual Electricity Cost = Power (Cost elect) 

### t op 

### 2.48 **Power = 0.105Q B**  

### [NOx**in** 

### ηNOxCFtotal + 0.5(ΔP **duct** Power = 0.105 * 5587 *( 0.321 * Power = 1558 kW Annual Electricity Cost = 1558 * **5431** * 0.05 Annual Electricity Cost = 423,063 $ 

### 2.51 Annual Catalyst Replacement Cost = (Catalyst Replacement Cost)FWF 2.5 Catalyst Replacement Cost = n SCR

### Volcatalyst 

### CC replace

### /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



### /h year Y = 24000 / **5431** Y = 4 FW F = 0.07 *( 1 /( 1 + FW F = 0.23 Annual Catalyst Cost = 693,796 $ 

### DAC = **2,794,842 $** 



### 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 = 2,794,842

$ + 7,649,847 $ Total Annual Cost = 10,444,689

$ + 1,480,000 $ for LNB+OFA Total Annual Cost = 11,924,689

$



### 2.57 NOx Removed = NOxin 

### η NOx 

### Q B 

### t op NOx Removed = 0.32 * 84% * 5587 ***NOx Removed = 12,764**  **data from CAM**



### 2.58 Cost effectiveness = TAC/NOx removed Cost effectiveness = 934

$ / ton

Cost effectiveness = 6,179,528

$ / dv

### DAC = Annual Maintenance Cost + Annual Reagent Cost + Annual Electricity Cost + Annual Water Cost + Annual Catalyst Cost

**SRP estimate frm table E-1 936,000**  **$**

**duct**

### + n **total** 

### ΔP **catalyst**

### )] 78% * 62% + 0.5 * ( 3 + **2** * 1 ))



### Annual Catalyst Replacement Cost = (Catalyst Replacement Cost)FWF /Rlayer 2

0.07 )^ 4.00

- 1 )

20 /(( 1 + 0.07 )^ 20

- 1 )



### Total Annual Cost = Direct Annual Cost + Indirect Annual Cost

**5431** / 2000