Androscoggin Power Boilers #1 or #2

Given/Assumptions

New or Retrofit? Retrofit

Extra retrofit cost factor 1.0

Generation capacity (MW) 68

SCR bypass included? No

Fuel High Heating Value (Btu/gal) 150,000

Maximum Fuel Consumption Rate (gal/hr) 4.5E+03

Maximum Annual Fuel Consumption (gal) 3.97E+07

Maximum Annual Heat Input (mmBtu) 5.96E+06

Number of SCR Operating Days 365

Uncontrolled NOx Concentration (lb/mmBtu) 0.41

Uncontrolled NOx Emissions (tpy) 383

Actual annual heat input (mmBtu) 1.87E+06

Required Controlled NOx Concentration (lb/mmBtu) 0.041

Acceptable Ammonia Slip (ppm) 2.0

Fuel Volume Flow Rate (dscf/mmBtu) 9,190

Fuel Sulfur Content 0.70%

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 1.35

Catalyst Cost, Initial ($/ft3) $ 85

Catalyst Cost, Replacement ($/ft3) $ 85

Electrical Power Cost ($/kWh) 0.08

29% Ammonia Solution Cost ($/lb) 0.058

Operating Life of Catalyst (hours) 24,000
OAQPS Control Cost Manual

estimated

estimated

OAQPS Control Cost Manual

company report

calculated 680 mmBtu/hr from company report

calculated

calculated

assumed

company report

company report

calculated

calculated from company estimate

OAQPS Control Cost Manual

AP-42 6,249,200

company report

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

CEPCI 2007/CEPCI 1998

calculated $ 3,000 /m3 from PacifiCorp report

calculated $ 3,000 /m3 from PacifiCorp report

company report

calculated $ 400.00 /ton from PacifiCorp report

OAQPS Control Cost Manual
Boiler Calculations

2.3 QB = HVm-dotfuel

QB = 150,000 Btu/gal * 4,533 gal/hr

QB = 680 mmBtu/hr

2.7 CFPlant = actual mfuel/maximum mfuel

CFPlant = 1.87E+06 mmBtu/yr / 5.96E+06 mmBtu/yr

CFPlant = 31%

2.8 CFSCR = tSCR/365 days

CFSCR = 365 days/ 365 days

CFSCR = 100%

CFTotal = CFPlant x CFSCR

CFTotal = 31% * 100%

CFTotal = 31%

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

F)nSCR

qfluegas = 9,190 ft3/min/(mmBtu/hr)* 680 mmBtu/hr*( 460 +

qfluegas = 5,979,838 acfm

2.9 ηNOx = (NOxin – NOxout) / NOxin

ηNOx = ( 0.41 lb/mmBtu - 0.041 lb/mmBtu)/ 0.41

ηNOx = 90%

Uncontrolled NOx emissions (tpy) 383
650 )/( 460 + 700 )/ 1

lb/mmBtu
SCR Reactor Calculations

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

Volcatalyst = 2.81 * 680 = 1911

2.2 ηadj = 0.2869 + (1.058 x η)

ηadj = 0.2869 +( 1.058 * 0.90 )

ηadj = 1.239

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 * 0.41 )

NOxadj = 0.984

2.23 Sadj = 0.9636 + (0.0455 x S)

Sadj = 0.9636 + ( 0.046 * 0.7 )

Sadj = 0.995

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 = 3,110 ft3 each = 88.12 m3 each

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

Acatalyst = 5,979,838 /( 16 * 60 )

Acatalyst = 6229 ft2 

2.26 ASCR = 1.15 x Acatalyst

ASCR = 1.15 * 6229

ASCR = 7163 ft2

2.27 l = w = ASCR

1/2

l = w = 84.6 ft

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

nlayer = 3110 /( 3.1 * 6229 )

nlayer (calc) = 0.2

nlayer = 2.0

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

hlayer = 3110 /( 2.0 * 6229 ) + 1

hlayer = 1.2

2.3 ntotal = nlayer + nempty

ntotal = 2 + 1

ntotal = 3
2.31

hSCR = ntotal(c

1

 + hlayer) + c

2

hSCR =3 * (7+ 1.2 ) +9

hSCR = 34 ft
422500
Reagent Calculations

2.32 m-dotreagent = NOxinQBASRηNOxMreagent/MNOx

m-dotreagent = 0.41 * 680 * 1.05 * 90% * 17.03

m-dotreagent = 98 lb/hr

2.33 m-dotsol = m-dotreagent/Csol

m-dotsol = 98 / 0.29

m-dotsol = 336 lb/hr

2.34 qsol = (m-dotvol/ρsol)Vsol

qsol = 336 * 7.481 / 56

qsol = 45 gph

2.35 Tank Volume = qsolt

Tank Volume = 45 * 14 * 24

Tank Volume = 15,094 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 = 680 (( $ 3,380 +

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

f(hSCR) = 6.12 * 34 - 187.9

f(hSCR) = $ 19 /mmBtu/hr

2.38 f(NH3

rate) = [($411/lb/hr)(m-dotreagent/QB)] - $47.3/(mmBtu/hr)

f(NH3rate) = 411 * 98 / 680 - 47.3

f(NH3rate) = $ 12 /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) = 3110 * 85

f(Volcatalyst) = $ 264,370

DC = 680 * ( $ 3,380 + $ 19 + $ 12 +

DC = $ 4,379,136 for each reactor

DC = $ 4,379,136 for all reactors

Inflation Adjustment = 1.35

DC = $ 5,911,834
+ f(bypass)](3500/QB)

0.35 + f(Volcatalyst)

87.9/(mmBtu/hr)

 - $47.3/(mmBtu/hr)

$ - + $ - )*( 3500 / 680 )^ 0.35 + $ 264,370
Indirect Capital Costs

Total Direct Capital Costs, A

Indirect Installation Costs 

General Facilities 0.05 A

Engineering and Home Office Fees 0.10 A

Process Contingencies 0.05 A

Total Indirect Installation Costs, B Retrofit factor = 1.0 * 0.20 A =

Project Contingency, C = Retrofit factor = 1.0 * 0.15 (A+B) =

Total Plant Cost D =

Allowance for Funds During Construction, E = 0

Royalty Allowance, F = 0

Preproduction Cost, G = 0.02

Inventory Capital, H =

Initial Catalyst and Chemicals, I = 0.058 /lb * 336 lb/r * 24 hr/day *

Total Capital Investment TCI = D+G+H
5,911,833.67

$295,592

$591,183

$295,592

0.20 A = $1,182,367

0.15 (A+B) = $1,064,130

A+B+C $8,158,330

$0

$0

(D+E) $163,167

14 days = $6,553

+D+E+F+G+H+I $8,328,050

Cost/kW = $122
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 * $ 8,328,050

Annual Maintenance Cost = $ 124,921

2.47 Annual Reagent Cost = qreagentCostreagenttop

2.47a top = CFtotal8760hr/yr

top = 31% * 8760

top = 2748

Annual Reagent Cost = 336 * 2748 * 0.058

Annual Reagent Cost = $ 53,600

2.49 Annual Electricity Cost = Power (Costelect)top

2.48 Power = 0.105QB[NOxinηNOx + 0.5(ΔPduct + ntotalΔPcatalyst

Power = 0.105 * 680 *( 0.41 *

Power = 241 kW

Annual Electricity Cost = 241 * 2748 * 0.08

Annual Electricity Cost = $ 52,886

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

2.5 Catalyst Replacement Cost = nSCRVolcatalystCCreplace/Rlayer

Catalyst Replacement Cost = 1 * 3110 * 85.01581521 /

Catalyst Replacement Cost = $ 132,185

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

-1]}

2.53 Y = hcatalyst/hyear

Y = 24000 /( 100% * 8760 )

Y = 3

FWF = 0.07 *( 1 /( 1 +

FWF = 0.31

Annual Catalyst Cost = $ 41,116

DAC = $ 272,523

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 * $ 8,328,050

Indirect Annual Cost = $ 786,109

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

Total Annual Cost = $ 272,523 + 786,109

Total Annual Cost = $ 1,058,632

2.57 NOx Removed = NOxinηNOxQBtop

NOx Removed = 0.41 * 90% * 680 *

NOx Removed = 345
2.58 Cost effectiveness = TAC/NOx removed

SCR Cost effectiveness ($/ton) = $ 3,070

Greatest dv improvement = 0.85

SCR Cost effectiveness ($/dv) = $ 1,245,449

Cumulative dv improvement = 2.3

SCR Cost effectiveness ($/dv) = $ 460,275
l Electricity Cost + Annual Water Cost + Annual Catalyst Cost

catalyst)]

90% + 0.5 * ( 3 + 3 * 1 ))

st Replacement Cost)FWF

2

0.07 )^ 3 - 1 )

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

ndirect Annual Cost

2748 / 2000
Mill High (dv)

Class I Area Mill PB #1+#2

Acadia NP 3.7 2.8

Great Gulf WA 2.2 1.7

Lye Brook WA 1.0

Moosehorn WA 1.7 1.3

Presidential Range-Dry River WA 2.9 2.3

Roosevelt Campobello IP 1.6

13.1 8.1

PB #1+#2 High (dv)

Class I Area 0.7% S WS SCR SNCR

Acadia NP 1.9 1.3 1.1 1.4

Great Gulf WA 1.0 0.8 0.7

Lye Brook WA

Moosehorn WA 0.7 0.3 0.6 0.6

Presidential Range-Dry River WA 1.3 0.8 1.0 1.1

Roosevelt Campobello IP

4.9 2.4 3.5 3.8
Improvement (dv)

0.7% S WS SCR SNCR

0.9 1.5 1.7 1.4

0.7 0.9 1.0

0.6 1.0 0.7 0.7

1.0 1.5 1.3 1.2

3.2 4.0 4.6 4.3