Gerald Gentleman #1 Dry Scrubber

Given/Assumed

Flow rate (acfm)

Flue Gas Temperature (degrees F)

Uncontrolled SO2 emissions (TPY) 24,893 2001 - 2003CAM data

Absorber + $48,377,000 company report

ductwork $48,404,000 company report

baghouse modifications $13,284,000 company report

Retrofit factor 1.0 NPS estimate

SO2 Control efficiency 90% NPS estimate

Control System Pressure Drop In. wc)

Operating Hours per Year 8760 NPS estimate

Operating Hours per Shift 8 NPS estimate

Operating Shifts per Year 1095 NPS estimate

Operating Labor Cost ($/hr) $ 40.60 company report

Maintenance Labor Cost ($/hr)

Waste generation (lb/hr)

Waste disposal cost ($/ton) $ 5.00 company report

Solvent usage (gpm)

Solvent cost ($/kgal) $ 1.00 company report

Chemical usage (lb/hr)

Chemical cost ($/ton) $ 95.00 company report

Electrical Cost ($/kWh)

Fan-Motor Efficiency (%)

Equipment Life (yr) 15 OAQPS Control Cost Manual

Interest Rate (%) 7.00% OAQPS Control Cost Manual
Gerald Gentleman #1 Dry Scrubber

Capital Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 9

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

Absorber + auxiliary equipment, EC A $110,065,000

Instrumentation 0.10 A

Sales taxes 0.03 A $3,301,950

Freight 0.05 A $5,503,250

Purchased equipment cost, PEC B= 1.18 A $118,870,200

Direct installation costs

Foundations & supports 0.12 B $14,264,424

Handling & erection 0.40 B $47,548,080

Electrical 0.01 B $1,188,702

Piping 0.30 B $35,661,060

Insulation 0.01 B $1,188,702

Painting 0.01 B $1,188,702

Direct installation costs x 1 x 0.85 B $101,039,670

Site preparation As required, SP

Buildings As required, Bldg.

Total Direct Costs, DC 1.85 B+SP+Bldg $219,909,870

Indirect Costs (installation)

Engineering 0.10 B $11,887,020

Construction and field expenses 0.10 B $11,887,020

Contractor fees 0.10 B $11,887,020

Start-up 0.01 B $1,188,702

Performance test 0.01 B $1,188,702

Contingencies 0.03 B $3,566,106

Total Indirect Costs, IC 0.35 B $41,604,570

Total Capital Investment = DC + IC 2.20 B+SP+Bldg $261,514,440
Gerald Gentleman #1 Dry Scrubber

Annual Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 5

Cost Item Factor

Direct Annual Costs, DC

Operating labor

Operator 0.5 hr/shift

Supervisor 15% of operator

Operating materials

Solvent 0 gpm * $ 1.00 /kgal =

Chemicals 0 lb/hr * $ 95.00 /ton =

Wastewater Disposal 0 lb/hr * $ 5.00 /ton =

Maintenance

Labor 0.5 hr/shift

Material 100.00% of maintenance

Electricity All electricity equal to:

fan 0.000181 * 0 acfm* 0 in.wc*

8760 hr/yr * 0 unit cost =

pump

Total DC

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs

Administrative charges 2% of Total Capital Investment

Property tax 1% of Total Capital Investment

Insurance 1% of Total Capital Investment

Capital recovery 0.1098 * Total Capital Investment

Total IC

Total Annual Cost DC + IC
Manual, Chap 5

Cost

$22,229

$3,334

$0

$0

$0

$0

$0

$0

$25,563

$15,338

$5,230,289

$2,615,144

$2,615,144

$28,712,880

$39,188,795

$39,214,358
Gerald Gentleman #1 Dry Scrubber

SO2

Uncontrolled emissions (TPY) 24,893

Control efficiency (%) 90%

Emission reduction (TPY) 22,403

Controlled emissions (TPY) 2,489

Total annualized cost ($/yr) $39,214,358

Cost/ton removed ($/T) $1,750