P. 1 

# OAR Box 1778 Prepped by Ollie Stewart



### Document

Number: 

# 28 ) ll-B-3 Docket Number: 

# A-90-0 6

Printed 10/28/20089:50:52 AM Sheet 28of 276P. 2 

# J2ADIA H CORPORATIO N

Augus t 5 , 198 8 

### ^ 1 0 

### 1988 U.S . FP AA° n 8r3n cr j • cr7 tregio n V Ms . Donn a Gree n UNITE D STATE S ENVIRONMENTA L PROTECTIO NAGENC Y (REGIO NFIVE ) 23 0 Sout h Deerhor n st . Bo x Numbe r 5AR2 6 Chicago , Illinoi s 6060 4 Dea r Ms . Green : A s par t o f th e Nationa l Aci d Precipitatio n Assessmen t Progra m(NAPAP) , Radia n i s conductin g a progra mdirecte d b yEPA-AEER L t o develo p sit e specifi c retrofi t cost s fo r SO - an d N O control s a t th e to p 20 0 SO p emittin g powe r plants . A t you r request , w e ftave use d th e procedure s develope d unde r th e NAPA P effor t t o estimat e th e cos t o f FG D system s a t th e Por t Washingto n plant . Tabl e 1 present s th e informatio n obtaine d fro mEIA-For m76 7 (1986 ) whic h wa s use d t o estimat e costs . Table s 2 an d 3 presen t th e sit e specifi c assumption s use d t o develo p retrofi t factor s and scop e adder s for :



## D 2 ) 3 ) - conventiona l limeston e we t FG D (L/LS-FGD) ,

- furnac e sorben t injectio n (FSI) , and

- duc t sorben t injectio n (DSD) . Fo r L/LS-FGD , adipi c aci d wa s use d a s a chemica l additive , an d S0
- remova l efficienc ywa s 9 0 percent . Absorber s wer e place d behin d th e existin g chimney s i n a n are a whic h currentl yi s th e as h settlin g pond . Appendi x A present s th e FG D uni t layou t fo r al l th e boiler s i n Por t Washington.

- Tabl e 4 present s th e cos t estimate s fo r th e thre e technologie s i n Marc h 198 8 dollars . Th e breakdow n o f th e cos t fo r L/LS-FG D combine d cas e ar e show n i n Appendi x B . Fo r L/LS-FG D tw o cost s ar e presented : fo r a singl e uni t o f 8 0 MW (10 0 percen t estimate d spar e absorbe r capacity ) an d fo r combine d FG D unit s o f 40 0 MW (3 3 precen t estimate d spar e absorbe r capacity) . Fo r LIM B technolog yElectr o Stati c Precipitato r specifi c collectio n are a bein g les s tha n 20 0 squar e actua l cubi c fee t pe r minute . I t ma yno t b e feasib l ESP s withou t majo r ES P upgrade s and plat e are a addi t baghous e optio n i s no t presente d her e sinc e i t i s n o cos t option . Duc t Spra yDryin g technolog y(DSD ) i s becaus e duc t residenc e tim e betwee n th e boiler s and i n insufficien t drople t evaporatio n residenc e time . ESP s ar e use d fo r sorben t injectio n and ne wbaghous e particulat e matte r contro l DS D coul d b e applicable , i s als o presente d i n Tabl e 4 . s (ESPs ) ar e smal l wit h fee t pe r thousand s o f e t o reus e th e existin g ions . LIM B wit h a ne w t considere d t o b e a lo w no t a lo wcos t option , ESP s ar e short , resultin g However , i f th e existin g s ar e installe d fo r cost s fo r thi s technolog y

Progres s Center,320 0 E . Chape l Hil l Rd./Nelso n Hwy./P.O . Bo x.3000/Researc h Triangl e Park , N.C . 27709/(919)541-910 0P. 3 -2 - Pleas e not e tha t thes e cost s wer e generate dusin g th e Integrate dAi r Pollutio nContro l Cos t mode l (IAPCS ) whic hi s currentl y bein g revise db

y anothe r EPA

contractor . However , I d o no t expec t an y majo r change s t o th e model , an

dreporte dcost s her e shoul dbe reasonabl y accurate . Unfortunately , I di dno t receiv e th e A& E cos t estimate s fro m th e plant ; however , base donm y conversation s wit hth e plan t personnel , Radia ncos t estimate s fo r L/LS-FG D ar e reasonabl y

clos e t o th e A& E cos t estimates . Cost s wer e no t develope dfo r LIM B an dDS Dtechnologie s b

y the plant , an

dtherefor e thes e coul dno t b e compare dwit hou r estimates . Pleas e cal l me i f yo uhav e an y question s o r comment s a t 919-541-9100 . Sincerely , . Mehd i Maibod i cc : Norm

Kaplan , EPA Tom m Emmel , Radia nP. 4



### TABL E 1 . POR T WASHINGTON STEA M PLANT OPERATIONAL DATA

BOILE RNUMBER1.- 5 GENERATINGCAPACIT Y(MW-each ) 8 0 INSTALLATION

DAT E 1935,43,48,49,5 0 FIRINGTYP E COAL SULFU

RCONTEN T (PERCENT ) 2. 0 COAL HEATIN

GVALU E (BTU/LB ) 1200 0 COA L AS H CONTEN T (PERCENT ) 7. 0 FL YAS H SYSTEM

DR YHANDLING AS HDISPOSAL METHO DOFF-SIT E STAC KNUMBER1- 2 COAL DELIVERYMETHOD S RAI L PARTICULAT E CONTRO L TYP E INSTALLATION

DAT E EMISSION (LB/M M BTU ) REMOVAL EFFICIENC Y DESIG N SPECIFICATION SULFURSPECIFICATION

(PERCENT ) SURFAC E AREA

(100 0 SQ.FT ) GA S EXI T RAT E (100 0 ACFM ) SCA (SQ.FT/100 0 ACFM ) OUTLE T TEMPERATUR E (°F ) ES P 1967-6 8 0.05-0. 1 98.6-99. 3 3. 1 8 7 45 0 19 3 39 0P. 5



### TABL E 2 . SUMMARYO F RETROFI T FACTORDAT A FO RPOR T WASHINGTO N

UNIT S 1- 5

SIT E ACCESS/CONGESTIO N S0 2 REMOVAL FLU E GA S HANDLING ES P REUS E CAS E BAGHOUS E CAS E DUC T WOR KDISTANC E ES P REUS E BAGHOUS E ES P REUS E NE W BAGHOUS E SCOP E ADJUSTMENT S WE T T O DRY (FEET )

ESTIMATE DCOS T (1000$ ) NE W CHIMNE Y ESTIMATE DCOS T (1000$ ) OTHE R RETROFI T FACTOR S FGDSYSTE M ES P REUS E CAS E BAGHOUS E CAS E ES P UPGRAD E NE W BAGHOUS E GENERAL FACILITIE S FGDTECHNOLOG Y FORCE D L/L S FGDOXIDATION

MEDIU M MEDIU M 100-30 0 N A N A

N O N A N O 0 N O 1.3 8 N A N A (PERCENT ) 1 0 N

A N A N A N A N A

N A N A N A 0

N A N A N A 0 LIM E SPRA YDRYING

N A N A N A N A N A N A N A

N A N A N A 0

N A N A N A N A 0P. 6

TABL E 3 . DUC T SPRA

YDRYINGANDFURNAC E SORBEN T INJECTION TECHNOLOGIE S FO

RPOR T WASHINGTON

UNIT S 1- 5

ITE M SIT E ACCESS/CONGESTIO N REAGEN T PREPARATION

MEDIU M ES P UPGRAD E MEDIU M NE W BAGHOUS E N A SCOP E ADDER S CHANG E ES P AS H DISCHARG E SYSTEM T O DR YHANDLINGNO ESTIMATE DCOS T (1000$ ) N A ADDITIONA L DUC T WOR K(FT ) NE W BAGHOUS E CAS E N A • ESTIMATE DCOS T (1000S ) N A ES P REUS E CAS E N A ESTIMATE DCOS T (1000$ ) N A DUC T DEMOLITION

LENGT H (FT ) 5 0 DEMOLITION

COS T (1000S ) 2 5 TOTAL COS T (1000$ ) ES P UPGRAD E CAS E 2 5 A NE W BAGHOUS E CAS E N A RETROFI T FACTOR S CONTRO L SYSTEM

(DS DSYSTEM

ONLY ) 1.2 5 ES P UPGRAD E 1.3 4 NE W BAGHOUS E N ATABLE 4 . COS T ESTIMATE S FO RFG D TECHNOLOGIE S A

T POR T WASHINGTO

N PLAN T (MARC H 198 8 S )

Cas e Uni t Numbe r Siz e

(MW ) Capacit y

facto r (X ) Retrofi t

facto r Existing/Additiona l

2 SC A slze/SC

A siz e Remova 1

efficienc

y Capita l cos t S/K W Uni t

cos t 51 ton LevelIzed

cos t (mLlls/Kvhr ) L/L S -I - additiv

e L/L S + additiv

e L/L S + additiv

e L/L S + additiv

e 4 FS I + • ES P FS I + ES P 1- 5 (each )

1- 5 (each )

1- 5 (each ) 1- 5 (each ) 8 0 1- 5 (total ) 40 0

8 0 1- 5 (total ) 40 0

8 0 8 0 14. 3

14. 3 5 0 5 0 14. 3 5 0 1.3 8

1.3 8 1.3 8 1.3 8 1.3 4 1.3 4 193/ 0

193/ 0 193/ 0 193/ 0 193/17 4 193/17 4 9 0 9 0 9 0 9 0 7 0 7 0 48 1

22 3 48 1 22 3 11 5 11 5 7,33 6

3,37 0 2,39 2 1,18 5 3.79 4 1.39 5 106. 5 48. 9 34. 7 17. 2 42.8 6 15. 8

DS D + F F DS D + F F DS D + F F

DS D + F F 1- 5 (each ) 1- 5 (each ) 8 0

8 0 2 unit s 16 0 combined 2 unit s 16 0 combined 14. 3 5 0 14. 3

5 0 1.3 4

1.3 4 1.3 4

1.3 4 193/N A 193/N A 193/N A

193/N A 7 7 7 7 7 7

7 7 41 1

41 1 22 3

22 3 7.15 7

2,19 1 3,89 4

1.23 3 89. 5 27. 4 48. 7

15. 4

'Retrofi t facto r fo r FS I an dDS D i s fo r ES P upgrad e an d baghous e sit e acces s /cogestio n respectively . SCA , specifi c collectio nare a insquar e fee t pe r thousand s actua l cubi c fee t pe r minut e o f fluega s flow . L/LS-FG D wit hadipi c aci da s a nadditive . U Furnac e sorben t injectio nwit hreuse do f th e existin g ESPs . Duc t spra y

dryin g wit hne w baghouses . No t applicable .P. 8



### ATTACHEMEN T A
FGDSYSTE M

LAYOU T FORPOR T WASHINGTO NP. 9P.1 0

ATTACHMEN TB
DETAILE D COSTOUTPU TP.1 1 POR T WASHINGTO N klMESTON E FGD+ADDITIV E FO R UNIT S 1- 5 

# DRAFT USE R INPU TSUMMAR

Y 

### DO NO TQUOT E O R CIT E

BOILE RSIZE . CAPACIT YFACTOR.T4. 3 * WAL L FIRED , DR Y BOTTO M 390 . DEG. F DAT E O F COMMERCIA L OPERATIO NO F BOILER : 197 5 CONSTRUCTIO NSTATU S O F CONTRO L SYSTEM : RETROFI T COA L CLEANIN G LEVEL : RUN-OF-MIN E SORTE D AN D SCREENE D COA L CHARACTERISTIC S A T THI S CLEANIN G LEVEL : HH V (BTU/# ) SULFUR CONTEN T (% ) AS H CONTEN T (% ) COS T ($/T0N ) CHLORIN E CONTEN T (% ) MOISTUR E CONTEN T (% ) VOLATIL E MATTE R CONTEN T (% ) FIXE D CARBO NCONTEN T (% ) 12000. 0 2.0 0 7.0 0 0.0 0 0.1 0 4.0 0 28.3 0 52.6 0 AS H CHARACTERISTIC S A T THI S CLEANIN G LEVEL : NA2 0 CONTEN T (% ) ALKALINIT Y (% ) FE20 3 CONTEN T (% ) 1.0 0

4.5 0 25.9 0

+ 1 CONTRO L SYSTE M CONFIGURATION : 1 - FG D

ECONOMI C PREMISE S (TVA/EPRI ) EPR I INTEGRATE D AI R POLLUTIO NCONTRO L SYSTE M COSTIN G PROGRAM

USE R INPUT SUMMAR Y (CONTINUED ) PARAMETE R FIL E USED : PARMFILE.EP R ADJUSTMEN T FIL E USED : DEFAULT.CA F BATC H DATAFIL E USED : PORT.DAT TH E FOLLOWIN G CHANGE S WER E MAD E T O THES E PARAMETE R FILE S FO R THI S RUN : NE W VALU E DESCRIPTIO N 0.1800E+0 7 FLO W RATE , ACF M (CALCULATE D I F ZERO ) 1.38 0 FGD RETROFI T FACTOR , DIMENSIONLES SP.1 2 

### 3 00 0 DURA T IDEALIZE D TIM E REQUIRE D FOR CONSTRUCTIO N(YRS) . 3*37 6 - ' WAST E DISPOSAL , DRY ($/TON ) 0 250 0 EXCES S AIR , FRACTIO N_ _hn 

### , ^ _ •51 0 0 XL GL/ GRATI O FOR SCRUBBER , GALLONS/100 0 CU . FT . DR/\P T 2 00 0 IS R L/G , EFFICIENC Y CONTRO L VARIABLES,1,2,3 ) L/I\tt , I l'07 0 STOICHIOMETRI C RATI O (FGD ) % 

### D O NO T OUOT E 0«? PIT F 2 00 0 IAD D CHEMICA L ADDITIV E OPTION(0,1,2 ) ¥ UU, t U a 

### CU E 0 OOO O IFO X FORCE D OXIDATIO NOPTIO N(0,1,2,3 ) i 00 0 IAL K ALKAL I ADDITIO NOPTIO N(1,2 ) 5*20 0 PHLIM E RECIRCULATIO NLIQUO R P H 33 5 5 C E PLANT INDE XFO R CORRESPONDIN GYEAR AN D MONT H O F COS T 364* 9 C E MATERIA L INDE XFO R CORRESPONDIN GYEAR AN D MONT H O F COS T 258* 9 C E LABO R INDE XFO R CORRESPONDINGYEAR AN D MONT H O F COS T 1 FGD + 

### TH E CONFIGURATIO NO F THI S SYSTE MINCLUDE S SPRA Y TOWERS . LIMESTON E SLURRY . ADIPI C ACI D CHEMICA L ADDITIV E I S USED . SPAR E ABSORBE R CAPACIT Y O F 3^*I S PROVIDED . TH E L/ GRATI O I S 60.9 . DESIGNS0 2 REMOVA L O F 90.0 % OCCUR S INTH E TREATE D GA S STREAM . 0. % O F TH E GA S STREAMI S BEINGBYPASSED . 0. % O F TH E WASTE S AR E DISPOSE D O F INANONSIT E FACILITY . FAN S TH E TOTA L SYSTE MPRESSUR E DRO P I S 6. 5 IN . H20 . TH E SYSTE MREQUIRE S 4 FAN(S ) RATE D A T 432 . H P EACH .

BOILER/SYSTE MPERFORMANC E UNI T THERMA L EFFICIENC Y 87.1 % BOILE R NE T HEA T RAT E 9929. 1 BTU/KWH HEA T INPU T 3971. 6 MMBTU/ H COA L US E 165. 5 TONS/ H ANNUA L COA L CONSUMPTION. . 2.0730E+0 5 TONS/Y R IAPC S ENERGY PENALT Y 36. 3 BTU/KW H SYSTE MNE T GENERATIO N398. 5 M W

SYSTE MMATERIA L BALANC E (100 % CAPACIT Y CONDITION) AI R UNCONT-.HEATE RP.1 3 FLUE GAS, a 100 0 ACFM .TEMPERATURE,DEG. F MOISTURE , LB/ H ALKALINITY , LB/ H PARTICULATE , LB/ H S02 , LB/ H N02 , LB/ H 1800 . 1800 . 1098 .

390 . 390 . 175 . 209608 . 209608 . 495997 . 886 . 886 . 886 . 19693 . 19693 . 19693 . 12908 . 12908 . 1291 . 3475 . 3475 . 3475 . 

# D8AF T MNOT QUO , cO

RCITE

POLLUTAN T PARTICULAT E S0 2 N0 2 EMISSION SUMMAR Y

LB/HR 19693 . 1291 . 3475 . PERCENT REDUCTIO N 0. 0 90. 0 0. 0 LB/MMBT U

4.95 8 0.32 5 0.87 5 PPM(V )

134 . 771 .

INSTALLE DCAPITAL COST S AUGUST , 198 6

FG D$ 4779630 0 MATERIAL HANDLIN

G$ 185690 0 FEE DPREPARATIO

N $ 504670 0 GA S HANDLIN

GS 811540 0 S0 2 SCRUBBIN

GS 2354410 0 OXIDATION

$ 0 REHEA T - - $ 528280 0 SOLI DSEPARATIO

N S 395040 0

PAN S $ 537050 0 TOTAL DIREC T CAPITA

L COSTS>»»»»»»»»»» $ 5316680 0 INDIREC T COSTS- - - - — $ 3104390 0 GENERAL FACILITIE S $ 531670 0 ENGINEERING/HOM E OFFICE... S 531670 0 PROJEC T CONTINGENC Y$ 147470 0 PROCES S CONTINGENC YS 1487590 0 SALE S TA X$ 0 TOTA L PLANT COST . S 8015080 0P.1 4

INVENTOR YCAPITA L $ 156690 0 INITIA L CATALYS T $ 0 LAN D $ 620 0

************ * TOTA L CAPITA L REQUIREMENT»»»»»»»»»»* $ 8922 Si22 I TOTA L SYSTE M COST»»»»»»»»»»»»»>» $ 22-yytflHf c ANNUA L OPERATIN

GCOST S AUGUST , 198 6 

# DRAF T *D 0 NO T QUOT E O

RCIT E

ITE M } OPERATIN GAN D SUPERVISOR

YLABO R SYSTE M 0 . ANALYSI S 0 . MAINTENANCE LABO

R0 . MAINTENANCE MATERIA

L 0 . ADMIN . & SUPPORT LABO

R0 , FIXE D COMPONEN

T 0 VARIABLE COMPONENT 0 UANTIT Y

_______ _ 305E+0 5 MANHR S 232E+0 4 MANHR S 404E+0 7 $ 404E+0 7 $ 226E+0 7 $ 536E+0 7 $ 536E+0 7 $ RAT E

_____ _ 19.4 4 23.3 3 0.4 0 0.6 0 0.3 0 0.1 4 0.8 6 $

$ $ $ $ $ $ ANNUAL COS T

59250 0 5420 0 161540 0 242310 0 67860 0 76700 0 459680 0 CONSUMABLE S SOLID S DISPOSAL , WE T ADIPI C ACI D WATE R STEA M ELECTRICIT

Y LIMESTON E TOTA L FIRS T YEA

RO& M EXPENS E LEVELIZE D CARRYIN

GCHARGE S BUSBA RCOS T O F POWE R LEVELIZE D FIRS T YEA

RO& M LEVELIZE D CARRYIN

GCHARGE S LEVELIZE D ANNUA L REQUIREMENT S 0.246E+0 5 TON S

16. 6 TON S 0.468E+0 5 KGA

L 0.846E+0 5 KLB S 0.529E+0 7 KW

H 0.131E+0 5 TON S 8922610 0 $

670820 0 $ 8922610 0 $ 13.1 2

1691.3 3 0.6 4 6.2 1 0.0 4 15.2 9 16.6 %

1.45 2 16.6 % S

S S S S $ $ $ 

### S S S 32310 0 2810 0 3010 0 52550 0 23760 0 20000 0 670820 0 1478340 0 2149160 0 973830 0 1478340 0 2452170 0

FIRS T YEA

RBUSBA RCOS T O F POWE R LEVELIZE D ANNUA L BUSBA RCOS T O F POWE R 42.8 9 MILLS/KW H 48.9 4 MILLS/KW

H

PARTICULAT E COS T EFFECTIVENES S S0 2 COS T EFFECTIVENES S NO XCOS T EFFECTIVENES S 1 0.0 0 $/TO N 3370.2 8 $/TO

N 0.0 0 $/TO

N