SNCR Capital Costs

Description Formula1

Value

Boiler Size (MMBtu/hr) QB 3982

NOx Removal Efficiency (%) ηNOx 25%

Cost Year 2010

Total Direct Capital Costs ($)2

A $6,265,759

Indirect Installation Costs

 General Facilities ($) 0.05 x A $313,288

 Engineering and Home Office Fees ($) 0.10 x A $626,576

 Process Contingency ($) 0.05 x A $313,288

Total Indirect Installation Costs ($) B = A × (0.05 + 0.10 + 0.05) $1,253,152

Project Contingency ($) C = (A + B)× 0.15 $1,127,837

Total Plant Costs ($) D = A + B+ C $8,646,747

Allowance for Funds During Construction ($) E = 0 (Assumed for SCR) $0

Royalty Allowance ($) F = 0 (Assumed for SCR) $0

Preproduction Cost ($) G = 0.02 × (D + E) $172,935

Inventory Capital* ($) H = Vol reagent (gal) × Cost reagent ($/gal) $53,463

Initial Catalyst and Chemicals ($) I = 0 (Assumed for SNCR) $0

T otal Capital Investment (TCI) ($) TCI = D + E + F + G + H + I $8,873,145

T otal Capital Investment (TCI) ($) Per kW $27

SNCR Annual Costs

Direct Annnual Costs

 Maintenance Cost $133,097

 Reagent Cost $1,073,352

 Electricity Cost $16,272

 Water Cost $4,573

 Annual ∆Coal Cost $123,650

 Annual ∆Ash Cost -

Total Direct Annual Costs DAC $1,350,944

Indirect Annual Costs IDAC = TCI x CRF $837,625

Total Annual Costs TAC = DAC + IAC $2,188,569

SOFA Captial Costs

Total Captial Investment for SOFA ($)3

TCI $4,507,528

Total Capital Investment for SOFA ($/kW) Per kW $14

SOFA Annual Costs

Total Direct Annual Costs4

DAC $664,884

Indirect Annual Costs IDAC = TCI x CRF $425,511

Total Annual Costs TAC = DAC + IAC $1,090,395

Cost Effectivness

SOFA NOx Removed (tons/yr) 1,432

SOFA Cost Effectiveness ($/ton removed) $761

SNCR NOx Removed (tons/yr) 664

SNCR Cost Effectiveness ($/ton removed) $3,294

SNCR+SOFA NOx Removed (tons/yr) 2,097

SNCR+SOFA Cost Effectiveness ($/ton removed) $1,564

1

Taken from "EPA Control Cost Manual", Section 4.2, Chapter 1, October 2000.

Colstrip Unit 1 BART Cost Analysis - SNCR+SOFA

(2010 Dollars)

2Direct capital costs for SNCR were derived from "IPM Model – Revisions to Cost and Performance for APC

Technologies SCR Cost Development Methodology," Sargent & Lundy, August 2010.

3,4Direct capital costs and direct annual costs for SOFA were taken from "Addendum to PPL Montana's Colstrip 

BART Report," TRC for PPL, June 2008. Direct capital costs were escalated to 2010 using the CEPCI.
SNCR Capital Cost Estimate Worksheet

Variable Designation Units Value Calculation

Boiler Type BT Tangential InputUnit Size A (MW) 333 InputRetrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Heat Rate C (Btu/kWh) 11958 InputNOx Rate D (lb/MMBtu) 0.200 Average for 2008-2010 from CAMDSO2 Rate E (lb/MMBtu) 1.8 InputType of Coal F PRB InputCoal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate Factor H 1.20 C/10000Heat Input I (Btu/hr) 3.98E+09 A*C*1000Capacity Factor J (%) 77.0 InputNOx Removal Efficiency K (%) 25.0 Input

NOx Removed L (lb/hr) 199.1 D*I/106*K/100

Urea Rate (100%) M (lb/hr) 866 L/UF/46*30; IF Boiler type = CFB OR D> 0.3 then UF =0.25; else UF 0.15Steam Required N (lb/hr) 7791 M*9Aux Power O (%) 0.05 Auxilliary power Dilution Water Rate P (1000 gph) 0.93 N*0.12/1000Urea Cost 50% wt sol. Q ($/ton) 450 InputAux Power Cost R ($/kWh) 0.045 InputDilution Water Cost S ($/klb) 1 InputOperating Labor Rate T ($/hr) 60 Labor cost including all benefitsCosts are all based on 2009 dollarsCapital Cost Calculation Include: equipment, installation, buildings, foundations, electrical, and retrofit difficulty. BMS ($) = BT*B*G/1.05*200000*(A*H)0.42; (If CFB then BT=0.75, else BT=1) $2,472,000 SNCR (injectors, blowers, DCS, reagent system) cost

 BMA ($) = If E >= 3 and F = Bituminous then 65000*(B)*(A*G*H)^0.78; else 0 $0 Air heater modification / SO3 control (bituminous only & > 3 lb/MMbtu)

 BMB ($) = BT*270000*(A)0.33*(L)0.12; (If CFB then BT=0.75, else BT=1) $3,465,000 Balance of plant cost (piping, including site upgrades)

 BM ($) = BMS + BMA + BMB $5,937,000 Total bare module cost including retrofit factor BM ($/kW) $18 Base cost per kWTotal Project Cost A1 = 10% of BM $594,000 Engineering and construction management costs A2 = 10% of BM $594,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $594,000 Contractor profit and fees CECC($) = BM+A1+A2+A3 $7,719,000 Capital, engineering and construction cost subtotal CECC($/kW) = $23 Capital, engineering and construction cost subtotal per kW B1 = 5% of CECC $386,000 Owners costs including "home office" costs (owner engineering, management, a TPC ($) = CECC + B1 $8,105,000 Total project cost TPC ($/kW) = $24 Total project cost per kW
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCR

Given/AssumptionsGeneration Capacity (MW Gross) 333Fuel High Heating Value (Btu/lb) 8,458 From EIA for 1999Maximum Fuel Consumption Rate (lb/hr) 465,831 Calculated from 3,940 MMBtu/hAverage Annual Fuel Consumption (lb) 3.14E+09 Calcuated from 26,578,089 MMBtu/yNumber of SNCR Operating Days 365 AssumedPlant Capacity Factor 77.0%Uncontrolled NOx Concentration (lb/mmBtu) 0.308 Average for 2008-2010 from CAMD

SOFA Total Capital Cost $ 4,507,528 TRC BART Report for PPl (6/25/2008) adjusted using 2010 CEPCISOFA Total Annual Cost $ 1,090,395 TRC BART Report for PPl (6/25/2008) adjusted using 2010 CEPCI

NOx concentration after combustion controls 0.200 NOx Control Update Report by TRC for PPL (September 2011)SNCR Controlled NOx Concentration (lb/mmBtu) 0.150 NOx Control Update Report by TRC for PPL (September 2011)

$ 8,873,145

ash product (Btu/mmBtu) 7.7E+04 OAQPS Control Cost Manual

Stored Urea Concentration 50% OAQPS Control Cost ManualInjected Urea Concentration 10% OAQPS Control Cost ManualReagent Heat of vaporization Hv (lb/Btu) 900 OAQPS Control Cost ManualReagent Molecular Weight (g/mole) 60.06 OAQPS Control Cost Manual

SRT 2 OAQPS Control Cost ManualReagent Density (lb/ft3 @ 60F) 71.0 OAQPS Control Cost Manual

Reagent Specific Volume (gal/ft3) 7.481 OAQPS Control Cost ManualNOx Molecular Weight (g/mole) 46.01 OAQPS Control Cost Manual

Number of Days of Storage for Urea 14 OAQPS Control Cost ManualEquipment Life (years) 20 OAQPS Control Cost ManualAnnual Interest Rate 7% OAQPS Control Cost ManualInflation Since 1998 1.34 CEPCI 2009/CEPCI 1998 Inflation Since 2006 1.04 CEPCI 2009/CEPCI 2006Water Consumption Cost ($/gal) 0.001 OAQPS Control Cost ManualElectrical Power Cost ($/kWh) $ 0.045 Ref50% Urea Solution Cost ($/gal) $ 1.07 calculated from $ 450 /ton

Coal Cost ($/mmBtu) $ 1.60

Ash Disposal Cost ($/ton) $ 7.19 OAQPS Control Cost Manual

Lost ash sales ($/yr) $0 Ash not sold

Additional Ash Disposal Cost ($/ton) $0 Ash not sold
Boiler Calculations

1.3 QB = HVm-dotfuel

QB = 8458 Btu/lb * 465,831 lb/hrQB = 3940 mmBtu/hr

1.7 CFPlant = actual heat input/maximum heat input

CFPlant = 77.0%

1.8 CFSNCR = tSCR/365 days

CFSCR = 365 days/ 365 daysCFSCR = 100%

1.6 CFTotal = CFPlant x CFSNCR

CFTotal = 77% * 100%CFTotal = 77%

1.9 ηNOx = (NOxin – NOxout) / NOxin

ηNOx = ( 0.200 lb/mmBtu - 0.15 lb/mmBtu)/ 0.2 lb/mmBtuηNOx = 25%Uncontrolled NOx emissions (tpy) 4,090
Reagent Calculations

1.14 NSR = [2NOxin + 0.7] ηNOx/ NOxin

NSR = ( 2 * 0.2 + 0.7 ) * 25% / 0.2NSR = 1.38

1.13 Utilization = ηNOx/NSR

Utilization = 18%

1.15 m-dotreagent = NOxinQBηNOxNSR Mreagent/MNOx/SRT

m-dotreagent = 0.200 * 3940 * 1.00 * 1.38 * 60.06 / 2 / 46.01m-dotreagent = 707 lb/hr

1.16 m-dotsol = m-dotreagent/Csol

m-dotsol = 707 / 0.50m-dotsol = 1414 lb/hr

1.17 qsol = m-dotvol/ρsol

qsol = 1414 * 7.481 / 71qsol = 149 gph

2.35 Tank Volume = qsolt

Tank Volume = 149 * 14 * 24Tank Volume = 50,073 gal
Annual Costs

2.45 DAC = Annual Maintenance Cost + Annual Reagent Cost + Annual Electricity Cost + Annual Water Cost + 

2.46 Annual Maintenance Cost = 0.015 TCI

Annual Maintenance Cost = 0.015 * $ 8,873,145Annual Maintenance Cost = $ 133,097

1.22 Annual Reagent Cost = qsolCostreagenttop

1.22.a top = CFtotal8760hr/yr

top = 77% * 8760top = 6746

Annual Reagent Cost = 149 * 1.067704852 * 6746Annual Reagent Cost = $ 1,073,352

1.24 Annual Electricity Cost = Power (Costelect)top1.23 Power = 0.47NOxinNSRQB/9.5

Power = 0.47 * 0.2 * 1.38 * 3940 / 9.5Power = 54 kW

Annual Electricity Cost = 54 * 6746 * 0.045Annual Electricity Cost = $ 16,272

1.27 Annual Water Cost = qwaterCostwater top1.25 qwater = m-dotsol/ρwater[Cureastored/Curea sol inj -1]

qwater = 1414 / 8.345 *( 50% / 10% - 1 )

qwater = 678

Annual Water Cost = 678 * 0.0010 * 6746

Annual Water Cost = $ 4,573

1.31 Annual ∆Coal cost = ∆Coal costcoal top1.28 ∆Coal(Btu/hr) = Hv(Btu/lb)* m-dotreagent(lb/hr)[1/ Curea sol inj -1]

∆Coal(Btu/hr) = 900 * 1414 *( 1 / 10% - 1 )∆Coal(Btu/hr) = 11,456,370

Annual ∆Coal cost = 11.5 * 1.60 $ * 6746

Annual ∆Coal cost = 123,650 $ 

1.32 Annual ∆Ash cost = ∆Ash costash top

1.30 ∆Ash = ∆Coal ash product/HHV

∆Ash = 11 * 77000 / 8458
∆Ash = 104

Annual ∆Ash cost = 104 * 7.19 $ * 6746 / 2000Annual ∆Ash cost = 2,529 $ 

Additional Ash Disposal Cost ($/ton) = - $ 

Lost ash sales ($/yr) = - $ 

Total Variable Cost = $ 1,220,376

Total Direct Annual Cost = $ 133,097 + $ 1,220,376Total Direct Annual Cost = $ 1,353,474

1.34 CRF = i(1+i)n/[(1+i)n-1]

CRF = 0.07 *( 1 + 0.07 )^ 20 /(( 1 + 0.07 CRF = 0.0944

1.33 IDAC = CRF*TCI

Indirect Annual Cost = 0.0944 * $ 8,873,145Indirect Annual Cost = $ 837,562

1.35 Total Annual Cost = Direct Annual Cost + Indirect Annual Cost

Total Annual Cost = $ 1,353,474 + 837,562Total Annual Cost = $ 2,191,036

1.36 NOx Removed SOFA = NOxinηNOxQBtop

NOx Removed = 0.308 * 35% * 3940 * 6746 / 2000NOx Removed = 1432

1.36 NOx Removed SNCR = NOxinηNOxQBtop

NOx Removed = 0.200 * 25% * 3940 * 6746 / 2000NOx Removed = 664

1.37 Cost effectiveness = TAC/NOx removed

Cost effectiveness = $ 3,298
STATE

FACILITY

_NAME

ORISPL 

CODE UNIT ID OP YEAR

SUM OP 

TIME

NUM 

MONTHS 

REPORT

ED

GROSS 

LOAD 

(MWh)

SO2 

MASS

SO2 

RATE

NOX 

RATE

NOX 

MASS CO

MT Colstrip 6076 1 2008 8,198 12 2,464,601 5,075 0.375 0.316 4,317 2

MT Colstrip 6076 1 2009 7,519 12 2,417,112 5,885 0.465 0.304 3,854 2MT Colstrip 6076 1 2010 8,160 12 2,563,419 5,684 0.416 0.303 4,138 2

Averages 7,959 2,481,711 5,548 0.418 0.308 4,103 2

MT Colstrip 6076 2 2008 7,109 12 2,135,046 4,241 0.352 0.310 3,744 2

MT Colstrip 6076 2 2009 8,590 12 2,573,748 6,152 0.444 0.297 4,117 2MT Colstrip 6076 2 2010 7,964 12 2,406,886 5,141 0.389 0.319 4,224 2

Averages 7,888 2,371,894 5,178 0.395 0.309 4,028 2