# SNCR Capital Costs

Description Formula 1 

# Value

Boiler Size (MMBtu/hr) Q B 

# 7540

NOx Removal Efficiency (%) **η** NOx 

# 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) 

# $96,899

Initial Catalyst and Chemicals ($) 

# I = 0 (Assumed for SNCR) $0

T otal Capital Investment (TCI) ($) TCI = D + E + F + G + H + I $8,916,582

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

SNCR Annual Costs

Direct Annnual Costs

Maintenance Cost 

# $133,749

Reagent Cost 

# $2,391,451

Electricity Cost 

# $36,255

Water Cost 

# $4,076

Annual **∆** Coal Cost 

# $275,495

Annual **∆** Ash Cost



# -

Total Direct Annual Costs DAC 

# $2,841,025

Indirect Annual Costs IDAC = TCI x CRF 

# $841,725

Total Annual Costs TAC = DAC + IAC 

# $3,682,750

Cost Effectivness

SNCR NOx Removed (tons/yr) 

# 1,336

SNCR Cost Effectiveness ($/ton removed) 

# $2,757

1 

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

# Colstrip Unit 4 RP Cost Analysis - SNCR+SOFA

(2010 Dollars)

2 

# Direct capital costs for SNCR were derived from "IP M Model – Revisions to Cost and Performance for APC

Technologies SNCR Cost Development Methodology," Sa rgent & Lundy, August 2010.SNCR Capital Cost Estimate WorksheetVariableDesignationUnitsValueCalculationBoiler TypeBTTangentialInputUnit SizeA(MW)333InputRetrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Heat RateC(Btu/kWh)11958InputNOxRateD (lb/MMBtu) 0.200Average for 2008-2010 from CAMDSO2RateE (lb/MMBtu) 1.8 InputType of CoalFPRBInputCoal FactorG1.05Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate FactorH1.20C/10000Heat InputI(Btu/hr)3.98E+09A*C*1000Capacity FactorJ(%)94.7InputNOxRemoval EfficiencyK (%) 25.0 InputNOxRemovedL (lb/hr) 199.1D*I/106*K/100Urea Rate (100%)M(lb/hr)866L/UF/46*30; IF Boiler type = CFB OR D> 0.3 then UF =0.25; else UF 0.15Steam RequiredN(lb/hr)7791M*9Aux PowerO(%)0.05Auxilliary powerDilution Water RateP(1000 gph)0.93N*0.12/1000Urea Cost 50% wt sol.Q($/ton)450InputAux Power CostR($/kWh)0.045InputDilution Water CostS($/klb)1InputOperating Labor RateT($/hr)60Labor cost including all benefitsCosts are all based on 2009 dollarsCapital Cost CalculationInclude: 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)$2,472,000 SNCR (injectors, blowers, DCS, reagent system) costBMA ($) = If E >= 3 and F = Bituminous then 65000*(B)*(A*G*H)^0.78; else 0 $0Air heater modification / SO3control (bituminous only & > 3 lb/MMbtu)BMB ($) = 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$5,937,000Total bare module cost including retrofit factorBM ($/kW)$18Base cost per kWTotal Project CostA1 = 10% of BM$594,000Engineering and construction management costsA2 = 10% of BM$594,000Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 10% of BM$594,000Contractor profit and feesCECC($) = BM+A1+A2+A3$7,719,000Capital, engineering and construction cost subtotalCECC($/kW) =$23Capital, engineering and construction cost subtotal per kWB1 = 5% of CECC$386,000Owners costs including "home office" costs (owner engineering, management, and procurement activities)TPC ($) = CECC + B1$8,105,000Total project costTPC ($/kW) =$24Total project cost per kWPPL Colstrip Unit 4Modified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsGeneration Capacity (MW Gross)805SourceFuel High Heating Value (Btu/lb)8,458From EIA for 1999Maximum Fuel Consumption Rate (lb/hr)891,464Calculated from7,540MMBtu/hr from TRC Report for PPL (6/25/2008)Average Annual Fuel Consumption (lb)7.39E+09Calcuated from62,524,674MMBtu/yr for 2010 from CAMDNumber of SNCR Operating Days365AssumedPlant Capacity Factor94.7%NOx concentration after combustion controls 0.171SNCR Controlled NOx Concentration (lb/mmBtu) 0.128ash product (Btu/mmBtu)7.7E+04OAQPS Control Cost ManualStored Urea Concentration50%OAQPS Control Cost ManualInjected Urea Concentration10%OAQPS Control Cost ManualReagent Heat of vaporization Hv (lb/Btu)900OAQPS Control Cost ManualReagent Molecular Weight (g/mole)60.06OAQPS Control Cost ManualSRT2OAQPS Control Cost ManualReagent Density (lb/ft3 @ 60F)71.0OAQPS Control Cost ManualReagent Specific Volume (gal/ft3)7.481OAQPS Control Cost ManualNOx Molecular Weight (g/mole)46.01OAQPS Control Cost ManualNumber of Days of Storage for Urea14OAQPS Control Cost ManualEquipment Life (years)20OAQPS Control Cost ManualAnnual Interest Rate7%OAQPS Control Cost ManualInflation Since 19981.34CEPCI 2009/CEPCI 1998Inflation Since 20061.04CEPCI 2009/CEPCI 2006Water Consumption Cost ($/gal)0.0004OAQPS Control Cost ManualElectrical Power Cost ($/kWh)0.045$Ref50% Urea Solution Cost ($/gal)1.07$calculated from450$/tonCoal Cost ($/mmBtu)1.60$Ash Disposal Cost ($/ton)7.19$OAQPS Control Cost ManualLost ash sales ($/yr)$0Ash not soldAdditional Ash Disposal Cost ($/ton)$0Ash not soldBoiler Calculations1.3QB= HVm-dotfuelQB = 8458 Btu/lb *891,464lb/hrQB = 7540 mmBtu/hr1.7CFPlant= actual heat input/maximum heat inputCFPlant =94.7%1.8CFSNCR= tSCR/365 daysCFSCR = 365 days/ 365 daysCFSCR =100%1.6CFTotal= CFPlantx CFSNCRCFTotal = 95% * 100%CFTotal =95%1.9ηNOx= (NOxin– NOxout) / NOxin**η**NOx = ( 0.171 lb/mmBtu - 0.128175 lb/mmBtu)/ 0.171 lb/mmBtu**η**NOx =25%Uncontrolled NOx emissions (tpy)5,343Reagent Calculations1.14NSR = [2NOxin+ 0.7]ηNOx/ NOxinNSR = ( 2 * 0.1709 + 0.7 ) * 25% / 0.171NSR = 1.521.13Utilization =ηNOx/NSRUtilization =16%1.15m-dotreagent= NOxinQBηNOxNSR Mreagent/MNOx/SRTm-dotreagent = 0.171 * 7540 * 1.00 * 1.52 * 60.06 / 2 / 46.01m-dotreagent = 1282 lb/hr1.16m-dotsol= m-dotreagent/Csolm-dotsol = 1282 / 0.50m-dotsol = 2563 lb/hr1.17qsol= m-dotvol/ρsolqsol = 2563 * 7.481 / 71qsol = 270 gph2.35Tank Volume = qsoltTank Volume = 270 * 14 * 24Tank Volume =90,755galAnnual Costs2.45 DAC = Annual Maintenance Cost + Annual ReagentCost + Annual Electricity Cost + Annual Water Cost+ Annual Catalyst Cost2.46 Annual Maintenance Cost = 0.015 TCIAnnual Maintenance Cost = 0.015 *8,916,582$Annual Maintenance Cost =133,749$1.22Annual Reagent Cost = qsolCostreagenttop1.22.atop= CFtotal8760hr/yrtop =95%*8760top =8292Annual Reagent Cost = 270 * 1.067704852 * 8292Annual Reagent Cost =2,391,451$1.24Annual Electricity Cost = Power (Costelect)top1.23Power = 0.47NOxinNSRQB/9.5Power = 0.47 * 0.1709 * 1.52 * 7540 / 9.5Power = 97 kWAnnual Electricity Cost = 97 * 8292 * 0.045Annual Electricity Cost =36,255$1.27Annual Water Cost = qwaterCostwatertop1.25qwater= m-dotsol/ρwater[Cureastored/Cureasol inj-1]qwater = 2563/ 8.345 *( 50% / 10% - 1 )qwater = 1229Annual Water Cost = 1229 *0.0004* 8292Annual Water Cost =4,076$1.31Annual∆Coal cost =∆Coal costcoaltop1.28∆Coal(Btu/hr) = Hv(Btu/lb)* m-dotreagent(lb/hr)[1/ Cureasol inj-1]∆Coal(Btu/hr) = 900* 2563 *( 1 / 10% - 1 )∆Coal(Btu/hr) = 20,764,134Annual∆Coal cost = 20.8* 1.60$ * 8292Annual∆Coal cost = 275,495$1.32Annual∆Ash cost =∆Ash costashtop1.30∆Ash =∆Coal ash product/HHV∆Ash = 21* 77000 / 8458∆Ash =189Annual∆Ash cost = 189* 7.19$ * 8292 / 2000Annual∆Ash cost = 5,635$Additional Ash Disposal Cost ($/ton) = -$Lost ash sales ($/yr) = -$Total Variable Cost =2,712,911$Total Direct Annual Cost = 133,749$ + 2,712,911$Total Direct Annual Cost = 2,846,660$1.34CRF = i(1+i)n/[(1+i)n-1]CRF = 0.07 *( 1 + 0.07 )^ 20 /(( 1 + 0.07 )^ 20 - 1 )CRF = 0.09441.33 IDAC = CRF*TCIIndirect Annual Cost = 0.0944 *8,916,582$Indirect Annual Cost =841,662$1.35 Total Annual Cost = Direct Annual Cost + Indirect Annual CostTotal Annual Cost = 2,846,660$ + 841,662Total Annual Cost =3,688,322$1.36NOx Removed SNCR = NOxinηNOxQBtopNOx Removed = 0.171 * 25% * 7540 *8292/ 2000NOx Removed = 13361.37Cost effectiveness = TAC/NOxremovedCost effectiveness =2,761$STATEFACILITY_NAMEORISPLCODE UNIT ID OP YEARSUM OPTIMENUMMONTHSREPORTEDGROSSLOAD(MWh)SO2 MASS SO2 RATE NOX RATENOXMASS CO2 MASSHEAT INPUT(MMBtu)HEATINPUT(MMBtu/hr)MTColstrip6076320088,665126,524,1032,8120.0850.1705,6286,893,82566,443,9867,668MTColstrip6076320098,539126,445,2402,6280.0810.1665,3956,807,71864,909,5927,601MTColstrip6076320108,412126,371,3632,4790.0800.1685,2626,535,34762,312,6057,408Averages8,5396,446,9022,6400.0820.1685,4286,745,63064,555,3957,559MTColstrip6076420088,519126,409,2882,9800.0880.34411,7717,010,94267,560,3927,931MTColstrip6076420093,652122,865,4691,2550.0850.2774,1513,100,62829,563,5998,095MTColstrip6076420108,417126,400,1302,6650.0850.1715,3476,557,58762,524,6747,429Averages6,8625,224,9622,3000.0860.2647,0905,556,38653,216,2227,818