Tilden Taconite Indurating Line #1

Venturi rod scrubber

Given/Assumed

Uncontrolled SO2 emissions (TPY) 1,153.20 Tilden 9/11/2009

Absorber + auxiliary equipment $ 2,120,661 Tilden 9/11/2009 Purchased Equipment cost

Sales taxes 6.0% Tilden 9/11/2009

Retrofit factor 1.0 assumed Barr estimates 1.6

SO2 Control efficiency 50% Tilden 9/11/2009

Operating Hours per Year 7,680 Tilden 9/11/2009

Operating Hours per Shift 8 assumed

Operating Shifts per Year 960 calculated

Utilization 100% Tilden 9/11/2009

Operating Labor Cost ($/hr) $ 85.00 Tilden 9/11/2009

Maintenance Labor Cost ($/hr) $ 85.00 Tilden 9/11/2009

Chemical cost ($/ton) $ 90.80 Tilden 9/11/2009

Chemical usage (lb/hr) 263 calculated from Tilden 9/11/2009 varies directly with assumed control efficiency

Solvent usage (gpm) 912 calculated from Tilden 9/11/2009 varies directly with assumed control efficiency

Solvent cost ($/kgal) $ 0.40 Tilden 9/11/2009

Wastewater disposal ($/kgal) $ 3.80 OAQPS Control Cost Manual example Tilden estimates $100/kgal for reverse osmosis.

Wastewater generation (gpm) 739 calculated from Tilden 9/11/2009 varies directly with assumed control efficiency

Electrical Cost ($/kWh) $ 0.05 Tilden 9/11/2009

Electrical Use (kW/hr) 1,999 Tilden 9/11/2009

Inflation Since 2009 1.06 CEPCI 2010/CEPCI 2009

Equipment Life (yr) 20 Tilden 9/11/2009

Interest Rate (%) 7.00% Tilden 9/11/2009
Tilden Taconite Indurating Line #1

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

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

Absorber + auxiliary equipment, EC A $2,238,092

Instrumentation 0.10 A $223,809

Sales taxes 0.060 A $134,286

Freight 0.05 A $111,905

Purchased equipment cost, PEC B= 0.21 A $2,708,091

Direct installation costs

Foundations & supports 0.12 B $324,971

Handling & erection 0.40 B $1,083,236

Electrical 0.01 B $27,081

Piping 0.30 B $812,427

Insulation 0.01 B $27,081

Painting 0.01 B $27,081

Direct installation costs x 1 x 0.85 B $2,301,877

Site preparation As required, SP

Buildings As required, Bldg.

Total Direct Costs, DC 1.85 B+SP+Bldg $5,009,968

Indirect Costs (installation)

Engineering 0.10 B $270,809

Construction and field expenses 0.10 B $270,809

Contractor fees 0.10 B $270,809

Start-up 0.01 B $27,081

Performance test 0.01 B $27,081

Contingencies 0.03 B $81,243

Total Indirect Costs, IC 0.35 B $947,832

Total Capital Investment = DC + IC 2.20 B+SP+Bldg $5,957,800
Tilden Taconite Indurating Line #1

Annual Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Table 1.4

Cost Item Factor Cost

Direct Annual Costs, DC

Operating labor

Operator 0.5 hr/shift $40,800

Supervisor 15% of operator $6,120

Operating materials

Solvent 912 gpm * $ 0.40 /kgal = $175,104

Chemicals 263 lb/hr * $ 90.80 /ton = $91,701

Wastewater Disposal 739 gal/min * 60 min/hr *

7,680 hr/yr * $ 3.80 /kgal = $1,294,019

Maintenance

Labor 0.5 hr/shift $40,800

Material 100.00% of maintenance $40,800

Electricity All electricity equal to:

$ 0.05 $/kwh, * 1,999 kW-hr * 7,680 hr/yr = $798,321

Total DC $2,487,664

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs $77,112

Administrative charges 2% of Total Capital Investment $119,156

Property tax 1% of Total Capital Investment $59,578

Insurance 1% of Total Capital Investment $59,578

Capital recovery 0.0944 * Total Capital Investment $562,374

Total IC $877,798

Total Annual Cost DC + IC $3,365,462
Tilden Taconite Indurating Line #1 SO2

Uncontrolled emissions (TPY) 1,153.2

Control efficiency (%) 50%

Emission reduction (TPY) 577

Controlled emissions (TPY) 577

Total annualized cost ($/yr) $3,365,462

Cost/ton removed ($/T) $5,837