### Development of Pond Operations Cost Factors - **Plant Capacity (MW) Factor**

This Excel file contains the following worksheet:

Plant MW Factor This Excel workbook documents EPA's analysis to calculate a factor to estimate unitized pond costs for different sized plants (relative to a 500 MW plant).

Contains data from EPA's 1985 study , Full-Scale Field Evaluation of W aste Disposal from Coal-fired Electric Generating Plants (Table 9 - Generic Annual Cost Esitmates for FGC Waste Disposal (L ate 1982 Dollars)), for fly ash and bottom ash wet sluicing transportation. Using these values, EPA calculated a relative factor for estimating unitized costs for different sized plants. EPA calculated the factors relative to a 500 MW plant because the pond operation costs from EPA's/TVA's 1981 study , Economics of Ash Disposal at Coal-fired Power Plants , represented a 500 MW plant. EPA used the calculated factors to generate a plot and corresponding equation for altering unitized costs based on plant size (in MW).This Excel workbook documents EPA's analysis to calculate a factor to estimate unitized pond costs for different sized

Full-Scale Field Evaluation of W aste Disposal (Table 9 - Generic Annual Cost Esitmates for FGC Waste Disposal (L ate 1982 Dollars)), for fly ash and bottom ash wet sluicing transportation. Using these values, EPA calculated a relative factor for estimating unitized costs for different sized plants. EPA calculated the factors relative to a 500 MW Economics of Ash , represented a 500 MW plant. EPA used the calculated factors to generate a plot and corresponding equation for altering unitized**Type of Cost Plant Size (MW)**  **Min Range (1982 $/ton)** 

Fly Ash - Transport (Wet Sluicing) 250 4.2 Fly Ash - Transport (Wet Sluicing) 500 3.2 Fly Ash - Transport (Wet Sluicing) 1000 2.5 Fly Ash - Transport (Wet Sluicing) 2000 2 Fly Ash - Placement/Disposal (Unlined Pond) 250 11.5 Fly Ash - Placement/Disposal (Unlined Pond) 500 9.1 Fly Ash - Placement/Disposal (Unlined Pond) 1000 7.2 Fly Ash - Placement/Disposal (Unlined Pond) 2000 5.7

Bottom Ash - Transport (Wet Sluicing) 250 9.2 Bottom Ash - Transport (Wet Sluicing) 500 7.3 Bottom Ash - Transport (Wet Sluicing) 1000 5.6 Bottom Ash - Transport (Wet Sluicing) 2000 4.3 Bottom Ash - Placement/Disposal (Unlined Pond) 250 9.2 Bottom Ash - Placement/Disposal (Unlined Pond) 500 7.9 Bottom Ash - Placement/Disposal (Unlined Pond) 1000 6.5 Bottom Ash - Placement/Disposal (Unlined Pond) 2000 5.4

**Type of Cost Plant Size (MW)**  **Min Range (1982 $/ton)** 

Fly Ash (Total) 250 15.7 Fly Ash (Total) 500 12.3 Fly Ash (Total) 1000 9.7 Fly Ash (Total) 2000 7.7

Bottom Ash (Total ) 250 18.4 Bottom Ash (Total ) 500 15.2 Bottom Ash (Total ) 1000 12.1 Bottom Ash (Total ) 2000 9.7 **Fly Ash**

**Bottom Ash** Data from EPA's 1985 study, Full-Scale Field Evaluation of Waste Disposal from Coal-fired Electric Generating Plants Table 9 - Generic Annual Cost Esitmates for FGC Waste Disposal (Late 1982 Dollars) for the fly ash wet sluicing and placement/disposal modules and the bottom ash wet sluicing and placement/disposal modules.

EPA calculated the total dollar per ton values for both fly and bottom ash numbers (Wet Sluicing + Unlined Pond) for all plant sizes. EPA also calculated the average 1982 dollar per ton value for each plant size using the min and max cost ranges and then calculated an average cost factor relative to the 500 MW plant (EPA used the 500 MW plant because the 1981 EPA/TVA pond cost data i s based on a 500 MW plant).

**Bottom Ash Fly Ash** **Type of Cost Plant Size (MW)**  **Average Cost Factors Relative to 500 MW**  **Plant** Com bined Ash ($/ton) 250 1.245 Com bined Ash ($/ton) 500 1.000 Com bined Ash ($/ton) 1000 0.797 Com bined Ash ($/ton) 2000 0.632

Using these calculated average cost factors and the plant size, EPA generated the following plot:



### Plant MW Factor = 7.569(MW) -0.32 EPA determ

ined that the power trend line generated the best r-squared value; therefore, used this equation in the pond operation costs methodology to cal culate plant-specific unitized cost values based on specific plant size (in MW). See the equation below: Aft er calculating the total fly ash- and bottom ash-specific average cost factor values, EPA combined the two by averaging the fly ash factor with th e bottom

ash factor, for each plant size. The results are presented below.

y = 7.5696x

- 0.326 R2 = 0.9998

0.000 0.200 0.400 0.600 0.800 1.000 1.200 1.400

0 500 1000 1500 2000 2500**A v** **g C** **o s** **t F** **a c** **t o** **r s** **R e** **l a** **t i** **v e** **t o** **5 0** **0 M** **W P** **l a** **n t** 

**Plant MW** 

## Plot A **verage Cost F actor V** 

**ersus Plant MW** 

Plot Average Cost Factor

versus Plant MW

Power (Plot Average Cost Factor versus Plant MW)**Max Range**

**(1982 $/ton)**

7.6

5.9 4.7 3.7 21.3 16.8 13.5 10.5

17.1 13.5 10.3 7.9 17.1 14.6 12.1 10

**Max Range (1982 $/ton)**  **Average**

**(1982 $/ton) Average Cost Factor** 

**Relative to 500 MW Plant** 

28.9 22.3 1.274 22.7 17.5 1.000 18.2 13.95 0.797 14.2 10.95 0.626

34.2 26.3 1.215 28.1 21.65 1.000 22.4 17.25 0.797 17.9 13.8 0.637 Full-Scale Field Evaluation of Waste Disposal from Coal-fired Electric Generating Plants , Table 9 - Generic Annual Cost Esitmates for FGC Waste Disposal (Late 1982 Dollars) for the fly ash wet sluicing and

EPA calculated the total dollar per ton values for both fly and bottom ash numbers (Wet Sluicing + Unlined Pond) for all plant sizes. EPA also calculated the average 1982 dollar per ton value for each plant size using the min and max cost ranges and then calculated an average cost factor relative to the 500 MW plant (EPA used the 500 MW plant because the 1981EPA determ ined that the power trend line generated the best r-squared value; therefore, used this equation in the pond operation costs methodology to cal culate plant-specific unitized cost values based on specific plant size (in MW). See the equation below: Aft er calculating the total fly ash- and bottom ash-specific average cost factor values, EPA combined the two by averaging the fly ash factor with