SNCR Capital Costs

Description Formula1Value

Boiler Size (MMBtu/hr) QB 7540

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) $96,366

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

T otal Capital Investment (TCI) ($) TCI = D + E + F + G + H + I $8,916,048

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

SNCR Annual Costs

Direct Annnual Costs

 Maintenance Cost $133,741

 Reagent Cost $2,455,534

 Electricity Cost $37,226

 Water Cost $4,185

 Annual ∆Coal Cost $282,877

 Annual ∆Ash Cost -

Total Direct Annual Costs DAC $2,913,563

Indirect Annual Costs IDAC = TCI x CRF $841,675

Total Annual Costs TAC = DAC + IAC $3,755,238

Cost Effectivness

SNCR NOx Removed (tons/yr) 1,356

SNCR Cost Effectiveness ($/ton removed) $2,769

1

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

Colstrip Unit 3 RP 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.
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 (%) 97.7 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 3

Modified from OAQPS Control Cost Manual Section 4.2, SCR

Given/AssumptionsGeneration Capacity (MW Gross) 805 SourceFuel High Heating Value (Btu/lb) 8,458 From EIA for 1999Maximum Fuel Consumption Rate (lb/hr) 891,464 Calculated from 7,540 MMBtu/hAverage Annual Fuel Consumption (lb) 7.63E+09 Calcuated from 64,555,395 MMBtu/yNumber of SNCR Operating Days 365 AssumedPlant Capacity Factor 97.7%NOx concentration after combustion controls 0.168 NOx Control Update Report by TRC for PPL (September 2011)SNCR Controlled NOx Concentration (lb/mmBtu) 0.126 NOx Control Update Report by TRC for PPL (September 2011)

$ 8,916,048

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 ($/gal) 0.0004 OAQPS Control Cost ManualElectrical Power Cost ($/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 * 891,464 lb/hr

QB = 7540 mmBtu/hr

1.7 CFPlant = actual heat input/maximum heat input

CFPlant = 97.7%

1.8 CFSNCR = tSCR/365 days

CFSCR = 365 days/ 365 daysCFSCR = 100%

1.6 CFTotal = CFPlant x CFSNCR

CFTotal = 98% * 100%CFTotal = 98%

1.9 ηNOx = (NOxin – NOxout) / NOxin

ηNOx = ( 0.168 lb/mmBtu - 0.126025 lb/mmBtu)/ 0.168 lb/mmBtu

ηNOx = 25%

Uncontrolled NOx emissions (tpy) 5,424
Reagent Calculations

1.14 NSR = [2NOxin + 0.7] ηNOx/ NOxin

NSR = ( 2 * 0.168 + 0.7 ) * 25% / 0.168NSR = 1.54

1.13 Utilization = ηNOx/NSR

Utilization = 16%

1.15 m-dotreagent = NOxinQBηNOxNSR Mreagent/MNOx/SRT

m-dotreagent = 0.168 * 7540 * 1.00 * 1.54 * 60.06 / 2 / 46.01m-dotreagent = 1275 lb/hr

1.16 m-dotsol = m-dotreagent/Csol

m-dotsol = 1275 / 0.50m-dotsol = 2549 lb/hr

1.17 qsol = m-dotvol/ρsol

qsol = 2549 * 7.481 / 71qsol = 269 gph

2.35 Tank Volume = qsolt

Tank Volume = 269 * 14 * 24Tank Volume = 90,255 gal
Annual Costs

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

2.46 Annual Maintenance Cost = 0.015 TCI

Annual Maintenance Cost = 0.015 * $ 8,916,048Annual Maintenance Cost = $ 133,741

1.22 Annual Reagent Cost = qsolCostreagenttop

1.22.a top = CFtotal8760hr/yr

top = 98% * 8760top = 8562

Annual Reagent Cost = 269 * 1.067704852 * 8562Annual Reagent Cost = $ 2,455,534

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

Power = 0.47 * 0.168033333 * 1.54 * 7540 / 9.5Power = 97 kW

Annual Electricity Cost = 97 * 8562 * 0.045Annual Electricity Cost = $ 37,226

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

qwater = 2549 / 8.345 *( 50% / 10% - 1 )

qwater = 1222

Annual Water Cost = 1222 * 0.0004 * 8562

Annual Water Cost = $ 4,185

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 * 2549 *( 1 / 10% - 1 )∆Coal(Btu/hr) = 20,649,863

Annual ∆Coal cost = 20.6 * 1.60 $ * 8562

Annual ∆Coal cost = 282,877 $ 

1.32 Annual ∆Ash cost = ∆Ash costash top

1.30 ∆Ash = ∆Coal ash product/HHV
∆Ash = 21 * 77000 / 8458

∆Ash = 188

Annual ∆Ash cost = 188 * 7.19 $ * 8562 / 2000Annual ∆Ash cost = 5,786 $ 

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

Lost ash sales ($/yr) = - $ 

Total Variable Cost = $ 2,785,608

Total Direct Annual Cost = 133,741 $ + 2,785,608 $ 

Total Direct Annual Cost = 2,919,349 $ 

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

CRF = 0.07 *( 1 + 0.07 )^ 20 /(( 1 + 0

CRF = 0.0944

1.33 IDAC = CRF*TCI

Indirect Annual Cost = 0.0944 * $ 8,916,048Indirect Annual Cost = $ 841,612

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

Total Annual Cost = 2,919,349 $ + 841,612

Total Annual Cost = $ 3,760,961

1.36 NOx Removed SNCR = NOxinηNOxQBtop

NOx Removed = 0.168 * 25% * 7540 * 8562 / 2000

NOx Removed = 1356

1.37 Cost effectiveness = TAC/NOx removed

Cost effectiveness = $ 2,774
STATE

FACILITY_

NAME

ORISPL 

CODE UNIT ID OP YEAR

SUM OP 

TIME

NUM 

MONTHS REPORTE

D

GROSS 

LOAD 

(MWh) SO2 MASS SO2 RATE NOX RATE

NOX 

MASS CO2 

MT Colstrip 6076 3 2008 8,665 12 6,524,103 2,812 0.085 0.170 5,628 6,8MT Colstrip 6076 3 2009 8,539 12 6,445,240 2,628 0.081 0.166 5,395 6,8MT Colstrip 6076 3 2010 8,412 12 6,371,363 2,479 0.080 0.168 5,262 6,5

Averages 8,539 6,446,902 2,640 0.082 0.168 5,428 6,7

MT Colstrip 6076 4 2008 8,519 12 6,409,288 2,980 0.088 0.344 11,771 7,0MT Colstrip 6076 4 2009 3,652 12 2,865,469 1,255 0.085 0.277 4,151 3,1MT Colstrip 6076 4 2010 8,417 12 6,400,130 2,665 0.085 0.171 5,347 6,5

Averages 6,862 5,224,962 2,300 0.086 0.264 7,090 5,5

CAMD Data