SCR Capital Costs

Description Formula1 Value

Boiler Size (MMBtu/hr) QB 572

NOx Removal Efficiency (%) ηNOx 80.8%

Cost Year 2010Total Direct Capital Costs ($)2 A $14,315,101

Indirect Installation Costs General Facilities ($) 0.05 x A $715,755 Engineering and Home Office Fees ($) 0.10 x A $1,431,510 Process Contingency ($) 0.05 x A $715,755Total Indirect Installation Costs ($) B = A × (0.05 + 0.10 + 0.05) $2,863,020Project Contingency ($) C = (A + B)× 0.15 $2,576,718Total Plant Costs ($) D = A + B+ C $19,754,839Allowance for Funds During Construction ($) E = 0 (Assumed for SCR) $0Royalty Allowance ($) F = 0 (Assumed for SCR) $0Preproduction Cost ($) G = 0.02 × (D + E) $395,097Inventory Capital* ($) H = Vol reagent (gal) × Cost reagent ($/gal) $6,491Initial Catalyst and Chemicals ($) I = 0 (Assumed for SCR) $0Total Capital Investment (TCI) ($) TCI = D + E + F + G + H + I $20,156,427Total Capital Investment (TCI) ($) Per kW $388

SCR Annual CostsDirect Annnual Costs Maintenance Cost Eq. 2.46 $302,346 Reagent Cost Eq. 2.47 $133,685 Electricity Cost Eq. 2.49 $87,895 Catalyst Cost Eq. 2.50 $63,180Total Direct Annual Costs DAC (Eq. 2.45) $587,106Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $1,902,767Total Annual Costs TAC = DAC + IAC (Eq. 2.56) $2,489,873SOFA/LNB Capital CostsTotal Captial Investment ($)3 TCI $2,195,000

Total Capital Investment ($/kW) Per kW $42

SOFA/LNB Annual CostsTotal Direct Annual Costs4 DAC $664,884

Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $207,208Total Annual Costs TAC = DAC + IAC (Eq. 2.56) $872,092

Cost EffectivnessSOFA/LNB NOx Removed (tons/yr) Eq. 2.57 277SOFA/LNB Cost Effectiveness ($/ton removed) Eq. 2.58 $3,147SCR NOx Removed (tons/yr) Eq. 2.57 416SCR Cost Effectiveness ($/ton removed) Eq. 2.58 $5,990SCR+SOFA/LNB NOx Removed (tons/yr) Eq. 2.57 693SCR+SOFA/LNB Cost Effectiveness ($/ton removed) Eq. 2.58 $4,8531Taken from "EPA Control Cost Manual", Section 4.2, Chapter 2, October 2000.

MDU Lewis and Clark Station

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

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

3,4MDU report, June 2011, Appendix C.2, Table C.2-6

(2010 Dollars)
MDU Lewis and Clark Station

Modified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsNew or Retrofit? RetrofitGeneration capacity (MW gross) 52SCR bypass included? No AssumedFuel High Heating Value (Btu/lb) From EIA for 1999 6,714

Maximum Fuel Consumption Rate (lb/hr) Calculated from 572 85,195 MMBtu/hr, MDU Control Cost Spreadsheets

Average Annual Fuel Consumption (lb) 5.90E+08 Calcuated from 3,958,469 Calculated from maximum heat input capaciNumber of SCR Operating Days 365 AssumedPlant Capacity Factor 79% MDU letter, March 17, 2009, p 2.Uncontrolled NOx Concentration (lb/MMBtu) 0.400 MDU letter, March 17, 2009, p 6.New LNB and SOFA Total Capital Cost $ MDU report, June 2011, Appendix C.2, Table C.2-6 2,195,000

New LNB and SOFA Total Annual Cost $ MDU report, June 2011, Appendix C.2, Table C.2-6 364,546

LNB/CCOFA/SOFA outlet = SCR inlet NOx Concentration (lb/MMBtu) 0.260 MDU report, June 2011, Appendix C.2, Table C.2-6Required Controlled NOx Concentration (lb/MMBtu) 0.05 IPM Base Case v4.10 Documentation, Appendix 5-2A (August 2010)Acceptable Ammonia Slip (ppm) 2.0 OAQPS Control Cost ManualFuel Volume Flow Rate (ft3/min/MMBtu/hr) 547 OAQPS Control Cost ManualFuel Sulfur Content 5.10% MDU letter, March 17, 2009, p. 7.Fuel Ash Content 9.30% MDU letter, March 17, 2009, p. 7.Number of SCR reactor chambers 2 AssumedNumber of spare catalyst layers 1 AssumedASR 1.05 EPA Control Cost ManualStored Ammonia Concentration 29% EPA Control Cost ManualReagent Molecular Weight (g/mole) 17.03 EPA Control Cost ManualReagent Density (lb/ft3 @ 60F) 56.0 EPA Control Cost ManualReagent Specific Volume (gal/ft3) 7.481 EPA Control Cost ManualNOx Molecular Weight (g/mole) 46.01 EPA Control Cost ManualNumber of Days of Storage for Ammonia 14 EPA Control Cost ManualPressure Drop for SCR Ductwork H2O") 3 EPA Control Cost ManualPressure Drop for each Catalyst Layer (H2O") 1 EPA Control Cost ManualTemperature at SCR Inlet (degrees F) 850 MDU report, June 2011, Appendix C.2, Table C.2-3.Equipment Life (years) 20 EPA Control Cost ManualAnnual Interest Rate 7% EPA Control Cost ManualInflation Since 1998 1.41 CEPCI 2010/CEPCI 1998Catalyst Cost, Initial ($/ft3) $ calculated from 6,000 170 $ Cichanowicz (Jan 2010); MDU claims $214.2

Catalyst Cost, Replacement ($/ft3) $ calculated from 6,000 170 $ Cichanowicz (Jan 2010); MDU claims $214.2

Electrical Power Cost ($/kWh) $ MDU Report, June 2011, Appendix C.2, Table C.2-3. 0.057

29% Aqueous Ammonia ($/lb) $ calculated from 240 0.120 $ Fuel Tech (3/2/2012)

Operating Life of Catalyst (hours) EPA Control Cost Manual 24,000

Natural gas unit cost ($/mcf) $ MDU Report, Appendix C.2, Table C.2-3. 6.85

Natural gas for reheat (mcf) NA
SCR Capital Cost Estimate Worksheet

Variable Designation Units Value Calculation

Unit Size (Gross) A (MW) 52 InputRetrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Heat Rate C (Btu/kWh) 13787 InputNOx Rate D (lb/MMBtu) 0.26 Input

SO2 Rate E (lb/MMBtu) 1.52 Input

Type of Coal F PRB InputCoal Factor G 1.07 Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate Factor H 1.3787 C/10000Heat Input I (Btu/hr) 7.17E+08 A*C*1000Capacity Factor J (%) 79.0 InputNOx Removal Efficiency K (%) 80.8 Input

NOx Removal Factor L 1.009615385 K/80

NOx Removed M (lb/hr) 151 D*I/106*K/100

Costs are all based on 2009 dollars

Capital Cost Calculation

 Include: equipment, installation, buildings, foundations, electrical, and retrofit difficulty. BMR ($) = 180000*(B)*(L)0.2*(A*G*H)0.92 $9,776,000 SCR (inlet ductwork, reactor, bypass) island cost

 BMF ($) = 410000*(M)0.25 $1,436,000 Base reagent preparation cost BMA ($) = If E >= 3 then 65000*(B)*(A*G*H)0.78; else 0 $0 Air heater modification / SO3 control (bituminous only & > 3 lb/MMbtu)

 BMB ($) = 380000*(B)*(A*G*H)0.42 $2,352,000 ID or booster fans & auxiliary power modification costs

 BM ($) = BMR + BMF + BMA + BMB $13,564,000 Total bare module cost including retrofit factor BM ($/kW) $261 Base cost per kW

Total Project Cost

 A1 = 10% of BM $1,356,000 Engineering and construction management costs A2 = 10% of BM $1,356,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $1,356,000 Contractor profit and fees

 CECC($) = BM+A1+A2+A3 $17,632,000 Capital, engineering and construction cost subtotal CECC($/kW) = $339 Capital, engineering and construction cost subtotal per kW

 B1 = 5% of CECC $881,600 Owners costs including "home office" costs (owners engineering, management, and procurement activities) B2 = 6% of (CECC + B1) $1,111,000 AFUDC (based on approximately 3% per year for a 2 year engineering and construction cycle)

 TPC ($) = CECC + B1 + B2 $19,624,600 Total project cost TPC ($/kW) = $377 Total project cost per kW

Work Sheet adpapted from "IPM Model-Revisions to Cost And Performance for APC Technologies-SCR Cost Development Methodology-FINAL", August 2010 Project 12301-007, Perrin Quarles Associates, Inc., prepared by Sargent & Lundy, LLC
Boiler Calculations (from Section 4.2 of EPA Control Cost Manual)

2.3 QB = HVm-dotfuel

QB = 6,714 Btu/lb * 85,195 lb/hr

QB = 572 Btu/hr

2.7 CFPlant = actual heat input/maximum annual heat input

CFPlant = 79%

2.8 CFSCR = tSCR/365 days

CFSCR = 365 days/ 365 days

CFSCR = 100%

2.6 CFTotal = CFPlant x CFSCR

CFTotal = 79% * 100%

CFTotal = 79%

2.12 qfluegas = qfuelQB(460+T)/(460+700oF)nSCR

qfluegas = 547 ft3/min/(mmBtu/hr)* 572 mmBtu/hr*( 460 + 850 )/( 460 + 700 )/ 2

qfluegas = 176,672 acfm

2.9 ηNOx = (NOxin – NOxout) / NOxin

ηNOx = ( 0.26 lb/mmBtu - 0.05 lb/mmBtu)/ 0.26 lb/mmBtu

ηNOx = 81%

Uncontrolled NOx emissions 792 tpy

2.57 NOx Removed = NOxinηNOxQBtop

SOFA NOx Removed = 0.40 * 35% * 572 * 6920 / 2000SOFA NOx Removed = 277 tpySCR NOx Removed = 0.26 * 0.81 * 572 * 6920 / 2000SCR NOx Removed = 416 tpyOverall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc

( 0.40 - 0.05 )/ 0.40 = 88%

Overall NOx removed = 693 tpyControlled NOx emissions = 99 tpy
SCR Reactor Calculations (from Section 4.2 of EPA Control Cost Manual)

2.19 Volcatalyst = 2.81 x QB x ηadj x Slipadj x NOxadj x Sadj x Tadj/NSCR

Volcatalyst = 2.81 * 572 = 1607.32

2.2 ηadj = 0.2869 + (1.058 x η)

ηadj = 0.2869 +( 1.058 * 0.81 )ηadj = 1.141

2.22 Slipadj = 1.2835 – (0.0567 x Slip)

Slipadj = 1.2835 - ( 0.057 * 2 )

Slipadj = 1.170

2.21 NOxadj = 0.8524 + (0.3208 x NOxin

)

NOxadj = 0.8524 + ( 0.321 * 0.26 )

NOxadj = 0.936

2.23 Sadj = 0.9636 + (0.0455 x S)

Sadj = 0.9636 + ( 0.046 * 5.1 )

Sadj = 1.196

2.24 Tadj = 15.16 – (0.03937 x T) + (2.74 x 10-5 x T

2

)

Tadj = 15.16 - ( 0.039 * 850 ) + 2.74E-05 * 722500

Tadj = 1.492Volcatalyst = 1,792 ft3 each =50.78m3 each

2.25 Acatalyst = qfluegas/(16 ft/sec x 60 sec/min)

Acatalyst = 176,672 /( 16 * 60 )

Acatalyst = 184 ft2

2.26 ASCR = 1.15 x Acatalyst

ASCR = 1.15 * 184

ASCR = 212 ft2

2.27 l = w = ASCR1/2

l = w = 14.5 ft

2.28 nlayer = Volcatalyst/(h’layer x Acatalyst

)

nlayer = 1,792 /( 3.1 * 184 )

nlayer = 3.0

nlayer = 3.0

2.29 hlayer = [Volcatalyst/(nlayer x Acatalyst)] + 1

hlayer = 1,792 /( 3.0 * 184 ) + 1hlayer = 4.2

2.3 ntotal = nlayer + nempty

ntotal = 3 + 1

ntotal = 4

2.31 hSCR = ntotal(c1 + hlayer) + c2

hSCR = 4 * ( 7 + 4.2 ) + 9
hSCR = 54 ft
SCR Bypass Calculations (from Section 4.2 of EPA Control Cost Manual)

2.41 f(bypass) = $0/(mmBtu/hr) for no bypass

f(bypass) = $ - /mmBtu/hr * inflation = $ - per Btu/hrf(bypass) = $0 each SCR reactor

$0 all SCR reactors
Initial Catalyst Calculations (from Section 4.2 of EPA Control Cost Manual)

2.43 f(Volcatalyst) = VolcatalystCCinitial

f(Volcatalyst) = 1792 * 170

f(Volcatalyst) = $304,675 each SCR reactor

$609,351 all SCR reactors