SCR Capital CostsDescriptionFormula1ValueBoiler Size (MMBtu/hr)QB572NOx Removal Efficiency (%)ηNOx80.8%Cost Year2010Total Direct Capital Costs ($)2A$14,315,101Indirect Installation CostsGeneral Facilities ($) 0.05 x A$715,755Engineering and Home Office Fees ($) 0.10 x A$1,431,510Process Contingency ($) 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$388SCR Annual CostsDirect Annnual CostsMaintenance Cost Eq. 2.46$302,346Reagent Cost Eq. 2.47$133,685Electricity Cost Eq. 2.49$87,895Catalyst 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) $2,489,873SOFA/LNB Capital CostsTotal Captial Investment ($)3TCI$2,195,000Total Capital Investment ($/kW) Per kW$42SOFA/LNB Annual CostsTotal Direct Annual Costs4DAC$664,884Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $207,208Total Annual Costs TAC = DAC + IAC (Eq. 2.56) $872,092Cost EffectivnessSOFA/LNB NOx Removed (tons/yr) Eq. 2.57277SOFA/LNB Cost Effectiveness ($/ton removed) Eq. 2.58$3,147SCR NOx Removed (tons/yr) Eq. 2.57416SCR Cost Effectiveness ($/ton removed) Eq. 2.58$5,990SCR+SOFA/LNB NOx Removed (tons/yr) Eq. 2.57693SCR+SOFA/LNB Cost Effectiveness ($/ton removed)Eq. 2.58$4,8531Taken from "EPA Control Cost Manual", Section 4.2, Chapter 2, October 2000.MDU Lewis and Clark Station2Direct capital costs for SCR were derived from "IPM Model – Revisions to Cost and Performance for APCTechnologies SCR Cost Development Methodology," Sargent & Lundy, August 2010.3,4MDU report, June 2011, Appendix C.2, Table C.2-6(2010 Dollars)MDU SCR Cost AnalysisMDU Lewis and Clark StationModified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsNew or Retrofit?RetrofitGeneration capacity (MW gross)52SCR bypass included?No AssumedFuel High Heating Value (Btu/lb)6,714From EIA for 1999Maximum Fuel Consumption Rate (lb/hr)85,195Calculated from 572MMBtu/hr, MDU Control Cost SpreadsheetsAverage Annual Fuel Consumption (lb)5.90E+08 Calcuated from 3,958,469 Calculated from maximum heat input capacity and plant capacity factor for 2008Number of SCR Operating Days365 AssumedPlant Capacity Factor79% MDU letter, March 17, 2009, p 2.Uncontrolled NOx Concentration (lb/MMBtu)0.400 MDU letter, March 17, 2009, p 6.New LNB and SOFA Total Capital Cost2,195,000$ MDU report, June 2011, Appendix C.2, Table C.2-6New LNB and SOFA Total Annual Cost364,546$ MDU report, June 2011, Appendix C.2, Table C.2-6LNB/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 Content5.10% MDU letter, March 17, 2009, p. 7.Fuel Ash Content9.30% MDU letter, March 17, 2009, p. 7.Number of SCR reactor chambers2 AssumedNumber of spare catalyst layers1 AssumedASR1.05 EPA Control Cost ManualStored Ammonia Concentration29% 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 Ammonia14 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 Rate7% EPA Control Cost ManualInflation Since 19981.41 CEPCI 2010/CEPCI 1998Catalyst Cost, Initial ($/ft3)170$ calculated from 6,000$ Cichanowicz (Jan 2010); MDU claims $214.29/ft2Catalyst Cost, Replacement ($/ft3)170$ calculated from 6,000$ Cichanowicz (Jan 2010); MDU claims $214.29/ft3Electrical Power Cost ($/kWh)0.057$ MDU Report, June 2011, Appendix C.2, Table C.2-3.29% Aqueous Ammonia ($/lb)0.120$ calculated from 240$ Fuel Tech (3/2/2012)Operating Life of Catalyst (hours)24,000EPA Control Cost ManualNatural gas unit cost ($/mcf)6.85$ MDU Report, Appendix C.2, Table C.2-3.Natural gas for reheat (mcf)NASCR Capital Cost Estimate WorksheetVariable Designation Units Value CalculationUnit Size (Gross)A(MW)52InputRetrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Heat RateC(Btu/kWh)13787InputNOxRateD (lb/MMBtu) 0.26 InputSO2RateE (lb/MMBtu) 1.52 InputType of CoalFPRBInputCoal FactorG1.07Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate FactorH1.3787C/10000Heat InputI(Btu/hr)7.17E+08A*C*1000Capacity FactorJ(%)79.0InputNOxRemoval EfficiencyK (%) 80.8 InputNOxRemoval FactorL 1.009615385 K/80NOxRemovedM (lb/hr) 151D*I/106*K/100Costs are all based on 2009 dollarsCapital Cost CalculationInclude: equipment, installation, buildings, foundations, electrical, and retrofit difficulty.BMR ($) = 180000*(B)*(L)0.2*(A*G*H)0.92$9,776,000 SCR (inlet ductwork, reactor, bypass) island costBMF ($) = 410000*(M)0.25$1,436,000 Base reagent preparation costBMA ($) = If E >= 3 then 65000*(B)*(A*G*H)0.78; else 0$0Air heater modification / SO3control (bituminous only & > 3 lb/MMbtu)BMB ($) = 380000*(B)*(A*G*H)0.42$2,352,000 ID or booster fans & auxiliary power modification costsBM ($) = BMR + BMF + BMA + BMB$13,564,000Total bare module cost including retrofit factorBM ($/kW)$261Base cost per kWTotal Project CostA1 = 10% of BM$1,356,000Engineering and construction management costsA2 = 10% of BM$1,356,000Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 10% of BM$1,356,000Contractor profit and feesCECC($) = BM+A1+A2+A3$17,632,000Capital, engineering and construction cost subtotalCECC($/kW) =$339Capital, engineering and construction cost subtotal per kWB1 = 5% of CECC$881,600Owners costs including "home office" costs (owners engineering, management, and procurement activities)B2 = 6% of (CECC + B1)$1,111,000AFUDC (based on approximately 3% per year for a 2 year engineering and construction cycle)TPC ($) = CECC + B1 + B2$19,624,600Total project costTPC ($/kW) =$377Total project cost per kWWork 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, LLCBoiler Calculations (from Section 4.2 of EPA Control Cost Manual)2.3 QB= HVm-dotfuelQB= 6,714Btu/lb * 85,195lb/hrQB= 572Btu/hr2.7 CFPlant= actual heat input/maximum annual heat inputCFPlant =79%2.8 CFSCR= tSCR/365 daysCFSCR= 365 days/ 365 daysCFSCR= 100%2.6 CFTotal= CFPlantx CFSCRCFTotal= 79% * 100%CFTotal= 79%2.12 qfluegas= qfuelQB(460+T)/(460+700oF)nSCRqfluegas= 547 ft3/min/(mmBtu/hr)* 572 mmBtu/hr*( 460 + 850 )/( 460 + 700 )/ 2qfluegas= 176,672acfm2.9 ηNOx= (NOxin– NOxout) / NOxinηNOx= ( 0.26 lb/mmBtu - 0.05 lb/mmBtu)/ 0.26 lb/mmBtuηNOx= 81%Uncontrolled NOx emissions792tpy2.57NOx Removed = NOxinηNOxQBtopSOFA NOx Removed =0.40*35%*572*6920/2000SOFA NOx Removed =277tpySCR NOx Removed =0.26*0.81*572*6920/2000SCR NOx Removed =416tpyOverall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc(0.40-0.05)/0.40=88%Overall NOx removed =693tpyControlled NOx emissions =99tpySCR Reactor Calculations (from Section 4.2 of EPA Control Cost Manual)2.19 Volcatalyst= 2.81 x QBx ηadjx Slipadjx NOxadjx Sadjx Tadj/NSCRVolcatalyst= 2.81 * 572 = 1607.322.2 ηadj= 0.2869 + (1.058 x η)ηadj= 0.2869 +( 1.058 * 0.81 )ηadj= 1.1412.22 Slipadj= 1.2835 – (0.0567 x Slip)Slipadj= 1.2835 - ( 0.057 * 2 )Slipadj= 1.1702.21 NOxadj= 0.8524 + (0.3208 x NOxin)NOxadj= 0.8524 + ( 0.321 * 0.26 )NOxadj= 0.9362.23 Sadj= 0.9636 + (0.0455 x S)Sadj= 0.9636 + ( 0.046 * 5.1 )Sadj= 1.1962.24 Tadj= 15.16 – (0.03937 x T) + (2.74 x 10-5x T2)Tadj= 15.16 - ( 0.039 * 850 ) + 2.74E-05 * 722500Tadj= 1.492Volcatalyst= 1,792ft3 each =50.78m3 each2.25 Acatalyst= qfluegas/(16 ft/sec x 60 sec/min)Acatalyst= 176,672/( 16 * 60 )Acatalyst= 184ft22.26 ASCR= 1.15 x AcatalystASCR= 1.15 * 184ASCR= 212ft22.27 l = w = ASCR1/2l = w =14.5ft2.28 nlayer= Volcatalyst/(h’layerx Acatalyst)nlayer= 1,792/( 3.1 * 184 )nlayer= 3.0nlayer= 3.02.29 hlayer= [Volcatalyst/(nlayerx Acatalyst)] + 1hlayer= 1,792/( 3.0 * 184 ) + 1hlayer= 4.22.3 ntotal= nlayer+ nemptyntotal= 3 + 1ntotal= 42.31 hSCR= ntotal(c1+ hlayer) + c2hSCR= 4 * ( 7 + 4.2 ) + 9hSCR= 54 ftSCR Bypass Calculations (from Section 4.2 of EPA Control Cost Manual)2.41f(bypass) = $0/(mmBtu/hr) for no bypassf(bypass) =-$/mmBtu/hr * inflation =-$per Btu/hrf(bypass) =$0each SCR reactor$0all SCR reactorsInitial Catalyst Calculations (from Section 4.2 of EPA Control Cost Manual)2.43 f(Volcatalyst) = VolcatalystCCinitialf(Volcatalyst) = 1792 * 170f(Volcatalyst) = $304,675 each SCR reactor$609,351all SCR reactors