Appendix Q 

Holcim-Clarksville SO2 Control Cost Evaluation 
Direct Costs Holcim MDNR

Purchased Equipment Costs

New Coal Mill ID Fan and associated equipment $2,000,000 $1,000,000 Holcim Estimate; Historical Fan Cost

Instrumentation (10% of EC) $200,000 $100,000 Holcim Regional Capital Expense ManaSales Tax (5% of EC) $100,000 $50,000 Holcim Regional Capital Expense ManaFreight (5% of EC) $100,000 $50,000 0.05 A

Subtotal, Purchased Equipment Cost (PEC) $2,400,000 $1,200,000 B

Direct Installation Costs

Foundation (6% of PEC) $144,000 $72,000 Holcim Regional Capital Expense ManaSupports (6% of PEC) $144,000 $72,000 Holcim Regional Capital Expense ManaHandling and Erection (40% of PEC) $960,000 $480,000 Holcim Regional Capital Expense ManaElectrical (1% of PEC) $24,000 $12,000 Holcim Regional Capital Expense ManaPiping (30% of PEC) $720,000 $360,000 0.30 B CCMInsulation for Ductwork (1% of PEC) $24,000 $12,000 Holcim Regional Capital Expense ManaPainting (1% of PEC) $24,000 $12,000 0.01 B CCM

Subtotal, Direct Installation Cost $2,040,000 $1,020,000

Site Preparation N/A N/ABuildings N/A N/A

Total Direct Cost $4,440,000 $2,220,000

Indirect Costs

Engineering (10% of PEC) $240,000 $120,000 CCMConstruction and Field Expense (10% of PEC) $240,000 $120,000 Holcim Regional Capital Expense ManaContractor Fees (10% of PEC) $240,000 $120,000 CCMStart-up (1% of PEC) $24,000 $12,000 CCMPerformance Test (1% of PEC) $24,000 $12,000 CCMContingencies (3% of PEC) $72,000 $36,000 Holcim Regional Capital Expense Mana

Total Indirect Cost $840,000 $420,000

Total Capital Investment (TCI) $5,280,000 $2,640,000
Direct Annual Costs

Scaled up from 2007 annual average cli

Increased Fuel Cost (calculated by scaling 2007 annual average fuel usage by the ratio of 3-year average clinker 2007 (1,035,283 ton

production (1,169,667 tons) to 2007 actual clinker production (1,035,283 tons)

####### Reduction in coke usage (metric ton/yr) 181,802 Holcim Engineering Estim 

160,91

Heat Value (Gj / Mt) 32.510 Holcim Plant DataHeat (Gj / yr) 5,910,397 Holcim Engineering EstimateCost ($/Gj) $1.74 Holcim Plant Data

Subtotal, reduction in coke cost -$10,284,091 -$10,284,091

####### Reduction in coal usage (metric ton/yr) 10,656 Holcim Engineering Estim 

9,43

Heat Value (Gj / Mt) 22.177 Holcim Plant DataHeat (Gj / yr) 236,325 Holcim Engineering EstimateCost ($/Gj) $2.41 Holcim Plant Data

Subtotal, reduction in coal cost -$569,543 -$569,543

####### Increase in low sulfur coal usage - Amount Requir Holcim Engineering Esti 198,736 m 

208,54

Heat Value (Gj / Mt) 25.818 Holcim Engineering EstimateHeat (Gj / yr) 5,131,033 Holcim Engineering EstimateCost ($/Mt) or Cost ($/Gj) $72.76 $2.82 Holcim Marketing and Engineering Esti

Subtotal, increase in Low Sulfur Coal cost $14,459,211 $14,460,031

Total Direct Annual Cost (increase) $3,605,577 $3,606,397
Indirect Annual Costs

Administrative (2% TCI) $105,600 $52,800 0.02 TCIProperty Tax (1% TCI) $52,800 $26,400 0.01 TCIInsurance (1% TCI) $52,800 $26,400 0.01 TCICapital Re (15 year life, 7 percent interest) $579,716 $289,858

Total Indirect Annual Cost $790,916 $395,458

Conclusion

Total Annualized Cost $4,396,493 $4,001,855Pollutant Emission Rate Prior to Scrubber (tons SO2/yr) 11,675 11,675 11675.16667 Average SO2 

Pollutant Removed (tons SO2/yr) - 23% 3,152 3,152 27% Removal

Cost Per Ton of Pollutant Removed $1,395 $1,270

Pollutant Emitted after Control 8,523 8,523 tons/yearMaximum Actual Historical Clinker Production (to 1,169,667 1,169,667

Incremental Cost/ton clinker $ $3.42 4

1169667 Average Production of 3 latest full production yea

 Gj/yr Heat Input from Fuel at Max

6,432,296
Maximum Annual Clinker Scale

Cost per Gj S% BTU/lb GJ/Mton $/Mton fuel $/ton fuel Ex/Repl Use GJ/yr 

(MT) 

Existing Coal $2.41 3.45% 9534.49 22.177 $53.45 $48.49 10,656.31 236,32

 

Pet Coke $1.74 5.72% 13976.93 32.51 $56.57 $51.32 181,802 5,910,39

 

3%S Coal $2.81815 3.00% 11100 25.81833508 $72.76 $66.01 198,736 5,131,03

 

Tires 1.83% 13432.5 31.24367441 24,705.02 771,875.4

 

PRB Coal $5.67 0.70% 11300.00 26.28353031 $149.03 $135.20 244,727 6,432,29

 

Other 529,387.5

0.9478171 MMBTU/Gj 

429.927 BTU/lb per Gj/MetricTon 

5,660,420.1

2.2046 lb/kg 

1000 kg/Metric Ton 

Tires

26.865 MMBTU/short ton

13432.5 BTU/lb

1.83 %S TDF

Modeled 4889.375 lb SO2/hour 117345 lb SO2/day 12/2/2004 4069.382956 TPD Clinker 28.836067

3049.375 lb NOx/hour 73185 lb NOx/day 11/24/2007 3762.70105 TPD Clinker 19.450123

MAX 30-day average 80529.88431 lb SO2/day 12/10/05 1/8/06 20.955492

52858.73258 lb NOx/day 10/29/07- 11/27/07 13.787769

2007 Ann Avg lb/ton SO2 17.310831752007 Ann Avg lb/ton Nox 10.05306488 Percentile SO2 UNC (lb/day) 

Max 2415897 80529

2006 Ann Avg lb/ton SO2 13.64712331 0.95 2239006 74633.5332006 Ann Avg lb/ton Nox 8.583653198 0.9 2043221 68107.366

0.8 1824675 60822

2005 Ann Avg lb/ton SO2 11.16488906 0.7 1666853 55561.7662005 Ann Avg lb/ton Nox 5.768385811 0.6 1509100 50303.333

0.5 1344408 44813

Percentile NOX UNC (lb/day) CON(lb/day) 

Max 1585762 52858.73333 42286.986

0.95 1251125 41704.16667 33363.333

0.9 1089332 36311.06667 29048.8530.8 921089 30702.96667 24562.3730.7 855838 28527.93333 22822.3460.6 730787 24359.56667 19487.6530.5 629996 20999.86667 16799.893
Direct Costs MDNR Alt

Purchased Equipment Costs

Wet Scrubber Unit including Limestone Prep System $10,524,352 $7,670,653

Based on Ash Grove CemeEstimate from Enviro-chem 25% possible increase). Sc0.6 power

Instrumentation (15% of EC) $1,578,653 $1,150,598

Holcim Regional CapEngineering Estimate 

Sales Tax (5% of EC) $526,218 $383,533

Holcim Regional CapEngineering Estimate 

Freight (5% of EC) $526,218 $383,533 CCM

Subtotal, Purchased Equipment Cost (PEC) $13,155,441 $9,588,317 

Clark

Direct Installation Costs

Foundation (10% of PEC) $1,315,544 $958,832

Holcim Regional CapEngineering Estimate 

Supports (10% of PEC) $1,315,544 $958,832

Holcim Regional CapEngineering Estimate 

Handling and Erection (50% of PEC) $6,577,720 $4,794,158

Holcim Regional CapEngineering Estimate 

Electrical (10% of PEC) $1,315,544 $958,832

Holcim Regional CapEngineering Estimate 

Piping (30% of PEC) $3,946,632 $2,876,495 CCMExtending gas line 1/2 mile to plant $500,000 $500,000 Engineering EstimateInsulation for Ductwork (5% of PEC) $657,772 $479,416

Holcim Regional CapEngineering Estimate 

Painting (1% of PEC) $131,554 $95,883 CCM

Subtotal, Direct Installation Cost $15,760,311 $11,622,447

Buildings N/A N/A

Total Direct Cost $28,915,752 $21,210,764
Indirect Costs

Engineering (10% of PEC) $1,315,544 $958,832 CCMConstruction and Field Expense (15% of PEC) $1,973,316 $1,438,248

Holcim Regional CapEngineering Estimate 

Contractor Fees (10% of PEC) $1,315,544 $958,832 CCMStart-up (1% of PEC) $131,554 $95,883 CCMPerformance Test (1% of PEC) $131,554 $95,883 CCMContingencies (5% of PEC) $657,772 $479,416

Holcim Regional CapEngineering Estimate 

Total Indirect Cost $5,525,285 $4,027,093

Total Capital Investment (TCI) $34,441,037 $25,237,857

Direct Annual Costs

Hours (365 days per year, 24 hours per day), 90% Uptime 7,884 7,884Operating Labor

Operator (8 men/yr, 2,080 hrs/yr, $64.50/hr) 4 men/yr $1,073,280 $1,073,280

Estimate - 8 man yearHolcim Durkee

Supervisor (15% of operator) $160,992 $160,992 CCM

Subtotal, Operating Labor $1,234,272 $1,234,272

Maintenance

Labor (6 men/yr, 2,080 hrs/yr, $64.50/hr) 3 men/yr $804,960 $804,960

Estimate - 6 man yearHolcim Durkee

Material (5% of Total Direct Cost) 1,445,788 $ $1,060,538 Holcim Lee Island PS

Subtotal, Maintenance $2,250,748 $1,865,498

Utilities

ElectricityPump (kW) 2,342 1,707

Scaled using Moapa dthe 0.6 power

Cost ($/kW-hr) $0.0410 $0.041 Clarksville Budget - 2

Subtotal, Electricity $757,054 $551,617

Limestone for slurry 
Amount Required (ton/yr) 15,972 9,423

(1.6 tons CaCO3/ ton evaluation = 1.03/1.0 

Cost ($/ton) $3.00 $3

Subtotal, Lime $47,915 $28,270

WaterAmount Required (gpm) 122.0 89

Scaled using Moapa dthe 0.6 

power

Cost ($/1000 gallons) $1.00 $1 Plant Estimate

Subtotal, Water $57,716 $42,054

Sludge DisposalAmount Generated (tpy) 66,288 39,110

Scale to synthetic gyp(170) / SO2 MW( 64) 50 

percent moisture

Disposal Fee ($/ton) $36.00 $36 Bid from Area DispoMonthly Rent for Trailer @ $120/month $1,440 $1,440 Bid from Area DispoCost for Box Transportation @ $220/load (assume 17 tons/trailer) $857,851 $506,132 Bid from Area Dispo

Subtotal, Sludge $3,245,677 $1,915,540

Subtotal, Utilities $4,108,361 $2,537,480

Natural Gas Reheat (assuming a 210 deg F temp drop and reheat)Gas Required (MMCF/yr) 1,074,722 634,135 See Calculations BeloCost ($/MMBTU) $10.06 $10.06 Missouri Energy Bull

Subtotal, Natural Gas $10,811,708 $6,379,395

Total Direct Annual Costs $18,405,089 $12,016,646

Indirect Annual Costs

Overhead (60% of sum of operating, supervisor, maintenance labor & material $2,091,012 $1,859,862

Administrative (2% TCI) $688,821 $504,757 0.02 TCIProperty Tax (1% TCI) $344,410 $252,379 0.01 TCIInsurance (1% TCI) $344,410 $252,379 0.01 TCICapita (15 year life, 7 percent interest) $3,781,441 $2,770,981

Total Indirect Annual Cost $7,250,094 $5,640,357
Conclusion

Total Annualized Cost $25,655,183 $17,657,003Pollutant Emission Rate Prior to Scrubber (tons SO2/yr) 11,675 11,675 

Pollutant Removed (tons SO2/yr) - 90% Removal, 95% Uptime 9,982 5,890

90% removal, 95% up

Pollutant Generated - NOx tons/yr 

Net Pollutant Removed - tons/yr 9,982 5,890

Cost Per Ton of Pollutant Removed $2,570 $2,998

Pollutant Emitted after Control 1,693 5,786 tons/year

Maximum Actual Historical Clinker Production (tons) 1,169,667 1,169,667 

Incremental Cost/ton clinker $ $15.10 22
Standard temperature 68 68 F

Density of air 0.0026 0.0026 lb-mole/scfSpecific heat of exhaust gas 7.542 7.542 Btu/lb-mole F

Specific heat of steam 14.7 psia 220 - 600 deg F 8.46 8.46 Btu/lb-mole FExhaust gas percent water 35% 0.35 PercentSpecific heat of exhaust gas 7.86 7.8633 Btu/lb-mole FExhaust gas temperature after WLS 170 256

Deg. F Based on Design. NW Email

Current ESP outlet gas temp 380 380 Deg F 

Heat input 3.60 1.868 Btu/acfExhaust gas flow rate - 367 828969 828,969 acfm

Exhaust gas flow rate - reduced temperature 717751.17 631,404Unit natural gas cost $10.06 $10.06 Missouri Energy BullNatural gas requirement - Based on 90% Plant Uptime, 95% Scrubber 

Uptime 1,074,722 634134.703 MMBTU/yr

Natural Gas Cost $10,811,708 $6,379,395.11 /yr

Additional NOx Generated 140 140

lbs/MMscf. *** LNB Control Inc

Conversion 1050 1050 MMBTU / MMSCF. Natural gas requirement in MMscf/yr 1023.5 603.94 MMSCF/yrNOx generated - tons/yr 72 42.28 tons/year