Summary of Heat Exchanger Costs and Cooling Water Pump Costs

This Excel file contains the following worksheets:

Heat Exchangers

Heat Exchanger Freight

Cooling Water

EPA contacted several vendors to obtain cost estimates for a heat changer to include as part of the biological treatment 

wastewater treatment system. This excel file combines the quotes from the five vendors providing quotes for heat 

exchangers and one vendor providing costs for the associated cooling water pumps needed for the system. EPA asked 

vendors to provide equipment costs for several different flow rates. These costs and flows were then used to generate a 

cost curve that could be applied to a range of FGD wastewater and cooling water flow rates.

EPA contacted five vendors (WCR, ITT, Funke, Tranter, and Sulzer) requesting costs for a 

heat exchanger capable of handling the FGD wastewater. Four of these vendors (WCR, 

ITT, Funke, and Tranter) provided quotes for titanium exchangers. The quotes from all four 

sources were graphed, and line of best fit was used to estimate equipment cost for specific 

FGD wastewater flow rates. The equation used is highlighted in yellow.

This Excel workbook documents the various vendor quotes received for heat exchangers and associated cooling water 

pumps. 

One vendor, Sulzer, provided costs associated with the cooling water pumps needed to 

properly operate the heat exchanger. Sulzer provided individual costs for pumps assuming 

five different cooling water flow rates: 50, 100, 500, 1500, and 3000 gpm. These costs and 

flows were used to generate a cost curve which was used to estimate costs for a variety of 

cooling water flow rates. The same methodology was used to estimate energy consumption 

for these pumps. The specific equations used in the cost model are highlighted in yellow.

Estimates for the freight costs associated with heat exchangers. EPA consulted a freight 

forwarding agent to estimate costs associated with transporting the heat exchanger based on 

the weight estimates provided by vendors. These freight costs were then used to estimate 

the percentage of capital cost associated with freight charges. The average percentage is 

highlighted in yellow.
Vendor WCR

478-738-0873 (SE), 937-223-0703 (Central)

Ed (sent ww characteristics to him)

WW Characteristics 120 F in earing@wcr-heatexchangers.com

95 F out

2% chlorides

Cooling Water Characteristics 65 F in

??

316 SS , 316L Generally recommend next step in materials if potential to corrode.

 100 gpm 2442.89

 500 gpm 5314.55

 1500 gpm 22716.8

 Maintenance

 Replacement frequency Anywhere from 2 months to 2 years. 

Titanium

100 4198

500 10691

1500 38764

 Maintenance

 Replacement frequency

6 Mo Stainless Steel SMO 254

 100 gpm Guarantee this material is going to be more expensive than SS or Ti due to s

 500 gpm

 1500 gpm

 Maintenance

 Replacement frequency

Offer cooling water pumps? No

 500 gpm

 1500 gpm

 3000 gpm

 Maintenance

Company FGD Wastewater Flow

WCR 100

WCR 500

WCR 1500

Tranter 1500

Funke 100

Funke 500

Funke 1500

ITT Standard 100

ITT Standard 500

ITT Standard 1500
ITT Standard Funke

704-844-1100 (Carotek); gary.latimer@carotek.com 717-891-8181

Gary Peter Frennborn

gary.latimer@carotek.com frennborn@us.funke.de

Would not provide material recommendation. Rely on customer to do this analysis. Will get back in a week. Email suggested 

1700

5600

14900

Recommended based on chlorides

5000 2300

11000 7600

26000 21600

be more expensive than SS or Ti due to stock. Do not generally keep this in stock; would make this option 

No

4198

10691

38764

44889

2300

7600

21600

5000

11000

26000

Cost

0

10000

20000

30000

40000

50000

0

Heat Exchanger Capital C

ost ($)

Titanium Heat Exchang
Tranter Sulzer Pumps

AZ (will forward on to PA Power group)

doug.cavin@sulzer.com

@us.funke.de Note that we can get pump curves on line "Sulzer Select"

nalysis. Will get back in a week. Email suggested Ti was safer than S/S

nded based on chlorides

44889

erally keep this in stock; would make this option more expensive.

NA

y = 0.0059x2 + 11.304x + 2643.6

R2 = 0.8215

0 200 400 600 800 1000 1200 1400 1600

Wastewater Flow Rate (gpm)

Titanium Heat Exchanger Cost versus 

Wastewater Flow Rate
Vendor Flow (gpm) Empty Weight (lb) HE Cost (from Summary of HE Vendo Costs.xlsx in heat exchangers folder) Freight

Tranter 1500 3074 44889 1108.33

Funke 1500 2613 21600 943.63

Funke 100 39 2300 261.47

WCR 1500 3432 38764 1224.03

WCR 500 1080 10691 445.05

WCR 100 450 4198 277.78

ITT 1500 2570 26000 928.25

ITT 500 1058 11000 455.43

ITT 100 318 5000 230.13

Min 39

Avg 1626

Max 3432

y = 1.8879x + 94.663

R2 = 0.9559

0

500

1000

1500

2000

2500

3000

3500

4000

0 200 400 600 800 1000 1200 1400

Empty

Weight (lbs)

Flow Rate (gpm)

HE Weight Equation based on Flow
Freight Factor (freight/cost ratio)

0.02469 NOTE: Freight data from freightcenter.com. Chose median freight quote.

0.043687

0.113683

0.031576 Use freight factor of 1.05 for heat exchanger.

0.041628

0.06617

0.035702

0.041403

0.046026

0.02469

0.049396

0.113683

1400 1600
gpm TDH Pump Modelhp rpm frame Pump Motor Total 

50 50 CPT12-1 2 1800 145T $3,814 $335 $4,149

100 50 CPT12-1B 3 1800 182T $4,183 $370 $4,553

500 50 CPT21-4 10 1800 215T $6,536 $660 $7,196

1500 50 CPT31-6 30 1200 326T $12,834 $2,070 $14,904

3000 50 CPT32-8C 50 1200 365T $14,849 $3,195 $18,044

y = 0.0165x + 1.9854

R2 = 0.9918

0

10

20

30

40

50

60

0 500 1000 1500 2000 2500 3000 3500

hp

Flow (gpm)

CW Pump Energy Consumption

y = 

$0

$5,000

$10,000

$15,000

$20,000

0 500 1000 1500

Pump+M

otor C

ost

Flow (gpm)

CW Pump Costs
y = -0.0017x2 + 9.9408x + 3392.8

R2 = 0.995

2000 2500 3000 3500

Flow (gpm)

ump Costs