## 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, IT T, 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 stock. 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 1500ITT 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 Ti was safer than S/S 1700 5600 14900

Recommended based on chlorides 5000 2300 11000 7600 26000 21600

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

No

4198 10691 38764 44889 2300 7600 21600 5000 11000 26000 Cost

0 10000 20000 30000 40000 50000

0**H e** **a t** **E x** **c h** **a n** **g e** **r C** **a p** **i t** **a l** **C o** **s t** **( $** **)** 

# Titanium Heat Ex **chang er Cost ver**  **sus**Tranter Sulzer Pumps AZ (will forward on to PA Power group) doug.cavin@sulzer.com frennborn@us.funke.de Note that we can get pump curves on line "Sulzer Select"

Would not provide material recommendation. Rely on customer to do this analysis. Will get back in a week. Email suggested Ti was safer than S/S

Recommended based on chlorides

44889

Do not generally keep this in stock; would make this option more expensive.

NA

y = 0.0059x 2 + 11.304x + 2643.6 R2 = 0.8215

0 200 400 600 800 1000 1200 1400 1600

**Wastewater Flow Rate (gpm)** 

# Titanium Heat Ex **chang er Cost ver**  **sus Wa**  **stewate r 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**E m** **p t** **y W** **e i** **g h** **t (** **l b** **s )** 

**Flow Rate (gpm)** 

# HE W **eight 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 1600gpm TDH Pump Model hp 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**h p** 

**Flow (gpm)** 

# CW Pump Ener **gy Consumption**

y =

$0 $5,000 $10,000 $15,000 $20,000

0 500 1000 1500**P u** **m p** **+ M** **o t** **o r** **C o** **s t** 

**Flow (gpm)**



# CW Pump Costsy =
- 0.0017x 2 + 9.9408x + 3392.8

R2 = 0.995

2000 2500 3000 3500 **Flow (gpm)** 

# CW Pump Costs