SCR Capital Costs

Description Formula1Value

Boiler Size (MMBtu/hr) QB 7540

NOx Removal Efficiency (%) ηNOx 70.2%

Cost Year 2010

Total Direct Capital Costs ($)2

A $94,933,055

Indirect Installation Costs

 General Facilities ($) 0.05 x A $4,746,653

 Engineering and Home Office Fees ($) 0.10 x A $9,493,306

 Process Contingency ($) 0.05 x A $4,746,653

Total Indirect Installation Costs ($) B = A × (0.05 + 0.10 + 0.05) $18,986,611

Project Contingency ($) C = (A + B)× 0.15 $17,087,950

Total Plant Costs ($) D = A + B+ C $131,007,616

Allowance for Funds During Construction ($) E = 0 (Assumed for SCR) $0

Royalty Allowance ($) F = 0 (Assumed for SCR) $0

Preproduction Cost ($) G = 0.02 × (D + E) $2,620,152

Inventory Capital* ($) H = Vol reagent (gal) × Cost reagent ($/gal) $48,089

Initial Catalyst and Chemicals ($) I = 0 (Assumed for SCR) $0

Total Capital Investment (TCI) ($) TCI = D + E + F + G + H + I $133,675,858

Total Capital Investment (TCI) ($) Per kW $166

SCR Annual Costs

Direct Annnual Costs

 Maintenance Cost Eq. 2.46 $2,005,138

 Reagent Cost Eq. 2.47 $1,225,384

 Electricity Cost Eq. 2.49 $951,076

 Catalyst Cost Eq. 2.50 $624,846

Total Direct Annual Costs DAC (Eq. 2.45) $4,806,443

Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $12,619,001

Total Annual Costs TAC = DAC + IAC (Eq. 2.56) $17,425,444

Cost Effectivness

SCR NOx Removed (tons/yr) Eq. 2.57 3,810

SCR Cost Effectiveness ($/ton removed) Eq. 2.58 $4,574

1

Taken from "EPA Control Cost Manual", Section 4.2, Chapter 2, October 2000.

Colstrip Unit 3 RP Cost Analysis - SCR plus SOFA

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.

(2010 Dollars)
Colstrip Unit 3 SCR Capital Cost Estimate Worksheet

Variable Designation Units Value Calculation

Unit Size (Gross) A (MW) 805 InputRetrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Heat Rate C (Btu/kWh) 9371 InputNOx Rate D (lb/MMBtu) 0.168033333 Input

SO2 Rate E (lb/MMBtu) 1.8 Input

Type of Coal F PRB InputCoal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate Factor H 0.9371 C/10000Heat Input I (Btu/hr) 7.54E+09 A*C*1000Capacity Factor J (%) 97.7 InputNOx Removal Efficiency K (%) 70.2 Input

NOx Removal Factor L 0.87804999 K/80

NOx Removed M (lb/hr) 890 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 $81,442,000 SCR (inlet ductwork, reactor, bypass) island cost

 BMF ($) = 410000*(M)0.25 $2,240,000 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 $6,270,000 ID or booster fans & auxiliary power modification costs

 BM ($) = BMR + BMF + BMA + BMB $89,952,000 Total bare module cost including retrofit factor BM ($/kW) $112 Base cost per kW

Total Project Cost

 A1 = 10% of BM $8,995,000 Engineering and construction management costs A2 = 10% of BM $8,995,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $8,995,000 Contractor profit and fees

 CECC($) = BM+A1+A2+A3 $116,937,000 Capital, engineering and construction cost subtotal CECC($/kW) = $145 Capital, engineering and construction cost subtotal per kW

 B1 = 5% of CECC $5,846,850 Owners costs including "home office" costs (owners engineering, management, and  B2 = 6% of (CECC + B1) $7,367,000 AFUDC (based on approximately 3% per year for a 2 year engineering and constructi

 TPC ($) = CECC + B1 + B2 $130,150,850 Total project cost TPC ($/kW) = $162 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 prepared by Sargent & Lundy, LLC
PPL Colstrip Unit 3

Modified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsNew or Retrofit? Retrofit SourceGeneration capacity (MW gross) 805 PPL NOx Control Supplement (9/11/2011)SCR bypass included? NoFuel High Heating Value (Btu/lb) 8,458 From EIA for 1999Maximum Fuel Consumption Rate (lb/hr) 891,464 Calculated from 7,540 MMBtu/hr from PPL Average Annual Fuel Consumption (lb) 7.63E+09 Calcuated from 64,555,395 MMBtu/yr average fNumber of SCR Operating Days 365 AssumedPlant Capacity Factor 97.7% Based on actual heat input 2008‐2010LNB/CCOFA/SOFA outlet = SCR inlet NOx Concentration (lb/MMBtu) 0.168Required 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) 516 OAQPS Control Cost ManualFuel Sulfur Content 0.67% PPL NOx Control Supplement (9/11/2011)Fuel Ash Content 10.10% From EIA for 1999Number 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) 700 AssumedEquipment 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) $ 170 calculated from $ 6,000 Cichanowicz (Jan 201Catalyst Cost, Replacement ($/ft3) $ 170 calculated from $ 6,000 Cichanowicz (Jan 201Electrical Power Cost ($/kWh) $ 0.045 TypicalAnhydous Ammonia ($/lb) $ 0.120 calculated from $ 240 Fuel Tech (3/2/2012Operating Life of Catalyst (hours) 24,000 EPA Control Cost ManualNatural gas unit cost ($/mcf) $ 4.98 EIA 2010 price forecastNatural gas for reheat (mcf) NA
Boiler Calculations (from Section 4.2 of EPA Control Cost Manual)

2.3 QB = HVm‐dotfuel

QB = 8,458 Btu/lb * 891,464 lb/hr

QB = 7,540 Btu/hr

2.7 CFPlant = actual heat input/maximum annual heat input

CFPlant = 98%

2.8 CFSCR = tSCR/365 days

CFSCR = 365 days/ 365 days

CFSCR = 100%

2.6 CFTotal = CFPlant x CFSCR

CFTotal = 98% * 100%

CFTotal = 98%

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

qfluegas = 516 ft3/min/(mmBtu/hr)* 7540 mmBtu/hr*( 460 + 700 )/( 460 + 700 )/ 2

qfluegas = 1,945,320 acfm

2.9 ηNOx = (NOxin – NOxout) / NOxin

ηNOx = ( 0.17 lb/mmBtu ‐ 0.05 lb/mmBtu)/ 0.17 lb/mmBtu

ηNOx = 70%

Uncontrolled NOx emissions 5,424 tpy

2.57 NOx Removed = NOxinηNOxQBtop

SCR NOx Removed = 0.17 * 0.70 * 7,540 * 8562 / 2000SCR NOx Removed = 3810 tpyOverall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc

( 0.17 ‐ 0.05 )/ 0.17 = 70%

Overall NOx removed = 3,810 tpyControlled NOx emissions = 1,614 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 * 7540 = 21187.4

2.2 ηadj = 0.2869 + (1.058 x η)

ηadj = 0.2869 +( 1.058 * 0.70 )

ηadj = 1.030

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 * 0.17 )

NOxadj = 0.906

2.23 Sadj = 0.9636 + (0.0455 x S)

Sadj = 0.9636 + ( 0.046 * 0.67 )

Sadj = 0.994

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

2

)

Tadj = 15.16 ‐ ( 0.039 * 700 ) + 2.74E‐05 * 490000

Tadj = 1.027Volcatalyst = 11,814 ft3 each =334.8m3 each

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

Acatalyst = 1,945,320 /( 16 * 60 )

Acatalyst = 2,026 ft2

2.26 ASCR = 1.15 x Acatalyst

ASCR = 1.15 * 2026

ASCR = 2,330 ft2

2.27 l = w = ASCR1/2

l = w = 48.3 ft

2.28 nlayer = Volcatalyst/(h’layer x Acatalyst

)

nlayer = 11,814 /( 3.1 * 2026 )

nlayer = 2.0nlayer = 2.0

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

hlayer = 11,814 /( 2.0 * 2026 ) + 1

hlayer = 3.9

2.3 ntotal = nlayer + nempty

ntotal = 2 + 1

ntotal = 3

2.31 hSCR = ntotal(c1 + hlayer) + c2

hSCR = 3 * ( 7 + 3.9 ) + 9

hSCR = 42 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) = 11814 * 170

f(Volcatalyst) = $2,008,817 each SCR reactor

$4,017,634 all SCR reactors
Reagant Calculations (from Section 4.2 of EPA Control Cost Manual)

2.32 m-dotreagent = NOxinQBASRηNOxMreagent/MNOx

m-dotreagent = 0.17 * 7540 * 1.05 * 70% * 17.03 / 46.01

m-dotreagent = 346 lb/hr

2.33 m-dotsol = m-dotreagent/Csol

m-dotsol = 346 / 0.29

m-dotsol = 1193 lb/hr

2.34 qsol = (m-dotvol/ρsol)Vsol

qsol = 1193 * 7.481 / 56

qsol = 159 gph

2.35 Tank Volume = qsolt

Tank Volume = 159 * 14 * 24Tank Volume = 53,535 gal

2.47 Annual Reagent Cost = qreagentCostreagenttop

2.47a top = CFtotal8760hr/yr

top = 98% * 8760

top = 8562

Annual Reagent Cost = 1193 * 8562 * 0.120Annual Reagent Cost = $ 1,225,384
Maintenance Cost Calculations (from Section 4.2 of EPA Control Cost Manual)

2.46 Annual Maintenance Cost = 0.015 * TCI

Annual Maintenance Cost = 0.015 * 133,675,858 $ 

Annual Maintenance Cost = $ 2,005,138
Electricity Cost Calculations (from Section 4.2 of EPA Control Cost Manual)

2.49 Annual Electricity Cost = Power (Costelect)top2.48 Power = 0.105QB[NOxinηNOx + 0.5(ΔPduct + ntotalΔPcatalyst)]

Power = 0.105 * 7540 *( 0.17 * 70% + 0.50 * ( 3 + 3 * 1 ))Power = 2469 kW

Annual Electricity Cost = 2469 * 8562 * 0.045Annual Electricity Cost = $ 951,076
Catalyst Replacement Cost Calculations (from Section 4.2 of EPA Control Cost Manual)

2.51 Annual Catalyst Replacement Cost = (Catalyst Replacement Cost)FWF

2.5 Catalyst Replacement Cost = nSCRVolcatalystCCreplace/Rlayer

Catalyst Replacement Cost = 2 * 11,814 * 170.0 / 2Catalyst Replacement Cost = $ 2,008,817

2.52 FWF = i{1/[(1+i)

Y-1]}

2.53 Y = hcatalyst/hyear

Y = 24000 /( 98% * 8760 )Y = 2.80

FWF = 0.07 *( 1 /( 1 + 0.07 )^ 3 - 1 )FWF = 0.31

Annual Catalyst Cost = $ 624,846
STATE

FACILITY

_NAME

ORISPL 

CODE UNIT ID OP YEAR

SUM OP 

TIME

NUM 

MONTHS 

REPORT

ED

GROSS 

LOAD 

(MWh)

SO2 

MASS

SO2 

RATE

NOX 

RATE

NOX 

MASS CO2 MASS

HEAT IN

(MMB

MT Colstrip 6076 3 2008 8,665 12 6,524,103 2,812 0.085 0.170 5,628 6,893,825 66,44MT Colstrip 6076 3 2009 8,539 12 6,445,240 2,628 0.081 0.166 5,395 6,807,718 64,90MT Colstrip 6076 3 2010 8,412 12 6,371,363 2,479 0.080 0.168 5,262 6,535,347 62,31

Averages 8,539 6,446,902 2,640 0.082 0.168 5,428 6,745,630 64,55

MT Colstrip 6076 4 2008 8,519 12 6,409,288 2,980 0.088 0.344 11,771 7,010,942 67,56MT Colstrip 6076 4 2009 3,652 12 2,865,469 1,255 0.085 0.277 4,151 3,100,628 29,56MT Colstrip 6076 4 2010 8,417 12 6,400,130 2,665 0.085 0.171 5,347 6,557,587 62,52

Averages 6,862 5,224,962 2,300 0.086 0.264 7,090 5,556,386 53,21

CAMD Data