# SCR Capital Costs

Description Formula 1 

# Value

Boiler Size (MMBtu/hr) Q B 

# 7540

NOx Removal Efficiency (%) η NOx 

# 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 (A ssumed 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 fo r 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

2 

# Direct capital costs for SCR were derived from "IPM Model – Revisions to Cost and Performance for APC

Technologies SCR Cost Development Methodology," Sar gent & Lundy, August 2010. 

# (2010 Dollars)Colstrip Unit 3 SCR Capital Cost Estimate WorksheetVariable Designation Units Value CalculationUnit Size (Gross)A(MW)805InputRetrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Heat RateC(Btu/kWh)9371InputNOxRateD (lb/MMBtu) 0.168033333 InputSO2RateE (lb/MMBtu) 1.8 InputType of CoalFPRBInputCoal FactorG1.05Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate FactorH0.9371C/10000Heat InputI(Btu/hr)7.54E+09A*C*1000Capacity FactorJ(%)97.7InputNOxRemoval EfficiencyK (%) 70.2 InputNOxRemoval FactorL 0.87804999 K/80NOxRemovedM (lb/hr) 890D*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$81,442,000 SCR (inlet ductwork, reactor, bypass) island costBMF ($) = 410000*(M)0.25$2,240,000 Base reagent preparation costBMA ($) = 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$6,270,000 ID or booster fans & auxiliary power modification costsBM ($) = BMR + BMF + BMA + BMB$89,952,000Total bare module cost including retrofit factorBM ($/kW)$112Base cost per kWTotal Project CostA1 = 10% of BM$8,995,000Engineering and construction management costsA2 = 10% of BM$8,995,000Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 10% of BM$8,995,000Contractor profit and feesCECC($) = BM+A1+A2+A3$116,937,000Capital, engineering and construction cost subtotalCECC($/kW) =$145Capital, engineering and construction cost subtotal per kWB1 = 5% of CECC$5,846,850Owners costs including "home office" costs (owners engineering, management, and procurement activities)B2 = 6% of (CECC + B1)$7,367,000AFUDC (based on approximately 3% per year for a 2 year engineering and construction cycle)TPC ($) = CECC + B1 + B2$130,150,850Total project costTPC ($/kW) =$162Total 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, LLCPPL Colstrip Unit 3Modified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsNew or Retrofit?RetrofitSourceGeneration capacity (MW gross)805PPL NOx Control Supplement (9/11/2011)SCR bypass included?NoFuel High Heating Value (Btu/lb)8,458From EIA for 1999Maximum Fuel Consumption Rate (lb/hr)891,464Calculated from7,540MMBtu/hr from PPL NOx Control Supplemental (9/11/2011)Average Annual Fuel Consumption (lb)7.63E+09Calcuated from64,555,395MMBtu/yr average for 2008‐2010 from CAMDNumber of SCR Operating Days365AssumedPlant Capacity Factor97.7%Based on actual heat input 2008‐2010LNB/CCOFA/SOFA outlet = SCR inlet NOx Concentration (lb/MMBtu)0.168Required Controlled NOx Concentration (lb/MMBtu)0.05IPM Base Case v4.10 Documentation, Appendix 5‐2A (August 2010)Acceptable Ammonia Slip (ppm)2.0OAQPS Control Cost ManualFuel Volume Flow Rate (ft3/min/MMBtu/hr)516OAQPS Control Cost ManualFuel Sulfur Content0.67%PPL NOx Control Supplement (9/11/2011)Fuel Ash Content10.10%From EIA for 1999Number of SCR reactor chambers2AssumedNumber of spare catalyst layers1AssumedASR1.05EPA Control Cost ManualStored Ammonia Concentration29%EPA Control Cost ManualReagent Molecular Weight (g/mole)17.03EPA Control Cost ManualReagent Density (lb/ft3 @ 60F)56.0EPA Control Cost ManualReagent Specific Volume (gal/ft3)7.481EPA Control Cost ManualNOx Molecular Weight (g/mole)46.01EPA Control Cost ManualNumber of Days of Storage for Ammonia14EPA Control Cost ManualPressure Drop for SCR Ductwork H2O")3EPA Control Cost ManualPressure Drop for each Catalyst Layer (H2O")1EPA Control Cost ManualTemperature at SCR Inlet (degrees F)700AssumedEquipment Life (years)20EPA Control Cost ManualAnnual Interest Rate7%EPA Control Cost ManualInflation Since 19981.41CEPCI 2010/CEPCI 1998Catalyst Cost, Initial ($/ft3)170$calculated from6,000$Cichanowicz (Jan 2010)Catalyst Cost, Replacement ($/ft3)170$calculated from6,000$Cichanowicz (Jan 2010)Electrical Power Cost ($/kWh)0.045$TypicalAnhydous Ammonia ($/lb)0.120$calculated from240$Fuel Tech (3/2/2012)Operating Life of Catalyst (hours)24,000EPA Control Cost ManualNatural gas unit cost ($/mcf)4.98$EIA 2010 price forecastNatural gas for reheat (mcf)NABoiler Calculations (from Section 4.2 of EPA Control Cost Manual)2.3 QB= HVm‐dotfuelQB= 8,458Btu/lb * 891,464lb/hrQB= 7,540Btu/hr2.7 CFPlant= actual heat input/maximum annual heat inputCFPlant =98%2.8 CFSCR= tSCR/365 daysCFSCR= 365 days/ 365 daysCFSCR= 100%2.6 CFTotal= CFPlantx CFSCRCFTotal= 98% * 100%CFTotal= 98%2.12 qfluegas= qfuelQB(460+T)/(460+700oF)nSCRqfluegas= 516 ft3/min/(mmBtu/hr)* 7540 mmBtu/hr*( 460 + 700 )/( 460 + 700 )/ 2qfluegas= 1,945,320acfm2.9 ηNOx= (NOxin– NOxout) / NOxinηNOx= ( 0.17 lb/mmBtu ‐ 0.05 lb/mmBtu)/ 0.17 lb/mmBtuηNOx= 70%Uncontrolled NOx emissions5,424tpy2.57NOx Removed = NOxinηNOxQBtopSCR NOx Removed =0.17*0.70*7,540*8562/2000SCR NOx Removed =3810tpyOverall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc(0.17‐0.05)/0.17=70%Overall NOx removed =3,810tpyControlled NOx emissions =1,614tpySCR 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 * 7540 = 21187.42.2 ηadj= 0.2869 + (1.058 x η)ηadj= 0.2869 +( 1.058 * 0.70 )ηadj= 1.0302.22 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 * 0.17 )NOxadj= 0.9062.23 Sadj= 0.9636 + (0.0455 x S)Sadj= 0.9636 + ( 0.046 * 0.67 )Sadj= 0.9942.24 Tadj= 15.16 – (0.03937 x T) + (2.74 x 10‐5x T2)Tadj= 15.16 ‐ ( 0.039 * 700 ) + 2.74E‐05 * 490000Tadj= 1.027Volcatalyst= 11,814ft3 each =334.8m3 each2.25 Acatalyst= qfluegas/(16 ft/sec x 60 sec/min)Acatalyst= 1,945,320/( 16 * 60 )Acatalyst= 2,026ft22.26 ASCR= 1.15 x AcatalystASCR= 1.15 * 2026ASCR= 2,330ft22.27 l = w = ASCR1/2l = w =48.3ft2.28 nlayer= Volcatalyst/(h’layerx Acatalyst)nlayer= 11,814/( 3.1 * 2026 )nlayer= 2.0nlayer= 2.02.29 hlayer= [Volcatalyst/(nlayerx Acatalyst)] + 1hlayer= 11,814/( 2.0 * 2026 ) + 1hlayer= 3.92.3 ntotal= nlayer+ nemptyntotal= 2 + 1ntotal= 32.31 hSCR= ntotal(c1+ hlayer) + c2hSCR= 3 * ( 7 + 3.9 ) + 9hSCR= 42 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) = 11814 * 170f(Volcatalyst) = $2,008,817 each SCR reactor$4,017,634all SCR reactors**Reagant Calculations (from Section 4.2 of EPA Control Cost Manual)**2.32 m-dotreagent= NOxinQBASRηNOxMreagent/MNOxm-dotreagent= 0.17 * 7540 * 1.05 ***70%*** 17.03 / 46.01m-dotreagent= 346 lb/hr2.33 m-dotsol= m-dotreagent/Csolm-dotsol= 346 / 0.29m-dotsol= 1193 lb/hr2.34 qsol= (m-dotvol/ρsol)Vsolqsol= 1193 * 7.481 / 56qsol= 159 gph2.35 Tank Volume = qsoltTank Volume = 159 * 14 * 24Tank Volume = 53,535gal2.47 Annual Reagent Cost = qreagentCostreagenttop2.47a top= CFtotal8760hr/yrtop= 98% * 8760top= 8562Annual Reagent Cost = 1193 * 8562 * 0.120Annual Reagent Cost =**1,225,384 $** **Maintenance Cost Calculations (from Section 4.2 of EPA Control Cost Manual)**2.46 Annual Maintenance Cost = 0.015 * TCIAnnual Maintenance Cost = 0.015 * 133,675,858$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 =2469kWAnnual Electricity Cost =2469*8562*0.045Annual Electricity Cost =**951,076 $** **Catalyst Replacement Cost Calculations (from Section 4.2 of EPA Control Cost Manual)**2.51Annual Catalyst Replacement Cost = (Catalyst Replacement Cost)FWF2.5 Catalyst Replacement Cost = nSCRVolcatalystCCreplace/RlayerCatalyst Replacement Cost =2*11,814*170.0/2Catalyst Replacement Cost =2,008,817$2.52FWF = i{1/[(1+i)Y-1]}2.53 Y = hcatalyst/hyearY =24000/(98%*8760)Y =2.80FWF =0.07*(1/(1+0.07)^3-1)FWF =0.31Annual Catalyst Cost =**624,846 $** STATEFACILITY_NAMEORISPLCODE UNIT ID OP YEARSUM OPTIMENUMMONTHSREPORTEDGROSSLOAD(MWh)SO2MASSSO2RATENOXRATENOXMASS CO2 MASSHEAT INPUT(MMBtu)HEATINPUT(MMBtu/hr)MT Colstrip 6076 3 2008 8,665 12 6,524,103 2,812 0.085 0.170 5,628 6,893,825 66,443,986 7,668MT Colstrip 6076 3 2009 8,539 12 6,445,240 2,628 0.081 0.166 5,395 6,807,718 64,909,592 7,601MT Colstrip 6076 3 2010 8,412 12 6,371,363 2,479 0.080 0.168 5,262 6,535,347 62,312,605 7,408Averages 8,539 6,446,902 2,640 0.082 0.168 5,428 6,745,63064,555,395 7,559MT Colstrip 6076 4 2008 8,519 12 6,409,288 2,980 0.088 0.344 11,771 7,010,942 67,560,392 7,931MT Colstrip 6076 4 2009 3,652 12 2,865,469 1,255 0.085 0.277 4,151 3,100,628 29,563,599 8,095MT Colstrip 6076 4 2010 8,417 12 6,400,130 2,665 0.085 0.171 5,347 6,557,587 62,524,674 7,429Averages 6,862 5,224,962 2,300 0.086 0.264 7,090 5,556,38653,216,222 7,818CAMD Data