Tilden Indurating Line #1

GSA

Given/Assumed

Flow rate (acfm) 1,148,000 Tilden 9/11/2009

Flue Gas Temperature (degrees F) 300 Tilden 9/11/2009

Uncontrolled SO2 emissions (TPY) 1153.2 Tilden 9/11/2009

SO2 molar weight 64

GSA (@ 910,000 acfm) $ 6,000,000 calculated from EPA cost info for 910,000 acfm @ 280 F at USS 6/18/12 USS email to EPA

Freight $ 1,074,758 EPA

Sales taxes 6.0% Tilden 9/11/2009

Retrofit factor 1.0 assumed

SO2 Control efficiency 90% PETC report

Operating Hours per Year 7,680 Barr 9/11/09

Operating Hours per Shift 8 assumed

Operating Shifts per Year 960 calculated

Utilization 100% Tilden 9/11/2009

Operating Labor Cost ($/hr) $85.00 Tilden 9/11/2009

Maintenance Labor Cost ($/hr) $85.00 Tilden 9/11/2009

Lime molar weight 56

Chemical usage molar ratio 1.3 PETC report

Chemical cost ($/ton) $ 125.00 EPA

Solvent usage (gal/kacfm)) 2.7 calculated from ESSAR Steel PSD application updated 5/09/11

Solvent cost ($/kgal) $0.40 Tilden 9/11/2009

CaSO4 molar weight 172 dihydrate

Waste disposal ($/ton) $ 33.00 from ESSAR Steel PSD application updated 5/09/11

Gas Cleanaing System Electricity Cost $ 252,308 calculated from EPA cost info of $ 200,000 /yr for 910,000 acfm at USS

ID Fan Power $ 1,419,231 calculated from EPA cost info of $ 1,125,000 /yr for 910,000 acfm at USS USS 7/19/12

Inflation Since 2009 1.06 CEPCI 2010/CEPCI 2009

Equipment Life (yr) 20 Tilden 9/11/2009

Interest Rate (%) 7.00% Tilden 9/11/2009
Tilden Indurating Line #1

Capital Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 5

Cost Item Factor Cost

Direct Costs

Purchased equipment costs

Absorber + auxiliary equipment, EC A $7,279,444 six-tenths power law

Instrumentation 0.10 A $727,944

Sales taxes 0.060 A $436,767

Freight A $1,074,758

Purchased equipment cost, PEC B= 1.18 A $9,518,913

Direct installation costs

Foundations & supports 0.12 B $1,142,270

Handling & erection 0.40 B $3,807,565

Electrical 0.01 B $95,189

Piping 0.30 B $2,855,674

Insulation 0.01 B $95,189

Painting 0.01 B $95,189

Direct installation costs x 1 x 0.85 B $8,091,076

Site preparation As required, SP

Buildings As required, Bldg.

Total Direct Costs, DC 1.85 B+SP+Bldg $17,609,988

Indirect Costs (installation)

Engineering 0.10 B $951,891

Construction and field expenses 0.10 B $951,891

Contractor fees 0.10 B $951,891

Start-up 0.01 B $95,189

Performance test 0.01 B $95,189

Contingencies 0.03 B $285,567

Total Indirect Costs, IC 0.35 B $3,331,619

Total Capital Investment = DC + IC 2.20 B+SP+Bldg $20,941,608
Tilden Indurating Line #1

Annual Cost factors for Gas Absorbers--OAQPS Control Cost Manual, Chap 5

Cost Item Cost

Direct Annual Costs, DC

Operating labor

Operator 0.5 hr/shift $ 40,800

Supervisor 15% of operator $ 6,120

Operating materials

Solvent 2.7 gal/kacfm * 1,148,000 acfm = 3,100 gpm = $ 571,318

Chemicals 1.3 lb-mole CaO/lb-mole SO2 * 36,038 lb-moles SO2/yr = 46,849 lb-mole CaO/yr

 46,849 lb-mole CaO/yr * 56 lb/lb-mole = 2,623,530 lb CaO/yr

 2,623,530 lb CaO/yr/ 2,000 lb/ton * $ 125.00 / ton = $ 163,971

Waste Disposal 1,038 ton SO2 removed/yr = 32,434 mole SO2 removed/yr = 32,434 mole CaSO4-2H2O produced/yr =

 32,434 mole CaSO4-2H2O produced/yr * 172 lb/lb-mole = 2,789 tpy CaSO4-2H2O

 2,789 tpy CaSO4-2H2O * $ 33.00 /ton = $ 92,047

23% of CaO is wasted = 303 tpy * $ 33.00 /ton = $ 9,990

Maintenance

Labor 0.5 hr/shift $ 40,800

Material 100.00% of maintenance $ 40,800

Electricity Gas Cleanaing System Electricity Cost $ 252,308

ID Fan Power $ 1,419,231

Total DC $ 2,637,384

Indirect Annual Costs, IC

Overhead 60% of total labor and material costs $ 77,112

Administrative charges 2% of Total Capital Investment $ 418,832

Property tax exempt in MN $ -

Insurance 1% of Total Capital Investment $ 209,416

Capital recovery 0.0944 * Total Capital Investment $ 1,976,740

Total IC $ 2,682,100

Total Annual Cost DC + IC $ 5,319,484
Tilden Indurating Line #1 SO2

Uncontrolled emissions (TPY) 1,153.2

Control efficiency (%) 90%

Emission reduction (TPY) 1,038

Controlled emissions (TPY) 115

Total annualized cost ($/yr) $5,319,484

Cost/ton removed ($/T) $5,125