**Tilden Indurating Line #1 GSA**  **Given/A ssumed**  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 Y ear 7,680 Barr 9/11/09 Operating Hours per Shift 8 assumed Operating Shifts per Y ear 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) $0.40 Tilden 9/11/2009 CaSO4 molar weight 172 dihydrate Wa ste disposal ($/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 (y r) 20 Tilden 9/11/2009 Interest Rate (%) 7.00% Tilden 9/11/2009

### Tilden Indurating Line #1

**Capital Cost factors for Gas A bsorbers--OA**  **QPS Control Cost Manual, Chap 5**

Cost Item Factor Cost Direct Costs Purchased equipment costs Absorber + auxiliary

equipment, EC A $7,279,444 six-tenths pow er 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 $

Wa ste 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% Em ission reduction (TPY) 1,038 Controlled emissions (TPY) 115 Total annualized cost ($/y r) $5,319,484 Cost/ton removed ($/T) $5,125