Lime Injection Wet ESP Lime Injection Wet ESP Lime Injection Wet ESP

Emission Reduction from Baseline (tons/yr) 697 1,035 705 1,047 644 1,123

Incremental Emission Reduction (tons/yr) -- 338 -- 342 -- 479

Total Capital Investment ($) 4,200,000 100,216,875 4,200,000 100,216,875 8,400,000 155,948,800

Total Annualized Cost ($/yr) 2,301,659 28,877,504 2,301,659 28,877,504 4,363,849 44,092,044

Total Cost Effectiveness ($/ton) 3,305 27,914 3,265 27,594 6,776 39,263

Incremental Cost Effectiveness ($/ton) -- 78,627 -- 77,821 -- 82,940

Unit 1 Unit 2 Unit 3

Table 2. BART Cost of Compliance Summary
Direct Costs Basis Cost

Purchased Equipment Costs (PEC)

Lime injection equipment (LE) $2,210,759

Instrumentation 0.10 LE $221,076

Sales taxes 0.03 LE $66,323

Freight 0.05 LE $110,538

PEC $2,608,696

Direct Installation Costs (DIC)

Foundations & supports 0.08 PEC $208,696

Handling & erection 0.14 PEC $365,217

Electrical 0.04 PEC $104,348

Piping 0.02 PEC $52,174

Insulation 0.01 PEC $26,087

Painting 0.01 PEC $26,087

DIC $782,609

Total Direct Costs (DC) $3,391,304

Indirect Costs 

Engineering 0.10 PEC $260,870

Construction and field expenses 0.05 PEC $130,435

Contractor fees 0.10 PEC $260,870

Start-up 0.02 PEC $52,174

Performance test 0.01 PEC $26,087

Contingencies 0.03 PEC $78,261

Total Indirect Costs (IC) $808,696

Total Capital Investment (TCI)=DC+IC $4,200,000

*Lime injection equipment costs based on experience at another TVA facility. 

Other costs based on information from the EPA Air Pollution Control Cost Manual, Sixth Ed.

Capital Costs for Hydrated Lime Injection: PAF Unit 1 or 2
Direct Annual Costs (DC) Bases & Assumptions

Operating Labor

Operator $ 5,475 1 hr/shift, 365 days/yr, $15/hr

Supervisor $ 821 15% of operator labor

Reagent costs $ 1,211,503 Hydrated lime

Maintenance

Labor $ 6,023 1 hr/shift, 365 days/yr, $16.5/hr

Material $ 26,087 1% of PEC

Utilities

Electricity $ 8,234 30 hp; capacity factor=0.7

Waste Disposal $ 290,675 $35/ton; capacity factor=0.7

Total DC $ 1,548,817

Indirect Annual Costs (IC)

Overhead $ 22,551 60% of operating labor and materials

Administrative charges $ 84,000 2% of TCI

Payment in lieu of taxes $ 42,000 1% of TCI

Insurance $ 42,000 1% of TCI

Capital recovery $ 562,291 CRF = 0.1339

Total IC $ 752,842

Total Annual Cost $ 2,301,659

*Reagent costs based on experience at another TVA facility. 

Other costs based on information from the EPA Air Pollution Control Cost Manual, Sixth Ed.

Capital recovery factor (CRF) based on 12% interest and 20-yr equipment life.

Annual Costs for Hydrated Lime Injection: PAF Unit 1 or 2
Direct Costs Basis Cost

Purchased Equipment Costs (PEC)

Lime injection equipment (LE) $4,421,518

Instrumentation 0.10 LE $442,152

Sales taxes 0.03 LE $132,646

Freight 0.05 LE $221,076

PEC $5,217,391

Direct Installation Costs (DIC)

Foundations & supports 0.08 PEC $417,391

Handling & erection 0.14 PEC $730,435

Electrical 0.04 PEC $208,696

Piping 0.02 PEC $104,348

Insulation 0.01 PEC $52,174

Painting 0.01 PEC $52,174

DIC $1,565,217

Total Direct Costs (DC) $6,782,609

Indirect Costs 

Engineering 0.10 PEC $521,739

Construction and field expenses 0.05 PEC $260,870

Contractor fees 0.10 PEC $521,739

Start-up 0.02 PEC $104,348

Performance test 0.01 PEC $52,174

Contingencies 0.03 PEC $156,522

Total Indirect Costs (IC) $1,617,391

Total Capital Investment (TCI)=DC+IC $8,400,000

*Lime injection equipment costs based on experience at another TVA facility. 

Other costs based on information from the EPA Air Pollution Control Cost Manual, Sixth Ed.

Capital Costs for Hydrated Lime Injection: PAF Unit 3
Direct Annual Costs (DC) Bases & Assumptions

Operating Labor

Operator $ 32,850 1 hr/shift, 365 days/yr, $15/hr

Supervisor $ 4,928 15% of operator labor

Cost of Lime $ 2,423,005 Hydrated lime

Maintenance

Labor $ 36,135 1 hr/shift, 365 days/yr, $16.5/hr

Material $ 36,135 1% of PEC

Utilities

Electricity $ 16,468 60 hp; capacity factor=0.7

Waste Disposal $ 290,675 $35/ton; capacity factor=0.7

Total DC $ 2,840,196

Indirect Annual Costs (IC)

Overhead $ 63,072 60% of operating labor and materials

Administrative charges $ 168,000 2% of TCI

Payment in lieu of taxes $ 84,000 1% of TCI

Insurance $ 84,000 1% of TCI

Capital recovery $ 1,124,582 CRF = 0.1339

Total IC $ 1,523,654

Total Annual Cost $ 4,363,849

*Reagent costs based on experience at another TVA facility. 

Other costs based on information from the EPA Air Pollution Control Cost Manual, Sixth Ed.

Capital recovery factor (CRF) based on 12% interest and 20-yr equipment life.

Annual Costs for Hydrated Lime Injection: PAF Unit 3
Direct Costs Basis Cost

Purchased Equipment Costs (PEC)

ESP+auxiliary equipment (ESP) $37,500,000

Instrumentation 0.10 ESP $3,750,000

Sales taxes 0.03 ESP $1,125,000

Freight Included --

PEC $42,375,000

Direct Installation Costs (DIC)

Foundations & supports 0.04 PEC $1,695,000

Handling & erection** 0.625 PEC $26,484,375

Electrical 0.08 PEC $3,390,000

Piping 0.01 PEC $423,750

Insulation for ductwork 0.02 PEC $847,500

Painting 0.02 PEC $847,500

DIC $33,688,125

Total Direct Costs (DC) $76,063,125

Indirect Costs 

Engineering 0.20 PEC $8,475,000

Construction and field expenses 0.20 PEC $8,475,000

Contractor fees 0.10 PEC $4,237,500

Start-up 0.01 PEC $423,750

Performance test 0.01 PEC $423,750

Model study 0.02 PEC $847,500

Contingencies 0.03 PEC $1,271,250

Total Indirect Costs (IC) $24,153,750

Total Capital Investment (TCI)=DC+IC $100,216,875

*Wet ESP equipment costs based on vendor estimate. Other costs 

based on information from the EPA Air Pollution Control Cost Manual, Sixth Ed.

**Includes 25% increase for retrofit difficulty.

Capital Costs for Wet ESP: PAF Unit 1 or 2
Direct Annual Costs (DC) Bases & Assumptions

Operating Labor

Operator $ 32,850 2 hrs/shift, 365 days/yr, $15/hr

Supervisor $ 4,928 15% of operator labor

Coordinator $ 10,950 1/3 of operator labor

Maintenance

Labor $ 38,369 SCA=103 ft2

/1000 cfm, 2.5 million acfm

Material $ 423,750 1% of PEC

Utilities

Electricity-fan $ 332,968 2" H2O ΔP, $0.06/kWh, capacity factor (CF)=0.7

Electricity-operating $ 183,794 $0.06/kWh, CF=0.7

Water $ 919,800 5 gal/min per 1000 acfm, $0.2/1000 gal, CF=0.7

Waste Disposal $ 9,198,000 $2/1000 gal

Total DC $ 11,145,408

Indirect Annual Costs (IC)

Overhead $ 306,508 60% of operating labor and materials

Administrative charges $ 2,004,338 2% of TCI

Payment in lieu of taxes $ 1,002,169 1% of TCI

Insurance $ 1,002,169 1% of TCI

Capital recovery $ 13,416,913 CRF = 0.1339

Total IC $ 17,732,096

Total Annual Cost $ 28,877,504

*Based on information from the EPA Air Pollution Control Cost Manual, Sixth Ed.

Capital recovery factor (CRF) based on 12% interest and 20-yr equipment life.

Annual Costs for Wet ESP: PAF Unit 1 or 2
Direct Costs Basis* Cost

Purchased Equipment Costs (PEC)

ESP+auxiliary equipment (ESP) $59,000,000

Instrumentation 0.10 ESP $5,900,000

Sales taxes 0.03 ESP $1,770,000

Freight 0.05 ESP $2,950,000

PEC $69,620,000

Direct Installation Costs (DIC)

Foundations & supports 0.04 PEC $2,784,800

Handling & erection 0.50 PEC $34,810,000

Electrical 0.08 PEC $5,569,600

Piping 0.01 PEC $696,200

Insulation for ductwork 0.02 PEC $1,392,400

Painting 0.02 PEC $1,392,400

DIC $46,645,400

Total Direct Costs (DC) $116,265,400

Indirect Costs 

Engineering 0.20 PEC $13,924,000

Construction and field expenses 0.20 PEC $13,924,000

Contractor fees 0.10 PEC $6,962,000

Start-up 0.01 PEC $696,200

Performance test 0.01 PEC $696,200

Model study 0.02 PEC $1,392,400

Contingencies 0.03 PEC $2,088,600

Total Indirect Costs (IC) $39,683,400

Total Capital Investment (TCI)=DC+IC $155,948,800

*Wet ESP equipment costs based on vendor estimate. Other costs 

based on information from the EPA Air Pollution Control Cost Manual, Sixth Ed.

Capital Costs for Wet ESP: PAF Unit 3
Direct Annual Costs (DC) Bases & Assumptions

Operating Labor

Operator $ 32,850 2 hrs/shift, 365 days/yr, $15/hr

Supervisor $ 4,928 15% of operator labor

Coordinator $ 10,950 1/3 of operator labor

Maintenance

Labor $ 65,994 SCA=103 ft2

/1000 cfm, 2.5 million acfm

Material $ 696,200 1% of PEC

Utilities

Electricity-fan $ 490,889 2" H2O ΔP, $0.06/kWh, capacity factor (CF)=0.7

Electricity-operating $ 270,966 $0.06/kWh, CF=0.7

Water $ 1,356,048 5 gal/min per 1000 acfm, $0.2/1000 gal, CF=0.7

Waste Disposal $ 13,560,480 $2/1000 gal

Total DC $ 16,489,304

Indirect Annual Costs (IC)

Overhead $ 486,553 60% of operating labor and materials

Administrative charges $ 3,118,976 2% of TCI

Payment in lieu of taxes $ 1,559,488 1% of TCI

Insurance $ 1,559,488 1% of TCI

Capital recovery $ 20,878,235 CRF = 0.1339

Total IC $ 27,602,740

Total Annual Cost $ 44,092,044

*Based on information from the EPA Air Pollution Control Cost Manual, Sixth Ed.

Capital recovery factor (CRF) based on 12% interest and 20-yr equipment life.

Annual Costs for Wet ESP: PAF Unit 3
BART Alternative

Filt. PM10 H2SO4 Filt. PM10 H2SO4 Filt. PM10 H2SO4 Filt. PM10 H2SO4 Filt. PM10 H2SO4

Unit 1

Baseline 1,114 1,101 1,132 1,202 1,123 1,152 -- -- -- --

Lime Injection 1,114 435 1,132 475 1,123 455 - 697 -- --

Wet ESP 218 112 238 122 228 117 895 1,035 895 338

Unit 2

Baseline 1,252 1,254 985 1,075 1,119 1,165 -- -- -- --

Lime Injection 1,252 495 985 424 1,119 460 - 705 -- --

Wet ESP 249 127 213 109 231 118 888 1,047 888 342

Unit 3

Baseline -- -- 562 1,289 562 1,289 -- -- -- --

Lime Injection -- -- 562 645 562 645 - 644 -- --

Wet ESP -- -- 324 166 324 166 238 1,123 238 479

Notes: (1) Filt. PM10 for baseline and lime injection based on particulate test results in 2005 & 2006. Wet ESP at 0.015 lbs/MMBtu.

(2) Emission for Units 1 and 2 based on average of actual emissions in 2005 & 2006.

(3) Emissions for Unit 3 based on fuel use in 2006, which includes only period of FGD operation.

(4) Calculated using electronic workbook PAF_CY06_BART.xls, which was submitted with the revised protocol document.

PAF BART Alternatives Emission Reductions (tons/yr)

2005 2006 Average Total Reduction Incremental Reduction

12/16/2011
BART Alternative

Total Annualized 

Cost ($/yr)

Total Emission 

Reduction 

(tons SO3/yr)

Total Cost 

Effectiveness 

($/ton)

Incremental 

Emission 

Reduction 

(tons SO3/yr)

Incremental 

Cost 

Effectiveness 

($/ton)

Unit 1

Lime Injection 2,301,659 697 3,305 --

Wet ESP 28,877,504 1,035 27,914 338 78,627

Unit 2

Lime Injection 2,301,659 705 3,265 --

Wet ESP 28,877,504 1,047 27,594 342 77,821

Unit 3

Lime Injection 4,363,849 644 6,776 --

Wet ESP 44,092,044 1,123 39,263 479 82,940

BART Alternative

Total Annualized 

Cost ($/yr)

Total Emission 

Reduction 

(tons PM10/yr)

Total Cost 

Effectiveness 

($/ton)

Incremental 

Emission 

Reduction 

(tons PM10/yr)

Incremental 

Cost 

Effectiveness 

($/ton)

Unit 1

Lime Injection 2,301,659 697 3,305 --

Wet ESP 28,877,504 1,930 14,966 1,233 21,554

Unit 2

Lime Injection 2,301,659 705 3,265 --

Wet ESP 28,877,504 1,934 14,931 1,229 21,624

Unit 3

Lime Injection 4,363,849 644 6,776 --

Wet ESP 44,092,044 1,361 32,397 717 55,409

Cost Effectiveness: SO3 Reduction

Cost Effectiveness: Total PM10 Reduction