# SNCR Capital Costs

Description Formula 1 

# Value

Boiler Size (MMBtu/hr) Q B 

# 3982

NOx Removal Efficiency (%) **η** NOx 

# 25%

Cost Year 2010

Total Direct Capital Costs ($) 2 

# A 

# $6,265,759

Indirect Installation Costs

General Facilities ($) 0.05 x A 

# $313,288

Engineering and Home Office Fees ($) 0.10 x A 

# $626,576

Process Contingency ($) 0.05 x A 

# $313,288

Total Indirect Installation Costs ($) 

# B = A × (0.05 + 0.10 + 0.05) $1,253,152

Project Contingency ($) C = (A + B)× 0.15 

# $1,127,837

Total Plant Costs ($) 

# D = A + B+ C $8,646,747

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) $172,935

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

# $53,463

Initial Catalyst and Chemicals ($) 

# I = 0 (Assumed for SNCR) $0

T otal Capital Investment (TCI) ($) TCI = D + E + F + G + H + I $8,873,145

T otal Capital Investment (TCI) ($) Per kW $27

SNCR Annual Costs

Direct Annnual Costs

Maintenance Cost 

# $133,097

Reagent Cost 

# $1,053,224

Electricity Cost 

# $15,967

Water Cost 

# $4,487

Annual **∆** Coal Cost 

# $121,331

Annual **∆** Ash Cost



# -

Total Direct Annual Costs DAC 

# $1,328,107

Indirect Annual Costs IDAC = TCI x CRF 

# $837,625

Total Annual Costs TAC = DAC + IAC 

# $2,165,732

SOFA Captial Costs

Total Captial Investment for SOFA ($) 3 

# TCI $4,507,528

Total Capital Investment for SOFA ($/kW) Per kW $13,536

SOFA Annual Costs

Total Direct Annual Costs 4 

# DAC $664,884

Indirect Annual Costs IDAC = TCI x CRF 

# $425,511

Total Annual Costs TAC = DAC + IAC 

# $1,090,395

Cost Effectivness

SOFA NOx Removed (tons/yr) 

# 1,420

SOFA Cost Effectiveness ($/ton removed) 

# $768

SNCR NOx Removed (tons/yr) 

# 652

SNCR Cost Effectiveness ($/ton removed) 

# $3,322

SNCR+SOFA NOx Removed (tons/yr) 

# 2,072

SNCR+SOFA Cost Effectiveness ($/ton removed) 

# $1,571

1 

# Taken from "EPA Control Cost Manual", Section 4.2, Chapter 1, October 2000. 

# Colstrip Unit 2 BART Cost Analysis - SNCR+SOFA

(2010 Dollars)

2 

# Direct capital costs for SNCR were derived from "IP M Model – Revisions to Cost and Performance for APC

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

3,4 

# Direct capital costs and direct annual costs for SO FA were taken from "Addendum to PPL Montana's Colst rip

BART Report," TRC for PPL, June 2008. Direct capit al costs were escalated to 2010 using the CEPCI.SNCR Capital Cost Estimate WorksheetVariableDesignationUnitsValueCalculationBoiler TypeBTTangentialInputUnit SizeA(MW)333InputRetrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Heat RateC(Btu/kWh)11958InputNOxRateD (lb/MMBtu) 0.200Average for 2008-2010 from CAMDSO2RateE (lb/MMBtu) 1.8 InputType of CoalFPRBInputCoal FactorG1.05Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate FactorH1.20C/10000Heat InputI(Btu/hr)3.98E+09A*C*1000Capacity FactorJ(%)75.6InputNOxRemoval EfficiencyK (%) 25.0 InputNOxRemovedL (lb/hr) 199.1D*I/106*K/100Urea Rate (100%)M(lb/hr)866L/UF/46*30; IF Boiler type = CFB OR D> 0.3 then UF =0.25; else UF 0.15Steam RequiredN(lb/hr)7791M*9Aux PowerO(%)0.05Auxilliary powerDilution Water RateP(1000 gph)0.93N*0.12/1000Urea Cost 50% wt sol.Q($/ton)450InputAux Power CostR($/kWh)0.045InputDilution Water CostS($/klb)1InputOperating Labor RateT($/hr)60Labor cost including all benefitsCosts are all based on 2009 dollarsCapital Cost CalculationInclude: equipment, installation, buildings, foundations, electrical, and retrofit difficulty.BMS ($) = BT*B*G/1.05*200000*(A*H)0.42; (If CFB then BT=0.75, else BT=1)$2,472,000 SNCR (injectors, blowers, DCS, reagent system) costBMA ($) = If E >= 3 and F = Bituminous then 65000*(B)*(A*G*H)^0.78; else 0 $0Air heater modification / SO3control (bituminous only & > 3 lb/MMbtu)BMB ($) = BT*270000*(A)0.33*(L)0.12;(If CFB then BT=0.75, else BT=1)$3,465,000 Balance of plant cost (piping, including site upgrades)BM ($) = BMS + BMA + BMB$5,937,000Total bare module cost including retrofit factorBM ($/kW)$18Base cost per kWTotal Project CostA1 = 10% of BM$594,000Engineering and construction management costsA2 = 10% of BM$594,000Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 10% of BM$594,000Contractor profit and feesCECC($) = BM+A1+A2+A3$7,719,000Capital, engineering and construction cost subtotalCECC($/kW) =$23Capital, engineering and construction cost subtotal per kWB1 = 5% of CECC$386,000Owners costs including "home office" costs (owner engineering, management, and procurement activities)TPC ($) = CECC + B1$8,105,000Total project costTPC ($/kW) =$24Total project cost per kWPPL Colstrip Unit 2Modified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsGeneration Capacity (MW Gross)333Fuel High Heating Value (Btu/lb)8,458From EIA for 1999Maximum Fuel Consumption Rate (lb/hr)465,831Calculated from3,940MMBtu/hr from TRC Report for PPL (6/25/2008)Average Annual Fuel Consumption (lb)3.08E+09Calcuated from26,079,693MMBtu/yr average for 2008-2010 from CAMDNumber of SNCR Operating Days365AssumedPlant Capacity Factor75.6%Uncontrolled NOx Concentration (lb/mmBtu)0.309Average for 2008-2010 from CAMDSOFA Total Capital Cost4,507,528$TRC BART Report for PPl (6/25/2008) adjusted using 2010 CEPCISOFA Total Annual Cost1,090,395$TRC BART Report for PPl (6/25/2008) adjusted using 2010 CEPCINOx concentration after combustion controls 0.200NOx Control Update Report by TRC for PPL (September 2011)SNCR Controlled NOx Concentration (lb/mmBtu) 0.150NOx Control Update Report by TRC for PPL (September 2011)8,873,145$ash product (Btu/mmBtu)7.7E+04OAQPS Control Cost ManualStored Urea Concentration50%OAQPS Control Cost ManualInjected Urea Concentration10%OAQPS Control Cost ManualReagent Heat of vaporization Hv (lb/Btu)900OAQPS Control Cost ManualReagent Molecular Weight (g/mole)60.06OAQPS Control Cost ManualSRT2OAQPS Control Cost ManualReagent Density (lb/ft3 @ 60F)71.0OAQPS Control Cost ManualReagent Specific Volume (gal/ft3)7.481OAQPS Control Cost ManualNOx Molecular Weight (g/mole)46.01OAQPS Control Cost ManualNumber of Days of Storage for Urea14OAQPS Control Cost ManualEquipment Life (years)20OAQPS Control Cost ManualAnnual Interest Rate7%OAQPS Control Cost ManualInflation Since 19981.34CEPCI 2009/CEPCI 1998Inflation Since 20061.04CEPCI 2009/CEPCI 2006Water Consumption Cost ($/gal)0.001OAQPS Control Cost ManualElectrical Power Cost ($/kWh)0.045$Ref50% Urea Solution Cost ($/gal)1.07$calculated from450$/tonCoal Cost ($/mmBtu)1.60$Ash Disposal Cost ($/ton)7.19$OAQPS Control Cost ManualLost ash sales ($/yr)$0Ash not soldAdditional Ash Disposal Cost ($/ton)$0Ash not soldBoiler Calculations1.3QB= HVm-dotfuelQB = 8458 Btu/lb *465,831lb/hrQB = 3940 mmBtu/hr1.7CFPlant= actual heat input/maximum heat inputCFPlant =75.6%1.8CFSNCR= tSCR/365 daysCFSCR = 365 days/ 365 daysCFSCR =100%1.6CFTotal= CFPlantx CFSNCRCFTotal = 76% * 100%CFTotal =76%1.9ηNOx= (NOxin– NOxout) / NOxin**η**NOx = ( 0.200 lb/mmBtu - 0.15 lb/mmBtu)/ 0.2 lb/mmBtu**η**NOx =25%Uncontrolled NOx emissions (tpy)4,028Reagent Calculations1.14NSR = [2NOxin+ 0.7]ηNOx/ NOxinNSR = ( 2 * 0.2 + 0.7 ) * 25% / 0.2NSR = 1.381.13Utilization =ηNOx/NSRUtilization =18%1.15m-dotreagent= NOxinQBηNOxNSR Mreagent/MNOx/SRTm-dotreagent = 0.200 * 3940 * 1.00 * 1.38 * 60.06 / 2 / 46.01m-dotreagent = 707 lb/hr1.16m-dotsol= m-dotreagent/Csolm-dotsol = 707 / 0.50m-dotsol = 1414 lb/hr1.17qsol= m-dotvol/ρsolqsol = 1414 * 7.481 / 71qsol = 149 gph2.35Tank Volume = qsoltTank Volume = 149 * 14 * 24Tank Volume =50,073galAnnual Costs2.45 DAC = Annual Maintenance Cost + Annual ReagentCost + Annual Electricity Cost + Annual Water Cost+ Annual Catalyst Cost2.46 Annual Maintenance Cost = 0.015 TCIAnnual Maintenance Cost = 0.015 *8,873,145$Annual Maintenance Cost =133,097$1.22Annual Reagent Cost = qsolCostreagenttop1.22.atop= CFtotal8760hr/yrtop =76%*8760top =6619Annual Reagent Cost =149*1.067704852*6619Annual Reagent Cost =1,053,224$1.24Annual Electricity Cost = Power (Costelect)top1.23Power = 0.47NOxinNSRQB/9.5Power =0.47*0.2*1.38*3940/9.5Power =54kWAnnual Electricity Cost =54*6619*0.045Annual Electricity Cost =15,967$1.27Annual Water Cost = qwaterCostwatertop1.25qwater= m-dotsol/ρwater[Cureastored/Cureasol inj-1]qwater = 1414/ 8.345 *( 50% / 10% - 1 )qwater = 678Annual Water Cost = 678 *0.0010* 6619Annual Water Cost =4,487$1.31Annual∆Coal cost =∆Coal costcoaltop1.28∆Coal(Btu/hr) = Hv(Btu/lb)* m-dotreagent(lb/hr)[1/ Cureasol inj-1]∆Coal(Btu/hr) = 900* 1414 *( 1 / 10% - 1 )∆Coal(Btu/hr) = 11,456,370Annual∆Coal cost = 11.5* 1.60$ * 6619Annual∆Coal cost = 121,331$1.32Annual∆Ash cost =∆Ash costashtop1.30∆Ash =∆Coal ash product/HHV∆Ash = 11* 77000 / 8458∆Ash =104Annual∆Ash cost = 104* 7.19$ * 6619 / 2000Annual∆Ash cost = 2,482$Additional Ash Disposal Cost ($/ton) = -$Lost ash sales ($/yr) = -$Total Variable Cost =1,197,492$Total Direct Annual Cost =133,097$+1,197,492$Total Direct Annual Cost =1,330,589$1.34CRF = i(1+i)n/[(1+i)n-1]CRF =0.07*(1+0.07)^20/((1+0.07)^20-1)CRF =0.09441.33 IDAC = CRF*TCIIndirect Annual Cost = 0.0944 *8,873,145$Indirect Annual Cost =837,562$1.35 Total Annual Cost = Direct Annual Cost + Indirect Annual CostTotal Annual Cost =1,330,589$+837,562Total Annual Cost =2,168,151$1.36NOx Removed SOFA = NOxinηNOxQBtopNOx Removed =0.309*35%*3940*6619/2000NOx Removed =14201.36NOx Removed SNCR = NOxinηNOxQBtopNOx Removed =0.200*25%*3940*6619/2000NOx Removed =6521.37Cost effectiveness = TAC/NOxremovedCost effectiveness =3,325$STATEFACILITY_NAMEORISPLCODE UNIT ID OP YEARSUM OPTIMENUMMONTHSREPORTEDGROSSLOAD(MWh)SO2MASSSO2RATENOXRATENOXMASS CO2 MASSHEAT INPUT(MMBtu)HEATINPUT(MMBtu/hr)MT Colstrip 6076 1 20088,198122,464,6015,0750.375 0.3164,3172,808,90227,066,3473,301MT Colstrip 6076 1 20097,519122,417,1125,8850.4650.3043,8542,654,97525,314,4073,367MT Colstrip 6076 1 20108,160122,563,4195,6840.4160.3034,1382,868,83727,353,5133,352Averages7,9592,481,7115,5480.4180.3084,1032,777,57126,578,0893,340MT Colstrip 6076 2 20087,109122,135,0464,2410.352 0.3103,7442,500,30324,082,8533,388MT Colstrip 6076 2 20098,590122,573,7486,1520.4440.2974,1172,908,43127,731,0183,228MT Colstrip 6076 2 20107,964122,406,8865,1410.3890.3194,2242,771,47226,425,2083,318Averages7,8882,371,8945,1780.3950.3094,0282,726,73526,079,6933,311