SNCR Control Costs

Kiln Capital Cost Annualized 

Capital Cost

Annual 

Operating 

Cost

Total 

Annual 

Cost

Emission 

Reduction

($) ($) ($) ($/yr) (tpy)

Kiln 1 450,000 42,477 358,459 400,936 491

Kiln 2 450,000 42,477 354,981 397,458 493

SO2 Control Costs

SO2 Control Technology Capital Cost

Annual 

Indirect Costs

Annual 

Direct 

Costs

Total 

Annual 

Cost

Emission 

Reduction

($) ($/yr) ($/yr) ($/yr) (tpy)

Kiln 1

Lower Sulfur Fuel Blend -- -- -- 313,096 366

Dry Sorbent Injection 2,497,559 371,174 2,620,862 2,992,036 628

Kiln 2

Lower Sulfur Fuel Blend -- -- -- 458,179 559

Dry Sorbent Injection 2,497,559 371,174 3,896,658 4,267,833 960
Cost 

Effectiveness

 ($/ton)

817

807

Average Incremental

856 --

4,763 10,215

819 --

4,445 9,504

Cost Effectiveness ($/ton)
Baseline Emission Factors

Emission Unit Lime Production

Max Daily2Annual3

Year Emission Factor

(tpd) (tpy) (lb/ton lime) (lb/day) (tpy)

Kiln 1 866 258,508 2010 7.59 6,573 981

Kiln 2 1,246 378,296 2012 5.21 6,492 985

1

 Factors from March, May and June 2013 CEMS testing.

2

 Maximum daily rates representing maximum rates that occurred during the March 2013 CEMS testing.

3

 The annual lime production represents the highest annual production rate for each kiln from2001 to 2012

NOx Control 

Control Option

Control 

Efficiency

Emission 

Factor

Emissions 

Removed

(%) (lb/ton lime) (lb/day) (tpy) (tpy)

Kiln 1

Baseline -- 7.59 6,573 981 --

SNCR 50% 3.80 3,286 491 491

Kiln 2

Baseline -- 5.21 6,492 985 --

SNCR 50% 2.61 3,246 493 493

SO2 Control

Control Option Ctrl Eff

Emission 

Factor

Emissions 

Removed

% (lb/ton lime) (lb/day) (tpy) (tpy)

Kiln 1

Baseline -- 12.15 10,522 1,570 --

Lower Sulfur Fuel Blend23.30% 9.32 8,070 1,205 366

Dry Sorbent Injection (SBC) 40% 7.29 6,313 942 628

Kiln 2

Baseline -- 12.69 15,812 2,400 --

Lower Sulfur Fuel Blend23.30% 9.73 12,128 1,841 559

Dry Sorbent Injection (SBC) 40% 7.61 9,487 1,440 960

NOx

Emission Rate

Emission Rate

Emissions
Emission Factor1

(lb/ton lime) (lb/day) (tpy)

12.15 10,522 1,570

12.69 15,812 2,400

h 2013 CEMS testing.

h kiln from2001 to 2012

SO2 Control TechnologyCtrl Eff

Emission 

Factor

% (lb/ton lime) (lb/day) (lb/hr) (g/s)

Kiln 1

Baseline -- 12.15 10,522 438 55

Lower Sulfur Fuel Blend23.30% 9.32 8,070 336 42

Dry Sorbent Injection (SBC) 40% 7.29 6,313 263 33

Kiln 2

Baseline -- 12.69 15,812 659 83

Lower Sulfur Fuel Blend23.30% 9.73 12,124 505 64

Dry Sorbent Injection (SBC) 40% 7.61 9,482 395 50

Maximum 24-hr Model Emission Rate

SO2

Emissions
Selective Non-Catalytic Reduction

Cost Item Units Kiln 1 Kiln 2

Capital Costs

Total Capital Investment $ 450,000 450,000

Capital Recovery Factor 0.094 0.094

Annual Costs

Variable Operating Costs (VOC)

Reagent Usage lb/hr 71 70

Reagent Usage lb/yr 558,578 551,671

Reagent Usage ton/yr 279 276

Reagent Cost $/ton 1,000 1,000

Reagent Cost $/yr 279,289 275,836

Aux Power kW/hr 5.00 4.93

Aux Power kWh/yr 39,390 38,903

Aux Power Cost $/kWh 0.05 0.05

Aux Power Cost $/yr 1,969 1,945

Total VOC 281,259 277,781

Fixed Operating Costs (FOC)

Additional Labor $/yr 59,200 59,200

Admin, Taxes, Insurance $/yr 4% 18,000 18,000

Total FOC 77,200 77,200

Annualized Capital Cost $/yr 42,477 42,477

Total Annual Costs $/yr 400,936 397,458

1 Interest Rate 7.0%

Equipment Lifetime (years) 20

Capital Recovery Factor 0.094

2 Anhydrous ammonia price established at approximately double historical urea price highs (excluding 2008 hig

http://www.indexmundi.com/commodities/?commodity=urea&months=360
Notes

Per Table 5-4, "Nelson BART Five Factor Analysis 09.27.13 - Public.pdf" 

See footnote 1 below

See Andover Technology Partners (ATP) memo, Equation E.16, "C_08_005_Cement Kiln Cost Analysis 2009-03-10.pdf." 

Based on anhydrous ammonia usage, 90% annual CF, normal stoichiometric ratio of 0.70.

See footnote 2 below; Based on use of anhydrous ammonia

See Andover Technology Partners memo, Equation E.17, 18, "C_08_005_Cement Kiln Cost Analysis 2009-03-10.pdf." 

Based on 90% annual capacity factor

Per contractor assumptions for Nelson Plant in "Non EGU_BART_Ch3.xlsx"

Aux power cost + Reagent cost

See Andover Technology Partners memo, page 17, "C_08_005_Cement Kiln Cost Analysis 2009-03-10.pdf." 

See Andover Technology Partners memo, page 17, "C_08_005_Cement Kiln Cost Analysis 2009-03-10.pdf." 

Total VOC + Total FOC + Annualized Capital cost

mately double historical urea price highs (excluding 2008 high) 

ty=urea&months=360
 Analysis 2009-03-10.pdf." 

nalysis 2009-03-10.pdf." 

09-03-10.pdf." 

09-03-10.pdf." 
Dry Sorbent Injection (using Sodium Bicarbonate)

Cost Item Units Kiln 1 Kiln 2

Capital Costs

Purchased Equipment Cost (PEC)

Equipment Cost (EC) $ 1,022,500 1,022,500

Instrumentation $ 10% 102,250 102,250

Sales Tax $ 3% 30,675 30,675

Freight $ 5% 51,125 51,125

Total PEC $ 1,206,550 1,206,550

Direct Installation Cost (DC)

Foundation and Supports $ 12% 144,786 144,786

Handling and Erection $ 40% 482,620 482,620

Electrical $ 1% -- --

Piping $ 30% 361,965 361,965

Insulation $ 1% 12,066 12,066

Painting $ 1% -- --

Total DC $ 1,001,437 1,001,437

Indirect Installation Cost (IC)

Engineering $ 10% -- --

Construction and field expenses $ 10% 120,655 120,655

Contractor Fees $ 10% 120,655 120,655

Performance Test $ 1% 12,066 12,066

Contingencies $ 3% 36,197 36,197

Total IC $ 289,572 289,572

Total Capital Investment (TCI), PEC+DC+IC 2,497,559 2,497,559

Annual Costs

Direct Annual Costs (DAC)

Reagent Usage Ratio 4.63 4.63

Reagent Usage lb/hr 1,624 2,440

Reagent Usage lb/yr 12,802,669 19,239,156

Reagent Usage ton/yr 6,401 9,620

Reagent Price $/ton 375 375

Reagent Cost $/yr 2,400,500 3,607,342

Waste Generated ton/yr 2,695 4,074

Waste Disposal Price $/ton 50 50

Waste Disposal Cost $/yr 134,750 203,705

Aux Power kW/hr 67 67

Aux Power kWh/yr 528,228 528,228

Aux Power Price $/kW 0.05 0.05

Aux Power Cost $/yr 26,411 26,411

Additional Labor $/yr 59,200 59,200

Total DAC 2,620,862 3,896,658
Indirect Annual Costs (IAC)

Overhead $/yr 60% 35,520 35,520

Admin, Taxes, Insurance $/yr 4% 99,902 99,902

Annualized Capital Cost $/yr 235,752 235,752

Total IAC 371,174 371,174

Total Annual Costs (DAC+IAC) 2,992,036 4,267,833

1 Interest Rate 7.0%

Equipment Lifetime (years) 20

Capital Recovery Factor 0.094 0.094 0.094

2 SO2 MW 64 lb/lbmol

SO4 MW 96 lb/lbmol
Notes

Noltech vendor quote, May 22, 2013. Included in attachments to "Nelson BART Five Factor Analysis 09.27.13 - Public.pdf"

10% of EC, Per EPA Control Cost Manual (CCM), Section 5.2, Chapter 1, Table 1.3

3% of EC, CCM, Section 5.2, Chapter 1, Table 1.3

5% of EC, CCM, Section 5.2, Chapter 1, Table 1.3

CCM, Section 5.2, Chapter 1, Table 1.3

CCM, Section 5.2, Chapter 1, Table 1.3

Included in EC

CCM, Section 5.2, Chapter 1, Table 1.3

CCM, Section 5.2, Chapter 1, Table 1.3

Included in EC

Included in EC

CCM, Section 5.2, Chapter 1, Table 1.3

CCM, Section 5.2, Chapter 1, Table 1.3

CCM, Section 5.2, Chapter 1, Table 1.3

CCM, Section 5.2, Chapter 1, Table 1.3

Sorbent-SO2 ratio of 4.63, per ATP calculations for Nelson Plant in "Non EGU_BART_Ch3.xlsx"

SBC, based on NSR=0.8

Includes $225/ton SBC cost and $150/ton transportation cost, "Non EGU_BART_Ch3.xlsx"

Waste consists of SO2 captured as SO4, plus sodium portion of SBC

Per contractor calculations for Nelson Plant in "Non EGU_BART_Ch3.xlsx"

67 MW additional pump required to overcome additional pressure head, per Noltech vendor quote

Based on 90% annual capacity factor

Per contractor calculations for Nelson Plant in "Non EGU_BART_Ch3.xlsx"

See Andover Technology Partners memo, page 17, "C_08_005_Cement Kiln Cost Analysis 2009-03-10.pdf." 
60% of labor and material costs, per CCM, Section 5.2, Chapter 1, Table 1.4 (used 'additional labor' category in this instance)

4% OF TCI, per CCM, Section 5.2, Chapter 1, Table 1.4
sis 09.27.13 - Public.pdf"
' category in this instance)
Fuel Mixture Change

Parameter Units Kiln 1 Kiln 2

Coal Heating Value Btu/lb 8800 8800

Coal Heating Value MMBtu/ton 17.6 17.6

Coal Fuel Price $/ton 46.29 46.29

Coal Fuel Price $/MMBtu 2.63 2.63

Petcoke Fuel Price $/MMBtu 2.25 2.25

Lime Prod Heat Input GJ/ton lime 3.02 3.02

Lime Prod Heat Input MMBtu/ton lime 6.37 6.37

Lime Production tons/yr 258,508 378,296

Heat Input MMBtu/yr 1,647,382 2,410,749

Fuel Cost $/yr 3,706,609 5,424,185

Fuel Cost $/yr 4,019,705 5,882,364

Cost increase $/yr 313,096 458,179

1 0.9478 kJ/Btu

2 50% Thermal efficiency for production process
Notes

Based on Powder River Basin coal, http://www.eia.gov/coal/news_markets/

2011 average coal price (U.S. Total), http://www.eia.gov/coal/annual/pdf/table34.pdf

Table 4.12.a, average cost of petroleum coke, July 2013, http://www.eia.gov/electricity/data.cfm#avgcost

Per Kirk-Othmer Encyclopedia of Chemical Technology, Vol 15 (Lime Production Entry), Fourth Ed., 1995

See notes 1, 2 below

Based on 100% petcoke mixture

Based on 50%/50% coal-petcoke mixture
data.cfm#avgcost

ourth Ed., 1995