Northshore Process Boiler

BART Report - Appendix A Emission Control Cost AnalysisTable 19: Cost Summary - Natural gas boiler

NOx Control Cost Summary baseline: 0.17 lb/mmBtu 11.625 lb/hr

Control Technology Control Eff % Controlled Emissions T/y Emission Reduction T/yr Installed Capital Cost $ Total Annual Cost $/yr Pollution Control Cost $/ton Incremental Cost $/ton

Selective Catalytic Reduction (SCR) 90% 4.1 37.1 $5,563,529 $1,119,307 $30,139Low NOx Burner / Flue Gas Recirculation 75% 10.3 30.9 $547,722 $77,510 $2,505 $30,626Low Nox Burner/Over Fire Air 68% 13.4 27.9 $1,091,532 $387,372 $13,908Low NOx Burner 50% 20.6 20.6 $95,851 $16,766 $813

Selective Non-Catalytic Reduction (SNCR) 50% 20.6 20.6 $925,876 $250,181 $12,126

SO2 Control Cost Summary baseline 0.24 lb/mmBtu 16.75 lb/hr

Control Technology Control Eff % Controlled Emissions T/y Emission Reduction T/yr Installed Capital Cost $ Total Annual Cost $/yr Pollution Control Cost $/ton

Wet ESPProcess Boiler 1 & 2 80% 11.9 61.5 $11,808,857 $2,247,725 $36,558

SO2 AbsorberProcess Boiler 1 & 2 80% 11.9 61.5 $3,935,118 $1,118,879 $18,198Spray Dryer and BaghouseProcess Boiler 1 & 2 90 11.9 61.5 $16,134,577 $2,754,704 $44,804DSI BaghouseProcess Boiler 1 & 2 55 11.9 61.5 $4,890,063 $1,412,189 $22,969Wet ScrubberProcess Boiler 1 & 2 80% 14.68 58.72 $13,618,522 $1,869,933 $31,845

Y:\23\00 MN Taconite BART (2006)\Facility BART Reports\NMC\NMC Furnace-Process Boiler\Appendices\Appendix A - NMC Process Boiler Control Cost.xls

Cost Summary 9/6/2006 
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost AnalysisTable 20: - Summary of Utility, Chemical and Supply Costs

Operating Unit: Process Boiler 1 & 2 Study Year 2006

Emission Unit Number 003 & 004Stack/Vent Number 003

Reference

Item Unit Cost Units Cost Year Data Source NotesOperating Labor 50.00 $/hr Estimated industry average

Maintenance Labor 60.00 $/hr Estimated industry average

Electricity 0.052 $/kwh 0.049 2004

DOE Average Retail Price of Industrial Electricity, 2004 http://www.eia.doe.gov/emeu/aer/txt/p

Natural Gas 2.31 $/mscf 2005

Average natural gas spot price July 04 - June 05, Henry La Hub., WTRG Economics, WWW.wtrg.com

Water 0.40 $/mgal 0.76 2004 Estimated industrial cost cost adjusted for 3% inflation

Cooling Water 0.28 $/mgal 0.23 1999

EPA Air Pollution Control Cost Manual, 6th ed. Section 3.1 Ch 1

Ch 1 Carbon Absorbers, 1999 $0.15 

3% inflation

Compressed Air 0.32 $/mscf 0.25 1998

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 1 

Example problem; Dried & Filtered, Cinflation

Wastewater Disposal Neutralization 3.80 $/mgal 1.50 2002

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 2 Chapter 2.5.5.5

Section 2 lists $1- $2/1000 gal. Cost 3 lists $1.30 - $2.15/1,000 gal

Wastewater Disposal Bio-Treat 4.28 $/mgal 3.80 2002

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 5.2 Chapter 1

Ch 1lists $1.00 - $6.00 for municipal tadjusted for 3% inflation

Solid Waste Disposal 11.48 $/ton 25.00 2002

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 2 Chapter 2.5.5.5

Section 2 lists $20 - $30/ton Used $25inflation

Hazardous Waste Disposal 281.38 $/ton 250.00 2002

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 2 Chapter 2.5.5.5

Section 2 lists $200 - $300/ton Used $inflation

Waste Transport 0.56 $/ton-mi 0.50 2002

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 3 Example problem. Cost adjusted for 

Internal Waste Recycle 1 $/ton 1.00 2000 Estimated waste cost Used $1/ton to cover cost of materials 

Chemicals & SuppliesLime 90.00 $/ton Info provided by Sonnek Engineeing

Caustic 305.21 $/ton 2005 Hawkins Chemical 50% solution (50 Deg Be) includes deUrea 405 $/ton 2005 Hawkins Chemical 50% solution of urea in water, include

Soda Ash $/tonOxygen 1.49 Mscf 1.40 2004 Industry estimate cost adjusted for 3% inflation

EPA Urea 179.1 $/tonAmmonia 0.92 $/lbReagent #8 0.00 $/tonCatalyst & Replacement Parts SCR Catalyst 500 $/ft3 Cormetech, Inc., 1/2006 bid

CO Catalyst 650 $/ft3 Vendor quote if neededCatalyst #3Catalyst #4Catalyst #5Filter Bags 37.94 $/bag 33.71 2002

EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6, Chapter 1 Example problem cost for 10 ft bags. 

Tower Packing 100 $/ft3

Y:\23\00 MN Taconite BART (2006)\Facility BART Reports\NMC\NMC Furnace-Process Boiler\Appendices\Appendix A - NMC Process Boiler Control Cost.xlsUtility Chem$ Data 9/6/2006 
Replacement Parts

Replacement PartsReplacement PartsOtherSales Tax 6.5% %Interest Rate 7.00% %

EPA Air Pollution Control Cost Manual Introduction, Chapter 2, section 2.4.2. Social (discount) rate used as a defau

Operating InformationAnnual Op. Hrs 7,650 Hours Engineering EstimateUtilization Rate 93%Equipment Life 20 yrs Engineering Estimate

Design Capacity 70 MMBtu/hrStandardized Flow Rate 64,771 scfm @ 32o F

Temperature 450 Deg F

Moisture Content 13.3%Actual Flow Rate 119,800 acfm

Standardized Flow Rate 69,510 scfm @ 68o F Based on Table 19.2 of 40 CFR 60, A

Dry Std Flow Rate 60,265 dscfm @ 68o F

Max Emis

Pollutant Lb/HrPM10 1.90

Total Particulates 1.90Nitrous Oxides (NOx) 11.60Sulfur Dioxide (SO2) 16.800

Sulfuric Acid MistFluoridesVolatile Organic Compounds (VOC) 0.99Carbon Monoxide (CO) 0.00Lead (Pb)Enter this data for each emission unitEnter data for this study (applies to all units)

Y:\23\00 MN Taconite BART (2006)\Facility BART Reports\NMC\NMC Furnace-Process Boiler\Appendices\Appendix A - NMC Process Boiler Control Cost.xlsUtility Chem$ Data 9/6/2006 
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 21: NOx Control - Low NOx Burner

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003 Chemical Engineering

Design Capacity 70 MMBtu/hr Standardized Flow Rate 64,771 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 450 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,650 Hours Moisture Content 13.3% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 49,000

 Purchased Equipment Total (B) 22% of control device cost (A) 59,535

 Installation - Standard Costs 30% of purchased equip cost (B) 17,861

 Installation - Site Specific Costs NA

 Installation Total 17,861

 Total Direct Capital Cost, DC 77,396

 Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 18,456

Total Capital Investment (TCI) = DC + IC 95,851

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 2,866

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 13,900

Total Annual Cost (Annualized Capital Cost + Operating Cost) 16,766

Emission Control Cost Calculation

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

PM10 6.8 1.9 6.8 - NA

Total Particulates 1.9 6.8 6.8 - NA

Nitrous Oxides (NOx) 11.6 41.3 50% 20.6 20.6 813 

Sulfur Dioxide (SO2) 59.8 16.8 59.8 - NA

Sulfuric Acid Mist - - 0.0 - NA

Fluorides - - 0.0 - NA

Volatile Organic Compounds (VOC) 1.0 3.5 3.5 - NA

Carbon Monoxide (CO) - - 0.0 - NA

Lead (Pb) - - 0.0 - NA

Notes & Assumptions

1 Burner cost scaled from MacTec Burner Estimate, March 2005 cost estimate

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2 

Thermal Oxidizer cost factor used because it has the lowest multipiler for installation cost

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 21: NOx Control - Low NOx Burner

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 49,000

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 

Instrumentation 10% of control device cost (A) 4,900

Mn Sales Taxes 6.5% of control device cost (A) 3,185

Freight 5% of control device cost (A) 2,450

Purchased Equipment Total (B) 22% 59,535

Installation

Foundations & supports 8% of purchased equip cost (B) 4,763

Handling & erection 14% of purchased equip cost (B) 8,335

Electrical 4% of purchased equip cost (B) 2,381

Piping 2% of purchased equip cost (B) 1,191

Insulation 1% of purchased equip cost (B) 595

Painting 1% of purchased equip cost (B) 595

Installation Subtotal Standard Expenses 30% 17,861

Site Preparation, as required Site Specific NA

Buildings, as required Site Specific NA

Site Specific - Other Site Specific NA

Total Site Specific Costs NA

Installation Total 17,861

Total Direct Capital Cost, DC 77,396

Indirect Capital Costs

Engineering, supervision 10% of purchased equip cost (B) 5,954

Construction & field expenses 5% of purchased equip cost (B) 2,977

Contractor fees 10% of purchased equip cost (B) 5,954

Start-up 2% of purchased equip cost (B) 1,191

Performance test 1% of purchased equip cost (B) 595

Model Studies of purchased equip cost (B) 0

Contingencies 3% of purchased equip cost (B) 1,786

Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 18,456

Total Capital Investment (TCI) = DC + IC 95,851

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 95,851

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 50.00 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr 478

Supervisor 15% 15% of Operator Costs 72

Maintenance

Maintenance Labor 60.00 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr 574

Maintenance Materials 100% of maintenance labor costs 574

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 3 kW-hr, 7650 hr/yr, 93% utilization 1,168

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

Total Annual Direct Operating Costs 2,866

Indirect Operating Costs

Overhead 60% of total labor and material costs 1,018

Administration (2% total capital costs) 2% of total capital costs (TCI) 1,917

Property tax (1% total capital costs) 1% of total capital costs (TCI) 959

Insurance (1% total capital costs) 1% of total capital costs (TCI) 959

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 9,048 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 13,900

Total Annual Cost (Annualized Capital Cost + Operating Cost) 16,766

See Summary page for notes and assumptions

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 21: NOx Control - Low NOx Burner

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst: Catalyst

Equipment Life 2 years

CRF 0.5531

Rep part cost per unit 650 $/ft3

Amount Required 39 ft3

Catalyst Cost 28,265 Cost adjusted for freight & sales tax

Installation Labor 4,240 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 37.940902 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm D P in H2O Efficiency Hp kW

Blower, Thermal 3,239 5 0.6 3.2 EPA Cont Cost Manual 6th ed - Oxidizers Chapter 2.5.2.1

Blower, Catalytic 0 23 0.6 0.0 EPA Cont Cost Manual 6th ed - Oxidizers Chapter 2.5.2.1

Oxidizer Type thermal (catalytic or thermal) 3.2

Reagent Use & Other Operating Costs Oxidizers - NA

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50 $/Hr 0.01 hr/8 hr shift 10 478 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr

Supervisor 15% of Op. NA 72 15% of Operator Costs

Maintenance

Maint Labor 60.00 $/Hr 0.01 hr/8 hr shift 10 574 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 574 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 3.2 kW-hr 22,465 1,168 $/kwh, 3 kW-hr, 7650 hr/yr, 93% utilization

Natural Gas 2.31 $/mscf 0 scfm 0 0 $/mscf, 0 scfm, 7650 hr/yr, 93% utilization

Water 0.40 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Cooling Water 0.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Comp Air 0.32 $/mscf 0 Mscfm 0 0 $/mscf, 0 Mscfm, 7650 hr/yr, 93% utilization

WW Treat Neutralization 3.80 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

WW Treat Biotreatement 4.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

SW Disposal 11.48 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Haz W Disp 281 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Transport 0.56 $/ton-mi 0.0 ton/hr 0 0 $/ton-mi, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Recycle 1.00 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

1 Lime 90 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

2 Caustic 305.21 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

5 Oxygen 1.49 Mscf 0.0 Mscf/hr 0 0 Mscf, 0 Mscf/hr, 7650 hr/yr, 93% utilization

2 CO Catalyst 650 $/ft3 0 ft30 0 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization

1 Filter Bags 37.94 $/bag 0 bags 0 0 $/bag, 0 bags, 7650 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 22: NOx Control - Low NOx Burner with Flue Gas Recirculation/Advanced Controls

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003 Chemical Engineering

Design Capacity 70 MMBtu/hr Standardized Flow Rate 64,771 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 450 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,650 Hours Moisture Content 13.3% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) 280,000

 Purchased Equipment Total (B) 22% of control device cost (A) 340,200

 Installation - Standard Costs 30% of purchased equip cost (B) 102,060

 Installation - Site Specific Costs NA

 Installation Total 102,060

 Total Direct Capital Cost, DC 442,260

 Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 105,462

Total Capital Investment (TCI) = DC + IC 547,722

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 2,881

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 74,628

Total Annual Cost (Annualized Capital Cost + Operating Cost) 77,510

Emission Control Cost Calculation

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

PM10 6.8 1.9 6.8 - NA

Total Particulates 1.9 6.8 6.8 - NA

Nitrous Oxides (NOx) 11.6 41.3 75% 10.3 30.9 2,505 

Sulfur Dioxide (SO2) 59.8 16.8 59.8 - NA

Sulfuric Acid Mist - - 0.0 - NA

Fluorides - - 0.0 - NA

Volatile Organic Compounds (VOC) 1.0 3.5 3.5 - NA

Carbon Monoxide (CO) - - 0.0 - NA

Lead (Pb) - - 0.0 - NA

Notes & Assumptions

1 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2 

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 22: NOx Control - Low NOx Burner with Flue Gas Recirculation/Advanced Controls

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 280,000

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 

Instrumentation 10% of control device cost (A) 28,000

MN Sales Taxes 6.5% of control device cost (A) 18,200

Freight 5% of control device cost (A) 14,000

Purchased Equipment Total (B) 22% 340,200

Installation

Foundations & supports 8% of purchased equip cost (B) 27,216

Handling & erection 14% of purchased equip cost (B) 47,628

Electrical 4% of purchased equip cost (B) 13,608

Piping 2% of purchased equip cost (B) 6,804

Insulation 1% of purchased equip cost (B) 3,402

Painting 1% of purchased equip cost (B) 3,402

Installation Subtotal Standard Expenses 30% 102,060

Site Preparation, as required Site Specific NA

Buildings, as required Site Specific NA

Site Specific - Other Site Specific NA

Total Site Specific Costs NA

Installation Total 102,060

Total Direct Capital Cost, DC 442,260

Indirect Capital Costs

Engineering, supervision 10% of purchased equip cost (B) 34,020

Construction & field expenses 5% of purchased equip cost (B) 17,010

Contractor fees 10% of purchased equip cost (B) 34,020

Start-up 2% of purchased equip cost (B) 6,804

Performance test 1% of purchased equip cost (B) 3,402

Model Studies of purchased equip cost (B) 0

Contingencies 3% of purchased equip cost (B) 10,206

Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 105,462

Total Capital Investment (TCI) = DC + IC 547,722

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 547,722

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 50.00 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr 478

Supervisor 15% 15% of Operator Costs 72

Maintenance

Maintenance Labor 60.00 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr 574

Maintenance Materials 100% of maintenance labor costs 574

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 3 kW-hr, 7650 hr/yr, 93% utilization 1,184

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

Total Annual Direct Operating Costs 2,881

Indirect Operating Costs

Overhead 60% of total labor and material costs 1,018

Administration (2% total capital costs) 2% of total capital costs (TCI) 10,954

Property tax (1% total capital costs) 1% of total capital costs (TCI) 5,477

Insurance (1% total capital costs) 1% of total capital costs (TCI) 5,477

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 51,701 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 74,628

Total Annual Cost (Annualized Capital Cost + Operating Cost) 77,510

See Summary page for notes and assumptions

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 22: NOx Control - Low NOx Burner with Flue Gas Recirculation/Advanced Controls

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst: Catalyst

Equipment Life 2 years

CRF 0.5531

Rep part cost per unit 650 $/ft3

Amount Required 39 ft3

Catalyst Cost 28,265 Cost adjusted for freight & sales tax

Installation Labor 4,240 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 37.940902 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm D P in H2O Efficiency Hp kW

Blower, Thermal 3,239 5 0.6 3.2 EPA Cont Cost Manual 6th ed - Oxidizers Chapter 2.5.2.1

Blower, Catalytic 0 23 0.6 0.0 EPA Cont Cost Manual 6th ed - Oxidizers Chapter 2.5.2.1

Oxidizer Type thermal (catalytic or thermal) 3.2

Reagent Use & Other Operating Costs Oxidizers - NA

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50 $/Hr 0.01 hr/8 hr shift 10 478 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr

Supervisor 15% of Op. NA 72 15% of Operator Costs

Maintenance

Maint Labor 60.00 $/Hr 0.01 hr/8 hr shift 10 574 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 574 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 3.2 kW-hr 22,766 1,184 $/kwh, 3 kW-hr, 7650 hr/yr, 93% utilization

Natural Gas 2.31 $/mscf 0 scfm 0 0 $/mscf, 0 scfm, 7650 hr/yr, 93% utilization

Water 0.40 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Cooling Water 0.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Comp Air 0.32 $/mscf 0 Mscfm 0 0 $/mscf, 0 Mscfm, 7650 hr/yr, 93% utilization

WW Treat Neutralization 3.80 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

WW Treat Biotreatement 4.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

SW Disposal 11.48 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Haz W Disp 281 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Transport 0.56 $/ton-mi 0.0 ton/hr 0 0 $/ton-mi, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Recycle 1.00 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

1 Lime 90 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

2 Caustic 305.21 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

5 Oxygen 1.48526 Mscf 0.0 Mscf/hr 0 0 Mscf, 0 Mscf/hr, 7650 hr/yr, 93% utilization

2 CO Catalyst 650 $/ft3 0 ft30 0 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization

1 Filter Bags 37.940902 $/bag 0 bags 0 0 $/bag, 0 bags, 7650 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

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Low NOx FGR 9/6/2006 Page 9 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 23: NOx Control - Low NOx Burner with Overfire Air

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003 Chemical Engineering

Design Capacity 70 MMBtu/hr Standardized Flow Rate 64,771 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 450 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,650 Hours Moisture Content 13.3% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs [2]

 Direct Capital Costs 468000

 Purchased Equipment (A) 558,000

 Purchased Equipment Total (B) 22% of control device cost (A) 677,970

 Installation - Standard Costs 30% of purchased equip cost (B) 203,391

 Installation - Site Specific Costs NA

 Installation Total 203,391

 Total Direct Capital Cost, DC 881,361

 Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 210,171

Total Capital Investment (TCI) = DC + IC 1,091,532

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 174,008

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 213,364

Total Annual Cost (Annualized Capital Cost + Operating Cost) 387,372

Emission Control Cost Calculation

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

PM10 6.8 1.9 6.8 - NA

Total Particulates 1.9 6.8 6.8 - NA

Nitrous Oxides (NOx) 11.6 41.3 68% 13.4 27.9 13,908 

Sulfur Dioxide (SO2) 59.8 16.8 59.8 - NA

Sulfuric Acid Mist - - 0.0 - NA

Fluorides - - 0.0 - NA

Volatile Organic Compounds (VOC) 1.0 3.5 3.5 - NA

Carbon Monoxide (CO) - - 0.0 - NA

Lead (Pb) - - 0.0 - NA

Notes & Assumptions

1 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 3.2 Chapter 2 

2 Cost based upon Analyzing Electric Power Gneration Under the CAAA.

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Low NOx OFA 9/6/2006 Page 10 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 23: NOx Control - Low NOx Burner with Overfire Air

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 558,000

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 

Instrumentation 10% of control device cost (A) 55,800

MN Sales Taxes 6.5% of control device cost (A) 36,270

Freight 5% of control device cost (A) 27,900

Purchased Equipment Total (B) 22% 677,970

Installation

Foundations & supports 8% of purchased equip cost (B) 54,238

Handling & erection 14% of purchased equip cost (B) 94,916

Electrical 4% of purchased equip cost (B) 27,119

Piping 2% of purchased equip cost (B) 13,559

Insulation 1% of purchased equip cost (B) 6,780

Painting 1% of purchased equip cost (B) 6,780

Installation Subtotal Standard Expenses 30% 203,391

Site Preparation, as required Site Specific NA

Buildings, as required Site Specific NA

Site Specific - Other Site Specific NA

Total Site Specific Costs NA

Installation Total 203,391

Total Direct Capital Cost, DC 881,361

Indirect Capital Costs

Engineering, supervision 10% of purchased equip cost (B) 67,797

Construction & field expenses 5% of purchased equip cost (B) 33,899

Contractor fees 10% of purchased equip cost (B) 67,797

Start-up 2% of purchased equip cost (B) 13,559

Performance test 1% of purchased equip cost (B) 6,780

Model Studies of purchased equip cost (B) 0

Contingencies 3% of purchased equip cost (B) 20,339

Total Indirect Capital Costs, IC 31% of purchased equip cost (B) 210,171

Total Capital Investment (TCI) = DC + IC 1,091,532

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 1,091,532

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 50.00 $/Hr, 2.0 hr/8 hr shift, 7650 hr/yr 95,625

Supervisor 15% 15% of Operator Costs 14,344

Maintenance

Maintenance Labor 60.00 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr 574

Maintenance Materials 100% of maintenance labor costs 574

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 170 kW-hr, 7650 hr/yr, 93% utilization 62,892

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

Total Annual Direct Operating Costs 174,008

Indirect Operating Costs

Overhead 60% of total labor and material costs 66,670

Administration (2% total capital costs) 2% of total capital costs (TCI) 21,831

Property tax (1% total capital costs) 1% of total capital costs (TCI) 10,915

Insurance (1% total capital costs) 1% of total capital costs (TCI) 10,915

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 103,033 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 213,364

Total Annual Cost (Annualized Capital Cost + Operating Cost) 387,372

See Summary page for notes and assumptions

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BART Report - Appendix A Emission Control Cost Analysis

Table 23: NOx Control - Low NOx Burner with Overfire Air

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst: Catalyst

Equipment Life 2 years

CRF 0.5531

Rep part cost per unit 650 $/ft3

Amount Required 39 ft3

Catalyst Cost 28,265 Cost adjusted for freight & sales tax

Installation Labor 4,240 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 37.940902 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm D P in H2O Efficiency Hp kW

Blower, Thermal 0 19 0.6 0.0 EPA Cont Cost Manual 6th ed - Oxidizers Chapter 2.5.2.1

Blower, Catalytic 0 23 0.6 0.0 EPA Cont Cost Manual 6th ed - Oxidizers Chapter 2.5.2.1

Oxidizer Type thermal (catalytic or thermal) 0.0

Reagent Use & Other Operating Costs Oxidizers - NA

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50 $/Hr 2.00 hr/8 hr shift 1,913 95,625 $/Hr, 2.0 hr/8 hr shift, 7650 hr/yr

Supervisor 15% of Op. NA 14,344 15% of Operator Costs

Maintenance

Maint Labor 60.00 $/Hr 0.01 hr/8 hr shift 10 574 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 574 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 170.0 kW-hr 1,209,465 62,892 $/kwh, 170 kW-hr, 7650 hr/yr, 93% utilization

Natural Gas 2.31 $/mscf 0 scfm 0 0 $/mscf, 0 scfm, 7650 hr/yr, 93% utilization

Water 0.40 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Cooling Water 0.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Comp Air 0.32 $/mscf 0 Mscfm 0 0 $/mscf, 0 Mscfm, 7650 hr/yr, 93% utilization

WW Treat Neutralization 3.80 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

WW Treat Biotreatement 4.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

SW Disposal 11.48 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Haz W Disp 281 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Transport 0.56 $/ton-mi 0.0 ton/hr 0 0 $/ton-mi, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Recycle 1.00 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

1 Lime 90 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

2 Caustic 305.21 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

5 Oxygen 1.48526 Mscf 0.0 Mscf/hr 0 0 Mscf, 0 Mscf/hr, 7650 hr/yr, 93% utilization

2 CO Catalyst 650 $/ft3 0 ft30 0 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization

1 Filter Bags 37.940902 $/bag 0 bags 0 0 $/bag, 0 bags, 7650 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 23: Selective Catalytic Reduction - Basis Power Plant Installed Cost

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003

Design Capacity 70 MMBtu/hr Standardized Flow Rate 64,771 scfm @ 32o F

Expected Utilization Rate 93% Temperature 450 Deg F

Expected Annual Hours of Operation 7,650 Hours Moisture Content 13.3%

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm

Expected Equipment Life 20 yrs Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs

 Purchased Equipment (A) NA

 Purchased Equipment Total (B) 22% of control device cost (A) NA

 Installation - Standard Costs 30% of purchased equip cost (B) NA

 Installation - Site Specific Costs NA

 Installation Total NA

 Total Direct Capital Cost, DC NA

 Total Indirect Capital Costs, IC 31% of purchased equip cost (B) NA

Total Capital Investment (TCI) = DC + IC 5,563,529

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 362,636

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 756,672

Total Annual Cost (Annualized Capital Cost + Operating Cost) 1,119,307

Emission Control Cost Calculation

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

PM10 6.8 1.9 6.8 - NA

Total Particulates 1.9 6.8 6.8 - NA

Nitrous Oxides (NOx) 11.6 41.3 90% 4.1 37.1 30,139 

Sulfur Dioxide (SO2

) 59.8 16.8 59.8 - NA

Sulfuric Acid Mist - - 0.0 - NA

Fluorides - - 0.0 - NA

Volatile Organic Compounds (VOC) 1.0 3.5 3.5 - NA

Carbon Monoxide (CO) - - 0.0 - NA

Lead (Pb) - - 0.0 - NA

Notes & Assumptions

Basis for SCR control cost:

1 The SCR capital investment is from vendor estimates (Babcok Power Inc, 2005). 

2 SCR catalyst quote based on information obtained from Cormetech, Inc. It is used for catalyst replacement costs.

3 The total direct and indirect operating costs are based on operation and maintenance costs in the

 "Pwr Plt SCR $" tab per EPA correlation of SCR costs for power plants.

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 23: Selective Catalytic Reduction - Basis Power Plant Installed Cost

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) NA

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 

Instrumentation 10% of control device cost (A) NA

MN Sales Taxes 6.5% of control device cost (A) NA

Freight 5% of control device cost (A) NA

Purchased Equipment Total (B) 22% NA

Installation

Foundations & supports 8% of purchased equip cost (B) NA

Handling & erection 14% of purchased equip cost (B) NA

Electrical 4% of purchased equip cost (B) NA

Piping 2% of purchased equip cost (B) NA

Insulation 1% of purchased equip cost (B) NA

Painting 1% of purchased equip cost (B) NA

Installation Subtotal Standard Expenses 30% NA

Site Preparation, as required Site Specific NA

Buildings, as required Site Specific NA

Site Specific - Other Site Specific NA

Total Site Specific Costs NA

Installation Total NA

Total Direct Capital Cost, DC NA

Indirect Capital Costs

Engineering, supervision 10% of purchased equip cost (B) NA

Construction & field expenses 5% of purchased equip cost (B) NA

Contractor fees 10% of purchased equip cost (B) NA

Start-up 2% of purchased equip cost (B) NA

Performance test 1% of purchased equip cost (B) NA

Model Studies of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) NA

Total Indirect Capital Costs, IC 31% of purchased equip cost (B) NA

Total Capital Investment (TCI) = DC + IC 5,563,529

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 5,425,183

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator NA - 

Supervisor NA - 

Maintenance

Maintenance Labor NA - 

Maintenance Materials 100% of maintenance labor costs - 

Utilities, Supplies, Replacements & Waste Management

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

CO Catalyst 650.00 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization 52,717

NA NA - 

Total Annual Direct Operating Costs 362,636

Indirect Operating Costs

Overhead 60% of total labor and material costs 22,032

Administration (2% total capital costs) 2% of total capital costs (TCI) 111,271

Property tax (1% total capital costs) 1% of total capital costs (TCI) 55,635

Insurance (1% total capital costs) 1% of total capital costs (TCI) 55,635

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 512,099 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 756,672

Total Annual Cost (Annualized Capital Cost + Operating Cost) 1,119,307

See Summary page for notes and assumptions

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 23: Selective Catalytic Reduction - Basis Power Plant Installed Cost

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst: Catalyst Estimate amount of catalyst required 

Equipment Life 3 years Vol. #1 5000 ft3

CRF 0.3811 Flow #1 359,256 acfm Basis SCR Bids for proposed 2001 Taconite Plant

Rep part cost per unit 65 $/ft3Flow #2 119,800 acfm

Amount Required 1667.3 ft3Vol #2 1667.3 ft3

Catalyst Cost 120,301 Cost adjusted for freight & sales tax

Installation Labor 18,045 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 138,346 Zero out if no replacement parts needed

Annualized Cost 52,717

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 37.940902 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm D P in H2O Efficiency Hp kW

Blower, Thermal 119,800 19 0.6 443.9 EPA Cont Cost Manual 6th ed - Oxidizers Chapter 2.5.2.1

Blower, Catalytic 119,800 23 0.6 537.3 EPA Cont Cost Manual 6th ed - Oxidizers Chapter 2.5.2.1

Oxidizer Type Catalytic (catalytic or thermal) 537.3

Reagent Use & Other Operating Costs Oxidizers - NA

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50 $/Hr 0.5 hr/8 hr shift 0 0 $/Hr, 0.5 hr/8 hr shift, 7650 hr/yr

Supervisor 15% of Op. NA - 15% of Operator Costs

Maintenance

Maint Labor 60.00 $/Hr 0.5 hr/8 hr shift 0 0 $/Hr, 0.5 hr/8 hr shift, 7650 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 0 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 537.3 kW-hr 0 0 $/kwh, 537 kW-hr, 7650 hr/yr, 93% utilization

Natural Gas 2.31 $/mscf 14676 scfm 0 0 $/mscf, 14,676 scfm, 7650 hr/yr, 93% utilization

Water 0.40 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Cooling Water 0.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Comp Air 0.32 $/mscf 0 Mscfm 0 0 $/mscf, 0 Mscfm, 7650 hr/yr, 93% utilization

WW Treat Neutralization 3.80 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

WW Treat Biotreatement 4.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

SW Disposal 11.48 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Haz W Disp 281 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Transport 0.56 $/ton-mi 0.0 ton/hr 0 0 $/ton-mi, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Recycle 1.00 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

1 Lime 90 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

2 Caustic 305.21 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

5 Oxygen 1.48526 Mscf 0.0 Mscf/hr 0 0 Mscf, 0 Mscf/hr, 7650 hr/yr, 93% utilization

2 CO Catalyst 650 $/ft3 0 ft30 52,717 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization

1 Filter Bags 37.940902 $/bag 0 bags 0 0 $/bag, 0 bags, 7650 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 23: Selective Catalytic Reduction - Basis Power Plant Installed Cost

EPA SCR Cost Worksheet for Coal Fired Power Plants

Determine Comparable Boiler Size Based on Flue Gas Exhaust Rate

stack exhaust flow scfm 69,510

Moisture Content 10%

Stack exhaust flow dcfm 60,265

Coal F Factor dscf/MMBtu 10,000

Equivalent Duty MMBtu/hr 362

Est. Power Plant Efficiency 35%

Watt per Btu/hr 0.29307

Equivalent Power Plant kW 37,090

Uncontrolled NOx t/yr 41

Annual Operating Hours 8,000

Uncontrolled NOx lb/MMBtu 0.029

Plant Capacity kW A 37,090

Uncontrolled NOx lb/MMBtu B 0.029

NOx Reduction Efficiency C 90

Capital Cost $/kW D $150.00 Total Capital Cost $5,563,529

 D= 75*(300,000((B/1.5)^0.05*(C/100)^0.04/A)^0.35

Plant Capacity kW A 37,090

Capital Cost $/kW D $150.00

Fixed O&M Cost, $/yr E $36,719

E = D*A*0.0066

Plant Capacity kW A 37,090

Uncontrolled NOx lb/MMBtu B 0.03

NOx Reduction Efficiency C 90

Capital Cost $/kW D $150.00

Annual Capacity Factor G 0.82

Heat Input MMBtu/hr H 6000

Variable O&M Cost $/yr F $362,636

F = G*(225(0.37*B*H*C/100*8760/2000)*1.005+0.075*D*A*((B/1.5)^0.05*(c/100)^.4)+1.45*A)

Note: used worst case factor for catalyst replacement

Note: Capital Cost kW is estimate from Tom Robinson @ Babcock Power Inc.

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BART Report - Appendix A Emission Control Cost Analysis

Table 25: Selective Non-Catalytic Reduction SNCR

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003 Chemical Engineering

Design Capacity 70 MMBtu/hr Standardized Flow Rate 64,771 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 450 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,650 Hours Moisture Content 13.3% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs Control Eff NOx in lb/MMBtu Year

 Direct Capital Costs EPRI Correlation, 1998 $'s 50% 0.17 1998 551,300

 Purchased Equipment (A) 2005 657,319

 Purchased Equipment Total (B) 0% of control device cost (A) 657,319

 Installation - Standard Costs 15% of purchased equip cost (B) 118,317

 Installation - Site Specific Costs 0

 Installation Total 0

 Total Direct Capital Cost, DC 0

 Total Indirect Capital Costs, IC 0% of purchased equip cost (B) 0

Total Capital Investment (TCI) = DC + IC 925,876

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 153,526

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 96,655

Total Annual Cost (Annualized Capital Cost + Operating Cost) 250,181

Emission Control Cost Calculation

Max Emis Annual Cont Eff Exit Conc. Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % Conc. Units T/yr T/yr $/Ton Rem

PM10 6.8 1.9 6.8 - NA

Total Particulates 1.9 6.8 6.8 - NA

Nitrous Oxides (NOx) 11.6 41.3 50% 20.6 20.6 12,126

Sulfur Dioxide (SO2) 59.8 16.8 59.8 - NA

Sulfuric Acid Mist - - 0.0 - NA

Fluorides - - 0.0 - NA

Volatile Organic Compounds (VOC) 1.0 3.5 3.5 - NA

Carbon Monoxide (CO) - - 0.0 - NA

Lead (Pb) - - 0.0 - NA

Notes & Assumptions

1 Cost Estimate from EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 1 

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 1 

3 Capital Cost per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 1 Eq 1.19 

4 Reagent Use per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 1 Eq 1.22

5 Water use per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 1 Eq 1.25

6 Additional Fuel Use per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 1 Eq 1.29

7 SNCR Electrical Demand per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 1 Eq 1.23

8 SNCR Maintenance Costs EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 4.2 Chapter 1 Eq 1.21

9 No coal ash disposal cost; fuel is natural gas

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BART Report - Appendix A Emission Control Cost Analysis

Table 25: Selective Non-Catalytic Reduction SNCR

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1)

Purchased Equipment Costs (A) - Absorber + packing + auxiliary equipment, EC 657,319

Instrumentation 10% of control device cost (A) NA

MN Sales Taxes 6.5% of control device cost (A) NA

Freight 5% of control device cost (A) NA

Purchased Equipment Total (A) 657,319

Indirect Installation

General Facilities 5% of purchased equip cost (A) 32,866

Engineering & Home Office 10% of purchased equip cost (A) 65,732

Process Contingency 5% of purchased equip cost (A) 32,866

Total Indirect Installation Costs (B) 20% of purchased equip cost (A) 131,464

Project Contingency ( C) 15% of (A + B) 118,317

Total Plant Cost D A + B + C 907,100

Allowance for Funds During Construction (E) 0 for SNCR 0

Royalty Allowance (F) 0 for SNCR 0

Pre Production Costs (G) 2% of (D+E)) 18,142

Inventory Capital Reagent Vol * $/gal 634

Initial Catalyst and Chemicals 0 for SNCR 0

Total Capital Investment (TCI) = DC + IC D + E + F + G +H + I 925,876

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 925,876

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator NA - 

Supervisor NA - 

Maintenance

Maintenance Total 15.00 % of Total Capital Investment 138,881

Maintenance Materials NA % of Maintenance Labor - 

Utilities, Supplies, Replacements & Waste Management

NA NA - 

Natural Gas 2.31 $/mscf, 0 scfh, 7650 hr/yr, 93% utilization 1,215

Water 0.40 $/mgal, 4 gph, 7650 hr/yr, 93% utilization 13

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

NA NA - 

Urea 405.00 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization 13,416

NA NA - 

NA NA - 

NA NA - 

Total Annual Direct Operating Costs 153,526

Indirect Operating Costs

Overhead NA of total labor and material costs NA

Administration (2% total capital costs) NA of total capital costs (TCI) NA

Property tax (1% total capital costs) NA of total capital costs (TCI) NA

Insurance (1% total capital costs) 0 of total capital costs (TCI) 9,259

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 87,396 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 96,655

Total Annual Cost (Annualized Capital Cost + Operating Cost) 250,181

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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 25: Selective Non-Catalytic Reduction SNCR

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst <- Enter Equipment Name to Get Cost

Equipment Life 5 years

CRF 0.2439

Rep part cost per unit 500 $/ft3

Amount Required 12 ft3

Packing Cost 6,690 Cost adjusted for freight & sales tax

Installation Labor 1,004 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment: <- Enter Equipment Name to Get Cost

Equipment Life 2 years

CRF 0.0000

Rep part cost per unit 38 $/ft3

Amount Required 0 Cages

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax See Control Cost Manual Sec 6 Ch 1 Table 1.8 for bag costs

Installation Labor 0 10 min per bag, Labor + Overhead (68% = $29.65/hr)

Total Installed Cost 0 Zero out if no replacement parts needed EPA CCM list replacement times from 5 - 20 min per bag.

Annualized Cost 0

Electrical Use

NOx in 0.17 lb/MMBtu kW

NSR 1.12

Power 0.0

Total 0.0

Reagent Use & Other Operating Costs Urea Use

NOx in 0.17 lb/MMBtu 5 lb/hr Neat

Efficiency 50% 50% solution 71.0 lb/ft3 Density 50% Solution

Duty 70 MMBtu/hr 9 lb/hr 1.0 gal/hr

Volume 14 day inventory 330 gal $634 Inventory Cost

Water Use 4 gal/hr Inject at 10% solution

Fuel Use 0.1 MMBtu/hr 0.1 mscfh natural gas

Ash Generation 0.6 lb/hr

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93.0%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50 $/Hr 0.0 hr/8 hr shift 0 0 $/Hr, 0.0 hr/8 hr shift, 7650 hr/yr

Supervisor 15% of Op. NA - 15% of Operator Costs

Maintenance

Maintenance Total 15 % of Total Capital Investment 138,881 % of Total Capital Investment

Maint Mtls 0 % of Maintenance Labor NA 0 0% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 0.0 kW-hr 0 0 $/kwh, 0 kW-hr, 7650 hr/yr, 93% utilization

Natural Gas 2.31 $/mscf 0.1 scfh 526 1,215 $/mscf, 0 scfh, 7650 hr/yr, 93% utilization

Water 0.40 $/mgal 4.5 gph 32 13 $/mgal, 4 gph, 7650 hr/yr, 93% utilization

Cooling Water 0.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Comp Air 0.32 $/mscf 0.0 scfm/kacfm** 0 0 $/mscf, 0 scfm/kacfm**, 7650 hr/yr, 93% utilization

WW Treat Neutralization 3.80 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

WW Treat Biotreatement 4.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

SW Disposal 11.48 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Haz W Disp 281 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Transport 0.56 $/ton-mi 0.0 ton/hr 0 0 $/ton-mi, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Recycle 1.00 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

1 Lime 90 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

3 Urea 405 $/ton 0.0047 ton/hr 33 13,416 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

5 Oxygen 1.48526 Mscf 0.0 Mscf/hr 0 0 Mscf, 0 Mscf/hr, 7650 hr/yr, 93% utilization

1 SCR Catalyst 500 $/ft3 0 ft30 0 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization

1 Filter Bags 37.940902 $/bag 0 bags 0 0 $/bag, 0 bags, 7650 hr/yr, 93% utilization

** Std Air use is 2 scfm/kacfm *annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

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NOx SNCR 9/6/2006 Page 19 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 26: SO2 Control - Wet ESP

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003 Chemical Engineering

Design Capacity 70 MMBtu/hr Standardized Flow Rate 64,771 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 450 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,650 Hours Moisture Content 13.3% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs Year

 Direct Capital Costs (1)

 Purchased Equipment (A) 2005 5,519,073 2,687,838

 Purchased Equipment Total (B) 22% of control device cost (A) 3,265,724

 Installation - Standard Costs 69% of purchased equip cost (B) 2,253,349

 Installation - Site Specific Costs 0

 Installation Total 2,253,349

 Total Direct Capital Cost, DC 5,519,073

 Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 1,861,462

Total Capital Investment (TCI) = DC + IC 11,808,857

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 742,986

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 1,504,739

Total Annual Cost (Annualized Capital Cost + Operating Cost) 2,247,725

Emission Control Cost Calculation

Baseline Predicted Limit Cont. Emis. Cont Emis Reduction Cont Cost (5)

Pollutant Emis. T/yr lb/hr lb/MMBtu T/yr T/yr $/Ton Rem

PM10 1.5 8.3 0.021 5.3 3.0 758,310 

Total Particulates 1.5 8.3 0.021 5.3 3.0 758,310 

Nitrous Oxides (NOx) 50.9 - 50.9 - NA

Sulfur Dioxide (SO2) 3.4 73.4 0.048 11.9 61.5 36,558 

Notes & Assumptions

1 Total Direct Capital Cost Cost Estimated, 19% as compared to dry ESP cost.

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 3 

3 ESP Maintenance costs Eq 3.45 EPA Cont Cost Manual Section 6 Chapter 3

4 ESP Maintenance Materials Eq 3.45 EPA Cont Cost Manual Section 6 Chapter 3

5 High control cost is due to the small additional decrease in emissions as compared to existing controls.

6 CUECost Workbook Version 1.0, USEPA Document Page 2.

Notes to User

1) Enter Data in Blue Highlighted Cells Throughout Worksheet 

2) Control cost basis calculated by % control efficiency or concentration. Enter valued in appropriate yellow highlighted cell

2a) If using % control efficiency, enter data only in coluND F, do not enter concentration units in coluND H

2b) If using concentration, enter concentration data in coluND Fand units in coluND H

3) If not data entered in colums F and G; control cost will show NA. This was done to prevent divide by zero errors

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SO2 WESP 9/6/2006 Page 20 of 42
4) See comments in cell V88 regarding selection of reagents, catalysts and supplies

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SO2 WESP 9/6/2006 Page 21 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 26: SO2 Control - Wet ESP

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 2,687,838

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 

Instrumentation 10% of control device cost (A) 268,784

MN Sales Taxes 6.5% of control device cost (A) 174,709

Freight 5% of control device cost (A) 134,392

Purchased Equipment Total (B) 22% 3,265,724

Installation

Foundations & supports 4% of purchased equip cost (B) 130,629

Handling & erection 50% of purchased equip cost (B) 1,632,862

Electrical 8% of purchased equip cost (B) 261,258

Piping 3% of purchased equip cost (B) 97,972

Insulation 2% of purchased equip cost (B) 65,314

Painting 2% of purchased equip cost (B) 65,314

Installation Subtotal Standard Expenses 69% 2,253,349

Installation Total 2,253,349

Total Direct Capital Cost, DC 5,519,073

Indirect Capital Costs

Engineering, supervision 20% of purchased equip cost (B) 653,145

Construction & field expenses 20% of purchased equip cost (B) 653,145

Contractor fees 10% of purchased equip cost (B) 326,572

Start-up 1% of purchased equip cost (B) 32,657

Performance test 1% of purchased equip cost (B) 32,657

Model Studies 2% of purchased equip cost (B) 65,314

Contingencies 3% of purchased equip cost (B) 97,972

Total Indirect Capital Costs, IC 57% of purchased equip cost (B) 1,861,462

7,380,535

Retrofit TCI (TCI*1.6) (6) 11,808,857

Total Capital Investment (TCI) = DC + IC Site Preparation, as required site preparation and foundations 0

Buildings, as required structural steel 0

Site Specific - Other Replacement Power - One 14 day outage [8] 0

Total Site Specific Costs 0

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 11,808,857

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 50.00 $/Hr, 1.0 hr/8 hr shift, 7650 hr/yr 47,813

Supervisor 48% % of Operator Costs. 22,950

Maintenance

Maintenance Labor (3) 66,249 ft2 grid area, 0.8 $/ft2 of grid area 54,656

Maintenance Materials (4) 1 1% of purchased equipment cost 32,657

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 228 kW-hr, 7650 hr/yr, 93% utilization 84,287

NA NA - 

Water 0.40 $/mgal, 24 gpm, 7650 hr/yr, 93% utilization 4,091

NA NA - 

NA NA - 

NA NA - 

NA NA - 

SW Disposal 11.48 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization 77

NA NA - 

NA NA - 

NA NA - 

NA NA - 

Caustic 305.21 $/ton, 227 lb/hr, 7650 hr/yr, 93% utilization 246,456

NA NA - 

Lost Revenue - Fly Ash NA 250,000

NA NA - 

Total Annual Direct Operating Costs 742,986

Indirect Operating Costs

Overhead 60% of total labor and material costs 94,845

Administration (2% total capital costs) 2% of total capital costs (TCI) 147,611

Property tax (1% total capital costs) 1% of total capital costs (TCI) 73,805 1

Insurance (1% total capital costs) 1% of total capital costs (TCI) 73,805 2

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 1,114,673 5

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 1,504,739 1

1

Total Annual Cost (Annualized Capital Cost + Operating Cost) 2,247,725

See Summary page for notes and assumptions

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SO2 WESP 9/6/2006 Page 22 of 42
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SO2 WESP 9/6/2006 Page 23 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 26: SO2 Control - Wet ESP

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst:

Equipment Life 5 years

CRF 0.0000

Rep part cost per unit 500 $/ft3

Amount Required 0 ft3

Packing Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 37.94090199 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower Baghouse & ESP 119,800 4.48 97.1 EPA Cost Cont Manual 6th ed Section 6 Chapter 3 Eq 3.46

Liq flow Liquid SPGR ∆ P ft H2O Efficiency Hp kW

WESP Pump 120 gpm 1.000 40 0.5 1.8 EPA Cost Cont Manual 6th ed Section 6 Chapter 3 Eq 3.47

WESP H2O WW Disch 24 gpm 1.000 40 0.5 0.4 EPA Cost Cont Manual 6th ed Section 6 Chapter 3 Eq 3.47

SCA Factor 553 ft2

/1000 acfm

ESP Grid 66,249 ft21.94E-03 kW/ft2128.5 EPA Cost Cont Manual 6th ed Section 6 Chapter 3 Eq 3.48

Total 227.8

Reagent Use & Other Operating Costs

WESP Pump 23,960 acfm 5 gpm/kacfm 120 gpm EPA Cost Cont Manual 6th ed Section 6 Chapter 3.4.1.9

WESP Water Makeup Rate/WW Disch 20% of circulating water rate = 24 gpm

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50.00 $/Hr 1.0 hr/8 hr shift 956 47,813 $/Hr, 1.0 hr/8 hr shift, 7650 hr/yr

Supervisor 48% of Operator Costs. NA 22,950 % of Operator Costs.

Maintenance

Maint Labor 66,249 ft2 grid area 0.825 $/ft2 of grid area 54,656 ft2 grid area, 0.8 $/ft2 of grid area

Maint Mtls 1 % of purchased equipment cost NA 32,657 1% of purchased equipment cost

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 227.8 kW-hr 1,620,903 84,287 $/kwh, 228 kW-hr, 7650 hr/yr, 93% utilization

Natural Gas 2.31 $/mscf 0 scfm 0 0 $/mscf, 0 scfm, 7650 hr/yr, 93% utilization

Water 0.40 $/mgal 24.0 gpm 10,228 4,091 $/mgal, 24 gpm, 7650 hr/yr, 93% utilization

Cooling Water 0.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Comp Air 0.32 $/mscf 0 kscfm 0 0 $/mscf, 0 kscfm, 7650 hr/yr, 93% utilization

WW Treat Neutralization 3.80 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

WW Treat Biotreatement 4.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

SW Disposal 11.48 $/ton 0.0 ton/hr 7 77 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Haz W Disp 281 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Transport 0.56 $/ton-mi 0.0 Mi 0 0 $/ton-mi, 0 Mi, 7650 hr/yr, 93% utilization

PRB Coal 1 $/ton 0.0 ton/hr 0 0 $/ton, $5.1MM/yr extra for PRB - $1MM/yr Lower O&M Cost

Lime 90.0 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

Caustic 305.21 $/ton 227.0 lb/hr 807 246,456 $/ton, 227 lb/hr, 7650 hr/yr, 93% utilization

Oxygen 1.48526 Mscf 0.0 kscf/hr 0 0 Mscf, 0 kscf/hr, 7650 hr/yr, 93% utilization

SCR Catalyst 500 $/ft3 0 ft3

0 0 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization

Filter Bags 37.94 $/bag 0 bags 0 0 $/bag, 0 bags, 7650 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Note: Select reagent, catayst and repacement parts by entering number in coluND U. Unhide Col U to enter choice.

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SO2 WESP 9/6/2006 Page 24 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 27: SO2 Absorber

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003 Chemical Engineering

Design Capacity 70 MMBtu/hr Standardized Flow Rate 64,771 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 450 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,650 Hours Moisture Content 13.3% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs Year

 Direct Capital Costs (1) 2002 [1] 1,908,056

 Purchased Equipment (A) 2005 2,274,990 1,012,119

 Purchased Equipment Total (B) 22% of control device cost (A) 1,229,724

 Installation - Standard Costs 85% of purchased equip cost (B) 1,045,266

 Installation - Site Specific Costs 0

 Installation Total 1,045,266

 Total Direct Capital Cost, DC 2,274,990

 Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 184,459

Total Capital Investment (TCI) = DC + IC 3,935,118

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 598,134

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 520,746

Total Annual Cost (Annualized Capital Cost + Operating Cost) 1,118,879

Emission Control Cost Calculation

Baseline Predicted Limit Cont. Emis. Cont Emis Reduction Cont Cost

Pollutant Emis. T/yr lb/hr lb/MMBtu T/yr T/yr $/Ton Rem

PM10 - 8.3 8.3 - NA

Total Particulates - 8.3 8.3 - NA

Nitrous Oxides (NOx) 50.9 - 50.9 - NA

Sulfur Dioxide (SO2) 3.4 73.4 0.05 11.9 61.5 18,198 

Notes & Assumptions

1 Original estimate was from Durr. Use 0.6 Powerlaw factor to adjust price to stack flow rate from bid basis of 500,000 acfm. 

2 Liquid/Gas ratio = 38 L/G = Gal/1,000 acf.

3 Water Makeup Rate/Wastewater Discharge = 2.0% of circulating water rate.

4 Evaporation rate calculated from steam table in Basic Principles and Calculations in Chemical Engineering Third Edition.

5 CUECost Workbook Version 1.0, USEPA Document Page 2.

Notes to User

1) Enter Data in Blue Highlighted Cells Throughout Worksheet 

2) Control cost basis calculated by % control efficiency or concentration. Enter valued in appropriate yellow highlighted cell

2a) If using % control efficiency, enter data only in coluND F, do not enter concentration units in coluND H

2b) If using concentration, enter concentration data in coluND Fand units in coluND H

3) If not data entered in colums F and G; control cost will show NA. This was done to prevent divide by zero errors

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SO2 Absorber 9/6/2006 Page 25 of 42
4) See comments in cell V88 regarding selection of reagents, catalysts and supplies

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SO2 Absorber 9/6/2006 Page 26 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 27: SO2 Absorber

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 1,012,119

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 

Instrumentation 10% of control device cost (A) 101,212

MN Sales Taxes 6.5% of control device cost (A) 65,788

Freight 5% of control device cost (A) 50,606

Purchased Equipment Total (B) 22% 1,229,724

Installation

Foundations & supports 12% of purchased equip cost (B) 147,567

Handling & erection 40% of purchased equip cost (B) 491,890

Electrical 1% of purchased equip cost (B) 12,297

Piping 30% of purchased equip cost (B) 368,917

Insulation 1% of purchased equip cost (B) 12,297

Painting 1% of purchased equip cost (B) 12,297

Installation Subtotal Standard Expenses 85% 1,045,266

Installation Total 1,045,266

Total Direct Capital Cost, DC 2,274,990

Indirect Capital Costs

Engineering, supervision 5% of purchased equip cost (B) 61,486

Construction & field expenses 0% of purchased equip cost (B) 0

Contractor fees 5% of purchased equip cost (B) 61,486

Start-up 1% of purchased equip cost (B) 12,297

Performance test 1% of purchased equip cost (B) 12,297

Model Studies NA of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) 36,892

Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 184,459

Total Capital Investment (TCI) = DC + IC 2,459,448

Retrofit TCI (TCI*1.6) (5) 3,935,118

Site Preparation, as required site preparation and foundations 0

Buildings, as required structural steel 0

Site Specific - Other Replacement Power - One 14 day outage [8] 0

Total Site Specific Costs 0

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 3,935,118

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 50.00 $/Hr, 0.5 hr/8 hr shift, 7650 hr/yr 23,906

Supervisor 15% 15% of Operator Costs 3,586

Maintenance

Maintenance Labor 60.00 $/Hr, 0.5 hr/8 hr shift, 7650 hr/yr 28,688

Maintenance Materials 100% of maintenance labor costs 28,688

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 246 kW-hr, 7650 hr/yr, 93% utilization 91,145

NA NA - 

Water 0.40 $/mgal, 112 gpm, 7650 hr/yr, 93% utilization 19,194

NA NA - 

NA NA - 

WW Treat Neutralization 3.80 $/mgal, 91 gpm, 7650 hr/yr, 93% utilization 147,690

NA NA - 

SW Disposal 11.48 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization 77

NA NA - 

NA NA - 

NA NA - 

Lime 90.00 $/ton, 16 lb/hr, 7650 hr/yr, 93% utilization 5,161

NA NA - 

NA NA - 

Lost Revenue - Fly Ash NA 250,000

NA NA - 

Total Annual Direct Operating Costs 598,134

Indirect Operating Costs

Overhead 60% of total labor and material costs 50,920

Administration (2% total capital costs) 2% of total capital costs (TCI) 49,189

Property tax (1% total capital costs) 1% of total capital costs (TCI) 24,594 1

Insurance (1% total capital costs) 1% of total capital costs (TCI) 24,594 2

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 371,447 5

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 520,746 1

1

Total Annual Cost (Annualized Capital Cost + Operating Cost) 1,118,879

See Summary page for notes and assumptions

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SO2 Absorber 9/6/2006 Page 27 of 42
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Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 27: SO2 Absorber

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst:

Equipment Life 5 years

CRF 0.0000

Rep part cost per unit 500 $/ft3

Amount Required 0 ft3

Packing Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 37.94 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Scrubber 119,800 8.55 0.7 - 171.2 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.48

Flow Liquid SPGR ∆ P ft H2O Efficiency Hp kW

Circ Pump 4,552 gpm 1 60 0.7 - 73.4 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

H2O WW Disch 112 gpm 1 60 0.7 - 1.8 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

Other 

Total 246.4

Reagent Use & Other Operating Costs

Caustic Use 16.75 lb/hr SO2 2.50 lb NaOH/lb SO2 41.88 lb/hr Caustic

Lime Use 16.75 lb/hr SO2 0.96 lb Lime/lb SO2 16.12 lb/hr lime, lime addition at 1.1 times the stoichiometric ratio 

Liquid/Gas ratio (2) 38.0 * L/G = Gal/1,000 acf

Circulating Water Rate 4,552 gpm

Water Makeup Rate/WW Disch = (3) 2.0% of circulating water rate + evap. loss = 112 gpm

Evaopration Loss = (4) 21.36 gpm

Pollutant BART Baseline Emissions Control Eff (%) Cont. Emis (lb/MMBtu)

T/yr lb/MMBtu lb/hr 80% 0.05

NOx 50.90 0.166071429 11.625

SO2 73.40 0.239285714 16.75

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50.00 $/Hr 0.5 hr/8 hr shift 478 23,906 $/Hr, 0.5 hr/8 hr shift, 7650 hr/yr

Supervisor 15% of Op. NA 3,586 15% of Operator Costs

Maintenance

Maint Labor 60.00 $/Hr 0.5 hr/8 hr shift 478 28,688 $/Hr, 0.5 hr/8 hr shift, 7650 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 28,688 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 246.4 kW-hr 1,752,797 91,145 $/kwh, 246 kW-hr, 7650 hr/yr, 93% utilization

Natural Gas 2.31 $/mscf 0 scfm 0 0 $/mscf, 0 scfm, 7650 hr/yr, 93% utilization

Water 0.40 $/mgal 112.4 gpm 47,984 19,194 $/mgal, 112 gpm, 7650 hr/yr, 93% utilization

Cooling Water 0.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Comp Air 0.32 $/mscf 0 kscfm 0 0 $/mscf, 0 kscfm, 7650 hr/yr, 93% utilization

WW Treat Neutralization 3.80 $/mgal 91.0 gpm 38,866 147,690 $/mgal, 91 gpm, 7650 hr/yr, 93% utilization

WW Treat Biotreatement 4.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

SW Disposal 11.48 $/ton 0.0 ton/hr 7 77 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Haz W Disp 281 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Transport 0.56 $/ton-mi 0.0 ton/hr 0 0 $/ton-mi, 0 ton/hr, 7650 hr/yr, 93% utilization

PRB Coal 1 $/ton 0.0 ton/hr 0 0 $/ton, $5.1MM/yr extra for PRB - $1MM/yr Lower O&M Cost

Lime 90.0 $/ton 16.1 lb/hr 57 5,161 $/ton, 16 lb/hr, 7650 hr/yr, 93% utilization

Caustic 305.21 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

Oxygen 1.48526 Mscf 0.0 kscf/hr 0 0 Mscf, 0 kscf/hr, 7650 hr/yr, 93% utilization

SCR Catalyst 500 $/ft3 0 ft3

0 0 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization

Filter Bags 37.94 $/bag 0 bags 0 0 $/bag, 0 bags, 7650 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Note: Select reagent, catayst and repacement parts by entering number in coluND U. Unhide Col U to enter choice.

Y:\23\00 MN Taconite BART (2006)\Facility BART Reports\NMC\NMC Furnace-Process Boiler\Appendices\Appendix A - NMC Process Boiler Control Cost.xls

SO2 Absorber 9/6/2006 Page 29 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 28: SO2 Control - Spray Dryer and Baghouse

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003 Chemical Engineering

Design Capacity 70 MMBtu/hr Standardized Flow Rate 64,771 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 450 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,650 Hours Moisture Content 13.3% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs Year

 Direct Capital Costs (1) 2002 [1] 7,786,400

 Purchased Equipment (A) 2005 9,283,785 4,391,365

 Purchased Equipment Total (B) 22% of control device cost (A) 5,335,508

 Installation - Standard Costs 74% of purchased equip cost (B) 3,948,276

 Installation - Site Specific Costs 0

 Installation Total 3,948,276

 Total Direct Capital Cost, DC 9,283,785

 Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 800,326

Total Capital Investment (TCI) = DC + IC (5) 16,134,577

Operating Costs (2)

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 693,518

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 2,061,186

Total Annual Cost (Annualized Capital Cost + Operating Cost) 2,754,704

Emission Control Cost Calculation

Baseline Predicted Limit Cont. Emis. Cont Emis Reduction Cont Cost

Pollutant Emis. T/yr lb/hr lb/MMBtu T/yr T/yr $/Ton Rem

PM10 - 8.3 8.3 - NA

Total Particulates - 8.3 8.3 - NA

Nitrous Oxides (NOx) 50.9 - 50.9 - NA

Sulfur Dioxide (SO2) 3.4 73.4 0.05 11.9 61.5 44,804 

Notes & Assumptions

1 Stone and Webster 2002 total direct installed cost estimate adjusted for inflation

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 1 

3 Compressed air for baghouse assumed to be 2 scfm / 1000 acfm EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 1.5.1.8

4 Bag replacement at 10 min/bag EPA Cost Cont Manual 6th ed Section 6 Chapter 1.5.1.4 lists replacement times from 5 - 20 min per bag.

5 Bag replacement costs for baghouse need to be updated. Bag costs from EPA example calculations were used. 

6 Dry scrubbing SO2 costs include addition of a baghouse. Assumed that the existing baghouse could not handle additional loading.

7 CUECost Workbook Version 1.0, USEPA Document Page 2.

Notes to User

1) Enter Data in Blue Highlighted Cells Throughout Worksheet 

2) Control cost basis calculated by % control efficiency or concentration. Enter valued in appropriate yellow highlighted cell

2a) If using % control efficiency, enter data only in coluND F, do not enter concentration units in coluND H

2b) If using concentration, enter concentration data in coluND Fand units in coluND H

3) If not data entered in colums F and G; control cost will show NA. This was done to prevent divide by zero errors

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Spray Dry Baghouse 9/6/2006 Page 30 of 42
4) See comments in cell V88 regarding selection of reagents, catalysts and supplies

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Spray Dry Baghouse 9/6/2006 Page 31 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 28: SO2 Control - Spray Dryer and Baghouse

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 4,391,365

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 

Instrumentation 10% of control device cost (A) 439,136

MN Sales Taxes 6.5% of control device cost (A) 285,439

Freight 5% of control device cost (A) 219,568

Purchased Equipment Total (B) 22% 5,335,508

Installation

Foundations & supports 4% of purchased equip cost (B) 213,420

Handling & erection 50% of purchased equip cost (B) 2,667,754

Electrical 8% of purchased equip cost (B) 426,841

Piping 1% of purchased equip cost (B) 53,355

Insulation 7% of purchased equip cost (B) 373,486

Painting 4% of purchased equip cost (B) 213,420

Installation Subtotal Standard Expenses 74% 3,948,276

Installation Total 3,948,276

Total Direct Capital Cost, DC 9,283,785

Indirect Capital Costs

Engineering, supervision 5% of purchased equip cost (B) 266,775

Construction & field expenses 0% of purchased equip cost (B) 0

Contractor fees 5% of purchased equip cost (B) 266,775

Start-up 1% of purchased equip cost (B) 53,355

Performance test 1% of purchased equip cost (B) 53,355

Model Studies NA of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) 160,065

Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 800,326

Total Capital Investment (TCI) = DC + IC 10,084,111

Retrofit TCI (TCI*1.6) (7) 16,134,577

Site Preparation, as required site preparation and foundations 0

Buildings, as required structural steel 0

Site Specific - Other Replacement Power - One 14 day outage [8] 0

Total Site Specific Costs 0

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 16,134,577

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 50.00 $/Hr, 2.0 hr/8 hr shift, 7650 hr/yr 95,625

Supervisor 15% 15% of Operator Costs 14,344

Maintenance

Maintenance Labor 60.00 $/Hr, 1.0 hr/8 hr shift, 7650 hr/yr 57,375

Maintenance Materials 100% of maintenance labor costs 57,375

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 217 kW-hr, 7650 hr/yr, 93% utilization 80,220

NA NA - 

Water 0.40 $/mgal, 141 gpm, 7650 hr/yr, 93% utilization 24,000

NA NA - 

Comp Air 0.32 $/mscf, 2 scfm/kacfm, 7650 hr/yr, 93% utilization 32,391

NA NA - 

NA NA - 

SW Disposal 11.48 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization 77

NA NA - 

NA NA - 

NA NA - 

Lime 90.00 $/ton, 16 lb/hr, 7650 hr/yr, 93% utilization 5,161

NA NA - 

Lost Revenue - Fly Ash NA 250,000

NA NA - 

Filter Bags 37.94 $/bag, 0 bags, 7650 hr/yr, 93% utilization 76,951

Total Annual Direct Operating Costs 693,518

Indirect Operating Costs

Overhead 60% of total labor and material costs 134,831

Administration (2% total capital costs) 2% of total capital costs (TCI) 201,682

Property tax (1% total capital costs) 1% of total capital costs (TCI) 100,841

Insurance (1% total capital costs) 1% of total capital costs (TCI) 100,841

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 1,522,990 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 2,061,186

Total Annual Cost (Annualized Capital Cost + Operating Cost) 2,754,704

See Summary page for notes and assumptions

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Spray Dry Baghouse 9/6/2006 Page 32 of 42
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Spray Dry Baghouse 9/6/2006 Page 33 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 28: SO2 Control - Spray Dryer and Baghouse

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalsyt:

Equipment Life 5 years

CRF 0.0000

Rep part cost per unit 500 $/ft3

Amount Required 0 ft3

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment: Filter bags & cages (4)

Equipment Life 4 years

CRF 0.2952

Rep part cost per unit 38 $/bag

Amount Required 4410

Total Rep Parts Cost 186,561 Cost adjusted for freight & sales tax

Installation Labor 74,088 10 min per bag, Labor + Overhead (68% = $29.65/hr) EPA Cost Cont Manual 6th ed Section 6 Chapter 1.5.1.4

Total Installed Cost 260,649 Zero out if no replacement parts needed lists replacement times from 5 - 20 min per bag.

Annualized Cost 76,951

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Baghouse 119,800 10 216.8

Baghouse Shaker 0.0 Gross fabric area ft20 EPA Cost Cont Manual 6th ed Section 6 Chapter 1 Eq 1.14

Other 

Other 

Other 

Other 

Other 

Total 216.8

Baghouse Filter Cost See Control Cost Manual Sec 6 Ch 1 Table 1.8 for bag costs

Gross BH Filter Area 0 ft2

Cages 0 ft long 0 in dia 0.00 area/cage ft20.000 $/cage

Bags 0 $/ft2 of fabric 0.00 $/bag

H2O Use (1) 140.56 gpm 0.000 Total

Lime Use 16.75 lb/hr SO2 0.96 lb Lime/lb SO2 16.12 lb/hr lime, lime addition at 1.1 times the stoichiometric ratio 

Pollutant BART Baseline Emissions Control Eff (%) Cont. Emis (lb/MMBtu)

T/yr lb/MMBtu lb/hr 80% 0.05

NOx 50.90 0.166071429 11.625

SO2 73.40 0.239285714 16.75

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50.00 $/Hr 2.0 hr/8 hr shift 1,913 95,625 $/Hr, 2.0 hr/8 hr shift, 7650 hr/yr

Supervisor 15% of Op. NA 14,344 15% of Operator Costs

Maintenance

Maint Labor 60.00 $/Hr 1.0 hr/8 hr shift 956 57,375 $/Hr, 1.0 hr/8 hr shift, 7650 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 57,375 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 216.8 kW-hr 1,542,694 80,220 $/kwh, 217 kW-hr, 7650 hr/yr, 93% utilization

Natural Gas 2.31 $/mscf 0 scfm 0 0 $/mscf, 0 scfm, 7650 hr/yr, 93% utilization

Water 0.40 $/mgal 140.6 gpm 60,000 24,000 $/mgal, 141 gpm, 7650 hr/yr, 93% utilization

Cooling Water 0.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

(3) Comp Air 0.32 $/mscf 2 scfm/kacfm 102,278 32,391 $/mscf, 2 scfm/kacfm, 7650 hr/yr, 93% utilization

WW Treat Neutralization 3.80 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

WW Treat Biotreatement 4.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

SW Disposal 11.48 $/ton 0.0 ton/hr 7 77 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Haz W Disp 281 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Transport 0.56 $/ton-mi 0.0 ton/hr 0 0 $/ton-mi, 0 ton/hr, 7650 hr/yr, 93% utilization

PRB Coal 1 $/ton 0.0 ton/hr 0 0 $/ton, $5.1MM/yr extra for PRB - $1MM/yr Lower O&M Cost

1 Lime 90.0 $/ton 16.1 lb/hr 57 5,161 $/ton, 16 lb/hr, 7650 hr/yr, 93% utilization

2 Caustic 305.21 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

5 Oxygen 1.48526 Mscf 0.0 kscf/hr 0 0 Mscf, 0 kscf/hr, 7650 hr/yr, 93% utilization

1 SCR Catalyst 500 $/ft3 0 ft30 0 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization

1 Filter Bags 37.940902 $/bag 0 bags NA 76,951 $/bag, 0 bags, 7650 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Note: Select reagent, catayst and repacement parts by entering number in coluND U. Unhide Col U to enter choice.

Y:\23\00 MN Taconite BART (2006)\Facility BART Reports\NMC\NMC Furnace-Process Boiler\Appendices\Appendix A - NMC Process Boiler Control Cost.xls

Spray Dry Baghouse 9/6/2006 Page 34 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 29: SO2 Control - Dry Sorbent Injection and Baghouse

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003 Chemical Engineering

Design Capacity 70 MMBtu/hr Standardized Flow Rate 64,771 scfm @ 32o F Chemical Plant Cost Index

Expected Utilization Rate 93% Temperature 450 Deg F 1998/1999 390

Expected Annual Hours of Operation 7,650 Hours Moisture Content 13.3% 2005 465

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm Inflation Adj 1.19

Expected Equipment Life 20 yrs Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs Year

 Direct Capital Costs (1) 1997 2,359,900

 Purchased Equipment (A) 2005 [6] 2,813,727 1,330,934

 Purchased Equipment Total (B) 22% of control device cost (A) 1,617,084

 Installation - Standard Costs 74% of purchased equip cost (B) 1,196,642

 Installation - Site Specific Costs 0

 Installation Total 1,196,642

 Total Direct Capital Cost, DC 2,813,727

 Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 242,563

Total Capital Investment (TCI) = DC + IC (5) 4,890,063

Operating Costs (2)

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 693,518

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 718,670

Total Annual Cost (Annualized Capital Cost + Operating Cost) 1,412,189

Emission Control Cost Calculation

Baseline Predicted Limit Cont. Emis. Cont Emis Reduction Cont Cost

Pollutant Emis. T/yr lb/hr lb/MMBtu T/yr T/yr $/Ton Rem

PM10 - 8.3 8.3 - NA

Total Particulates - 8.3 8.3 - NA

Nitrous Oxides (NOx) 50.9 - 50.9 - NA

Sulfur Dioxide (SO2) 3.4 73.4 0.05 11.9 61.5 22,969 

Notes & Assumptions

1 Total Direct Capital Cost Cost Estimated using the Integrated Air Pollution Control Sytem Program Version 5a, EPA May 1999

2 Calculations per EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 1 

3 Compressed air for baghouse assumed to be 2 scfm / 1000 acfm EPA Air Pollution Control Cost Manual 6th Ed 2002, Section 6 Chapter 1.5.1.8

4 Bag replacement at 10 min/bag EPA Cost Cont Manual 6th ed Section 6 Chapter 1.5.1.4 lists replacement times from 5 - 20 min per bag.

5 Dry scrubbing SO2 costs include addition of a baghouse. Assumed that the existing Ebaghouse could not handle additional loading.

6 Stone and Webster 2002 total direct installed cost estimate adjusted for inflation adjusted for costs already included

7 CUECost Workbook Version 1.0, USEPA Document Page 2.

Notes to User

1) Enter Data in Blue Highlighted Cells Throughout Worksheet 

2) Control cost basis calculated by % control efficiency or concentration. Enter valued in appropriate yellow highlighted cell

2a) If using % control efficiency, enter data only in coluND F, do not enter concentration units in coluND H

2b) If using concentration, enter concentration data in coluND Fand units in coluND H

3) If not data entered in colums F and G; control cost will show NA. This was done to prevent divide by zero errors

Y:\23\00 MN Taconite BART (2006)\Facility BART Reports\NMC\NMC Furnace-Process Boiler\Appendices\Appendix A - NMC Process Boiler Control Cost.xls

DSI Baghouse 9/6/2006 Page 35 of 42
4) See comments in cell V88 regarding selection of reagents, catalysts and supplies

Y:\23\00 MN Taconite BART (2006)\Facility BART Reports\NMC\NMC Furnace-Process Boiler\Appendices\Appendix A - NMC Process Boiler Control Cost.xls

DSI Baghouse 9/6/2006 Page 36 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 29: SO2 Control - Dry Sorbent Injection and Baghouse

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1) 1,330,934

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 

Instrumentation 10% of control device cost (A) 133,093

MN Sales Taxes 6.5% of control device cost (A) 86,511

Freight 5% of control device cost (A) 66,547

Purchased Equipment Total (B) 22% 1,617,084

Installation

Foundations & supports 4% of purchased equip cost (B) 64,683

Handling & erection 50% of purchased equip cost (B) 808,542

Electrical 8% of purchased equip cost (B) 129,367

Piping 1% of purchased equip cost (B) 16,171

Insulation 7% of purchased equip cost (B) 113,196

Painting 4% of purchased equip cost (B) 64,683

Installation Subtotal Standard Expenses 74% 1,196,642

Installation Total 1,196,642

Total Direct Capital Cost, DC (6) 2,813,727

Indirect Capital Costs

Engineering, supervision [6] 5% of purchased equip cost (B) 80,854

Construction & field expenses [6] 0% of purchased equip cost (B) 0

Contractor fees [6] 5% of purchased equip cost (B) 80,854

Start-up 1% of purchased equip cost (B) 16,171

Performance test 1% of purchased equip cost (B) 16,171

Model Studies NA of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) 48,513

Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 242,563

Total Capital Investment (TCI) = DC + IC 3,056,290

Retrofit TCI (TCI*1.6) (7) 4,890,063

Site Preparation, as required site preparation and foundations 0

Buildings, as required structural steel 0

Site Specific - Other Replacement Power - One 14 day outage [8] 0

Total Site Specific Costs 0

Adjusted TCI for Replacement Parts (Catalyst, Filter Bags, etc) for Capital Recovery Cost 4,890,063

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 50.00 $/Hr, 2.0 hr/8 hr shift, 7650 hr/yr 95,625

Supervisor 15% 15% of Operator Costs 14,344

Maintenance

Maintenance Labor 60.00 $/Hr, 1.0 hr/8 hr shift, 7650 hr/yr 57,375

Maintenance Materials 100% of maintenance labor costs 57,375

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 217 kW-hr, 7650 hr/yr, 93% utilization 80,220

NA NA - 

Water 0.40 $/mgal, 141 gpm, 7650 hr/yr, 93% utilization 24,000

NA NA - 

Comp Air 0.32 $/mscf, 2 scfm/kacfm, 7650 hr/yr, 93% utilization 32,391

NA NA - 

NA NA - 

SW Disposal 11.48 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization 77

NA NA - 

NA NA - 

NA NA - 

Lime 90.00 $/ton, 16 lb/hr, 7650 hr/yr, 93% utilization 5,161 (3)

NA NA - 

Lost Revenue - Fly Ash NA 250,000

NA NA - 

Filter Bags 37.94 $/bag, 0 bags, 7650 hr/yr, 93% utilization 76,951

Total Annual Direct Operating Costs 693,518

Indirect Operating Costs 1

Overhead 60% of total labor and material costs 134,831 2

Administration (2% total capital costs) 2% of total capital costs (TCI) 61,126 5

Property tax (1% total capital costs) 1% of total capital costs (TCI) 30,563 1

Insurance (1% total capital costs) 1% of total capital costs (TCI) 30,563 1

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 461,587 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 718,670

Total Annual Cost (Annualized Capital Cost + Operating Cost) 1,412,189

See Summary page for notes and assumptions

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DSI Baghouse 9/6/2006 Page 37 of 42
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DSI Baghouse 9/6/2006 Page 38 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 29: SO2 Control - Dry Sorbent Injection and Baghouse

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalsyt:

Equipment Life 5 years

CRF 0.0000

Rep part cost per unit 500 $/ft3

Amount Required 0 ft3

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment: Filter bags & cages (4)

Equipment Life 4 years

CRF 0.2952

Rep part cost per unit 38 $/bag

Amount Required 4410

Total Rep Parts Cost 186,561 Cost adjusted for freight & sales tax

Installation Labor 74,088 10 min per bag, Labor + Overhead (68% = $29.65/hr) EPA Cost Cont Manual 6th ed Section 6 Chapter 1.5.1.4

Total Installed Cost 260,649 Zero out if no replacement parts needed lists replacement times from 5 - 20 min per bag.

Annualized Cost 76,951

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Baghouse 119,800 10 216.8

Baghouse Shaker 0.0 Gross fabric area ft20 EPA Cost Cont Manual 6th ed Section 6 Chapter 1 Eq 1.14

Other 

Other 

Other 

Other 

Other 

Total 216.8

Baghouse Filter Cost See Control Cost Manual Sec 6 Ch 1 Table 1.8 for bag costs

Gross BH Filter Area 0 ft2

Cages 0 ft long 5 in dia 0.00 area/cage ft20.000 $/cage

Bags 0 $/ft2 of fabric 0.00 $/bag

H2O Use (6) 140.56 gpm 0.000 Total

Lime Use 16.75 lb/hr SO2 0.96 lb Lime/lb SO2 16.12 lb/hr lime, lime addition at 1.1 times the stoichiometric ratio 

Pollutant BART Baseline Emissions Control Eff (%) Cont. Emis (lb/MMBtu)

T/yr lb/MMBtu lb/hr 80% 0.05

NOx 50.90 0.166071429 11.625

SO2 73.40 0.239285714 16.75

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50.00 $/Hr 2.0 hr/8 hr shift 1,913 95,625 $/Hr, 2.0 hr/8 hr shift, 7650 hr/yr

Supervisor 15% of Op. NA 14,344 15% of Operator Costs

Maintenance

Maint Labor 60.00 $/Hr 1.0 hr/8 hr shift 956 57,375 $/Hr, 1.0 hr/8 hr shift, 7650 hr/yr

Maint Mtls 100 % of Maintenance Labor NA 57,375 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 216.8 kW-hr 1,542,694 80,220 $/kwh, 217 kW-hr, 7650 hr/yr, 93% utilization

Natural Gas 2.31 $/mscf 0 scfm 0 0 $/mscf, 0 scfm, 7650 hr/yr, 93% utilization

Water 0.40 $/mgal 140.6 gpm 60,000 24,000 $/mgal, 141 gpm, 7650 hr/yr, 93% utilization

Cooling Water 0.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

Comp Air 0.32 $/mscf 2 scfm/kacfm 102,278 32,391 $/mscf, 2 scfm/kacfm, 7650 hr/yr, 93% utilization

WW Treat Neutralization 3.80 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

WW Treat Biotreatement 4.28 $/mgal 0.0 gpm 0 0 $/mgal, 0 gpm, 7650 hr/yr, 93% utilization

SW Disposal 11.48 $/ton 0.0 ton/hr 7 77 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Haz W Disp 281 $/ton 0.0 ton/hr 0 0 $/ton, 0 ton/hr, 7650 hr/yr, 93% utilization

Waste Transport 0.56 $/ton-mi 0.0 ton/hr 0 0 $/ton-mi, 0 ton/hr, 7650 hr/yr, 93% utilization

PRB Coal 1 $/ton 0.0 ton/hr 0 0 $/ton, $5.1MM/yr extra for PRB - $1MM/yr Lower O&M Cost

Lime 90.0 $/ton 16.1 lb/hr 57 5,161 $/ton, 16 lb/hr, 7650 hr/yr, 93% utilization

Caustic 305.21 $/ton 0.0 lb/hr 0 0 $/ton, 0 lb/hr, 7650 hr/yr, 93% utilization

Oxygen 1.49 Mscf 0.0 kscf/hr 0 0 Mscf, 0 kscf/hr, 7650 hr/yr, 93% utilization

SCR Catalyst 500 $/ft3 0 ft30 0 $/ft3, 0 ft3, 7650 hr/yr, 93% utilization

Filter Bags 37.94 $/bag 0 bags NA 76,951 $/bag, 0 bags, 7650 hr/yr, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

Note: Select reagent, catayst and repacement parts by entering number in coluND U. Unhide Col U to enter choice.

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DSI Baghouse 9/6/2006 Page 39 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 30: SOx Control - Wet Scrubber

Operating Unit: Process Boiler 1 & 2

Emission Unit Number 003 & 004 Stack/Vent Number 003

Standardized Flow Rate 64,771 scfm @ 32o F

Expected Utilization Rate 93% Temperature 450 Deg F

Expected Annual Hours of Operation 7,650 0 Moisture Content 13% 0

Annual Interest Rate 7.0% Actual Flow Rate 119,800 acfm

Expected Equipment Life 20 0 Standardized Flow Rate 69,510 scfm @ 68o F

Dry Std Flow Rate 60,265 dscfm @ 68o F

CONTROL EQUIPMENT COSTS

Capital Costs

 Direct Capital Costs (1)

 Purchased Equipment (A) 1,908,056

 Purchased Equipment Total (B) 22% of control device cost (A) 2,318,288

 Installation - Standard Costs 85% of purchased equip cost (B) 1,970,545

 Installation - Site Specific Costs 6,200,000

 Installation Total 1,970,545

 Total Direct Capital Cost, DC 4,288,833

 Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 347,743

Total Capital Investment (TCI) = DC + IC 13,618,522

Operating Costs

 Total Annual Direct Operating Costs Labor, supervision, materials, replacement parts, utilities, etc. 348,057

 Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 1,521,875

Total Annual Cost (Annualized Capital Cost + Operating Cost) 1,869,933

Actual

Emission Control Cost Calculation Emis Emissions

Max Emis Annual Cont Eff Cont Emis Reduction Cont Cost

Pollutant Lb/Hr T/Yr % T/yr T/yr $/Ton Rem

Nitrous Oxides (NOx) 11.6 50.9 0% 50.9 - NA

Sulfur Dioxide (SO2) 73.4 16.8 80% 14.7 58.7 31,845 

Notes & Assumptions

1 Original estimate from STS Consultants. Use 0.6 Power law factor to adjust price to stack flow rate from bid basis of 500,000 acfm. 

2 Liquid/Gas ratio = 38 L/G = Gal/1,000 acf.

3 Water Makeup Rate/Wastewater Discharge = 2.0% of circulating water rate.

4 Evaporation rate calculated from steam table in Basic Principles and Calculations in Chemical Engineering Third Edition.

5 CUECost Workbook Version 1.0, USEPA Document Page 2.

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 Wet Scrubber 9/6/2006 Page 40 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 30: SOx Control - Wet Scrubber

CAPITAL COSTS

Direct Capital Costs

Purchased Equipment (A) (1)

Purchased Equipment Costs (A) - Absorber + packing + auxillary equipment, EC 1,908,056

Instrumentation 10% of control device cost (A) 190,806

MN Sales Taxes 6.5% of control device cost (A) 124,024

Freight 5% of control device cost (A) 95,403

Purchased Equipment Total (B) 22% 2,318,288

Installation

Foundations & supports 12% of purchased equip cost (B) 278,195

Handling & erection 40% of purchased equip cost (B) 927,315

Electrical 1% of purchased equip cost (B) 23,183

Piping 30% of purchased equip cost (B) 695,486

Insulation 1% of purchased equip cost (B) 23,183

Painting 1% of purchased equip cost (B) 23,183

Installation Subtotal Standard Expenses 85% 1,970,545

Total Direct Capital Cost, DC 4,288,833

Indirect Capital Costs

Engineering, supervision 5% of purchased equip cost (B) 115,914

Construction & field expenses 0% of purchased equip cost (B) 0

Contractor fees 5% of purchased equip cost (B) 115,914

Start-up 1% of purchased equip cost (B) 23,183

Performance test 1% of purchased equip cost (B) 23,183

Model Studies NA of purchased equip cost (B) NA

Contingencies 3% of purchased equip cost (B) 69,549

Total Indirect Capital Costs, IC 15% of purchased equip cost (B) 347,743

Total Capital Investment (TCI) = DC + IC 4,636,576

Retrofit multiplier560% of TCI 2,781,946

Sitework and foundations Site Specific 1,400,000

Structural steel Site Specific 4,800,000

Site Specific - Other Site Specific 0

Total Site Specific Costs 6,200,000

Total Capital Investment (TCI) Retrofit Installed 13,618,522

OPERATING COSTS

Direct Annual Operating Costs, DC

Operating Labor

Operator 37.00 $/Hr, 0.5 hr/8 hr shift, Annual Operating Hours, 23,906

Supervisor 15% 15% of Operator Costs 3,586

Maintenance

Maintenance Labor 40.00 $/Hr, 0.5 hr/8 hr shift, Annual Operating Hours, 28,688

Maintenance Materials 100% of maintenance labor costs 28,688

Utilities, Supplies, Replacements & Waste Management

Electricity 0.05 $/kwh, 246 kW-hr, Annual Operating Hours, 93% utilization 91,145

Water 0.40 $/kgal, 112 gpm, Annual Operating Hours, 93% utilization 19,194

WW Treat Neutralization 3.80 $/kgal, 91 gpm, Annual Operating Hours, 93% utilization 147,690

Lime 90.00 $/ton, 16 lb/hr, Annual Operating Hours, 93% utilization 5,161

Total Annual Direct Operating Costs 348,057

Indirect Operating Costs

Overhead 60% of total labor and material costs 50,920

Administration (2% total capital costs) 2% of total capital costs (TCI) 92,732

Property tax (1% total capital costs) 1% of total capital costs (TCI) 46,366

Insurance (1% total capital costs) 1% of total capital costs (TCI) 46,366

Capital Recovery 0.0944 for a 20- year equipment life and a 7% interest rate 1,285,492 

Total Annual Indirect Operating Costs Sum indirect oper costs + capital recovery cost 1,521,875

Total Annual Cost (Annualized Capital Cost + Operating Cost) 1,869,933

See Summary page for notes and assumptions

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 Wet Scrubber 9/6/2006 Page 41 of 42
Northshore Process Boiler

BART Report - Appendix A Emission Control Cost Analysis

Table 30: SOx Control - Wet Scrubber

Capital Recovery Factors

Primary Installation

Interest Rate 7.00%

Equipment Life 20 years

CRF 0.0944

Replacement Catalyst:

Equipment Life 20 years

CRF 0.0000

Rep part cost per unit 0 $/ft3

Amount Required 0 ft3

Packing Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 Assume Labor = 15% of catalyst cost (basis labor for baghouse replacement)

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Replacement Parts & Equipment:

Equipment Life 3

CRF 0.3811

Rep part cost per unit 0.00 $ each

Amount Required 0 Number

Total Rep Parts Cost 0 Cost adjusted for freight & sales tax

Installation Labor 0 10 min per bag (13 hr total) Labor at $29.65/hr OAQPS list replacement times from 5 - 20 min per bag.

Total Installed Cost 0 Zero out if no replacement parts needed

Annualized Cost 0

Electrical Use

Flow acfm ∆ P in H2O Efficiency Hp kW

Blower, Scrubber 119,800 8.55 0.7 - 171.2 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.48

Flow Liquid SPGR ∆ P ft H2O Efficiency Hp kW

Circ Pump 4,552 gpm 1 60 0.7 - 73.4 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

H2O WW Disch 112 gpm 1 60 0.7 - 1.8 EPA Cost Cont Manual 6th ed Section 5.2 Chapter 1 Eq 1.49

Other 

Total 246.4

Reagent Use & Other Operating Costs

Caustic Use 16.75 lb/hr SO2 2.50 lb NaOH/lb SO2 41.88 lb/hr Caustic

Lime Use 16.75 lb/hr SO2 0.96 lb Lime/lb SO2 16.12 lb/hr lime, lime addition at 1.1 times the stoichiometric ratio 

Liquid/Gas ratio 38.0 * L/G = Gal/1,000 acf

Circulating Water Rate2

4,552 gpm

Water Makeup Rate/WW Disch3

 = 2.0% of circulating water rate + evap. loss = 112 gpm

Evaopration Loss4 = 21.36 gpm

Operating Cost Calculations Annual hours of operation: 7,650

Utilization Rate: 93%

Unit Unit of Use Unit of Annual Annual Comments

Item Cost $ Measure Rate Measure Use* Cost

Operating Labor

Op Labor 50.00 $/Hr 0.5 hr/8 hr shift 478 23,906 $/Hr, 0.5 hr/8 hr shift, Annual Operating Hours, 

Supervisor 15% of Op. NA 3,586 15% of Operator Costs

Maintenance

Maint Labor 60.00 $/Hr 0.5 hr/8 hr shift 478 28,688 $/Hr, 0.5 hr/8 hr shift, Annual Operating Hours, 

Maint Mtls 100 % of Maintenance Labor NA 28,688 100% of Maintenance Labor

Utilities, Supplies, Replacements & Waste Management

Electricity 0.052 $/kwh 246.4 kW-hr 1,752,797 91,145 $/kwh, 246 kW-hr, Annual Operating Hours, 93% utilization

Water 0.40 $/kgal 112.4 gpm 47,984 19,194 $/kgal, 112 gpm, Annual Operating Hours, 93% utilization

WW Treat Neutralization 3.80 $/kgal 91.0 gpm 38,866 147,690 $/kgal, 91 gpm, Annual Operating Hours, 93% utilization

Lime 90.0 $/ton 16.1 lb/hr 57 5,161 $/ton, 16 lb/hr, Annual Operating Hours, 93% utilization

*annual use rate is in same units of measurement as the unit cost factor

See Summary page for notes and assumptions

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 Wet Scrubber 9/6/2006 Page 42 of 42