# FGD Capital Costs

Description Formula 1 

# Value

Boiler Size (MMBtu/hr) Q B 

# 1941

SO2 Removal Efficiency (%) η NOx 

# 85.9%

Cost Year 2010

Capital Costs ($) 2



# Base module absorber island cost BMR 

# $25,626,606

Base module reagent preparation and waste

recycle/handling cost BMF 

# $10,741,603

Base module balance of plant cost including ID or

booster fans, piping, ductwork, electrical, etc.. BMB 

# $35,306,502

Total bare module cost including retrofit factor BM=BMR+BMF+BMB $71,674,710

Total Project Costs ($)



# Engineering and construction management costs A1 = 10% of BM $7,167,049

Labor adjustment for 6 x 10 hour shift premium, per

diem, etc.. A2 = 10% of BM $7,167,049

Contractor profit and fees A3 = 10% of BM $7,167,049

Total Capital Investment (TCI) ($) BM+A1+A2+A3 $93,175,857

Total Capital Investment (TCI) ($) Per kW $575

FGD Annual Costs

Direct Annnual Costs

Fixed O&M costs for operations staff 

# $998,400

Fixed O&M costs for maintenance labor and materi als 

# $1,075,121

Fixed O&M costs for adminstrative labor 

# $42,177

Variable O&M costs for lime reagent $390,936

Variable O&M costs for waste disposal $283,802

Variable O&M costs for additional auxillary power

required including additional fan power $1,066,750

Variable O&M costs for makeup water $75,577

Total Direct Annual Costs DAC (Eq. 2.45) 

# $3,932,763

Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) 

# $8,795,801

Total Annual Costs TAC = DAC + IAC (Eq. 2.56) 

# $12,728,564

Cost Effectivness

SDA FGD SO2 Removed (tons/yr) 

# 2,339

SDA FGD Cost Effectiveness ($/ton removed) 

# $5,442 Corette BART Cost Analysis - SDA FGD

(2010 Dollars)Corette SDA FGD Capital Cost Estimate WorksheetVariableDesignationUnitsValueCalculationUnit Size (Gross)A(MW)162Input (Greater than 50 MW)Retrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Gross Heat RateC(Btu/kWh)11982InputSO2RateD (lb/MMBtu) 0.461 InputType of CoalEPRBInputCoal FactorF1.05Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate FactorG1.20C/10000Heat InputH(Btu/hr)1.94E+09A*C*1000Lime Rate K (ton/hr) 0.61(0.6702*D2+13.42*D)*A*G/2000Waste Rate L (ton/hr) 1.41(0.8016*D2+31.1917*D)*A*G/2000Aux Power M (%) 1.64(0.000547*D2+0.00649*D+1.3)*F*GMakeup Water Rate N (1000 gph) 11.29(0.04898*D2+0.5925*D7+55.11)*A*F*G/1000Lime CostP($/ton)95.00Water Disposal CostQ($/ton)30.00Aux Power CostR($/kW)0.06Makeup Water CostS($/1000)1.00Operating Labor RateT($/hr)60Labor cost including all benefitsCosts are all based on 2009 dollarsCapital Cost CalculationInclude: equipment, installation, buildings, foundations, electrical, and retrofit difficulty.BMR ($) = If A>600 then (A*92000) else 566000*(A0.716)*(F*G)0.6*(D/4)0.01$24,282,000 Base module absorber island costBMF ($) = If A> 600 then (A*48700) else 300000*(A0.716)*B*(D*G)0.2$10,178,000 Base module reagent preparation and waste recycle/handling costBMB ($) = If A>600 then (A*129900) else 799000*(A0.716)*B*(F*G)0.4$33,454,000 Base module balance of plant cost including ID or booster fans, piping, ductwork, electrical, etc..BM ($) = BMR + BMF + BMB$67,914,000Total bare module cost including retrofit factorBM ($/kW)$419Base module cost per kWTotal Project CostA1 = 10% of BM$6,791,000Engineering and construction management costsA2 = 10% of BM$6,791,000Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 10% of BM$6,791,000Contractor profit and feesCECC($) - excludes owner's costs = BM+A1+A2+A3$88,287,000Capital, engineering and construction cost subtotalCECC($/kW) - excludes owner's costs =$545Capital, engineering and construction cost subtotal per kWB1 = %5 of CECC$4,414,000Owners costs including "home office" costs (owner engineering, management, and procurement activities)TPC ($) - includes owner's costs = CECC + B1$92,701,000Total project cost without AFUDCTPC ($/kw) - includes owner's costs =$572Total project cost per kW without AFUDCB2 = 10% of (CECC + B1)$9,270,000AFUDC (based on 3 year enginering and construction cycle)TPC ($) - includes owner's costs and AFUDC = CECC + B1 + B2$101,971,000Total project costTPC ($/kw) - includes owner's costs and AFUDC ($/kW) =$629Total project cost per kWCorette SDA FGD Capital Cost Estimate WorksheetVariableDesignationUnitsValueCalculationUnit Size (Gross)A(MW)162Input (Greater than 50 MW)Retrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Gross Heat RateC(Btu/kWh)11982InputSO2RateD (lb/MMBtu) 0.461345067 InputType of CoalEPRBInputCoal FactorF1.05Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate FactorG1.20C/10000Heat InputH(Btu/hr)1.94E+09A*C*1000Lime Rate K (ton/hr) 0.61(0.6702*D2+13.42*D)*A*G/2000Waste Rate L (ton/hr) 1.41(0.8016*D2+31.1917*D)*A*G/2000Aux Power M (%) 1.64(0.000547*D2+0.00649*D+1.3)*F*GMakeup Water Rate N (1000 gph) 11.29(0.04898*D2+0.5925*D7+55.11)*A*F*G/1000Lime CostP($/ton)95.00Water Disposal CostQ($/ton)30.00Aux Power CostR($/kW)0.06Makeup Water CostS($/1000 gal)1.00Operating Labor RateT($/hr)60.00Labor cost including all benefitsCosts are all based on 2009 dollarsFixed O&M CostFOMO ($/kW yr) = (8 additional operators)*2080*T/(A*1000)$6.163Fixed O&M additional operating labor costsFOMM ($/kW yr) = BM*0.015/(B*A*1000)$6.288Fixed O&M maintenance material and labor costsFOMA ($/kW yr) = 0.03*(FOMO+0.4*FOMM)$0.260Fixed O&M additional addministrative labor costsFOM ($/kW yr) = FOMO + FOMM$12.712Total Fixed O&M costsVariable O&MVOMR ($/MWh) = K*P/A$0.360Variable O&M costs for lime reagentVOMW ($/MWh)= L*Q/A$0.262Variable O&M costs for waste disposalVOMP ($/MWh) = M*R*10$0.984Variable O&M costs for additional auxillary power required including additional fan powerVOMM ($/MWh) = N*S/A$0.070Variable O&M costs for makeup waterVOM ($/MWh) = VOMR + VOMW + VOMP + VOMM$1.676Total variable O&M costsSTATEFACILITY_NAMEORISPLCODE UNIT ID OP YEARSUM OPTIMENUMMONTHSREPORTEDGROSSLOAD(MWh)SO2 MASS SO2 RATE NOX RATENOXMASSHEAT INPUT(MMBtu)HEATINPUT(MMBtu/hr)MTJ E Corette2187220087,314121,086,4772,8170.4720.2781,65811,925,7341,631MTJ E Corette2187220097,824121,141,2922,8320.4550.2611,64112,445,1521,591MTJ E Corette2187220107,401121,025,5972,5190.4570.2821,57511,037,7061,491Averages7,5131,084,4552,7230.4610.2741,62511,802,8641,571CAMD Data