FGD Capital Costs

Description Formula1Value

Boiler Size (MMBtu/hr) QB 1941

SO2 Removal Efficiency (%) ηNOx 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 materials $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 Worksheet

Variable Designation Units Value Calculation

Unit Size (Gross) A (MW) 162 Input (Greater than 50 MW)Retrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Gross Heat Rate C (Btu/kWh) 11982 InputSO2 Rate D (lb/MMBtu) 0.461 InputType of Coal E PRB InputCoal Factor F 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate Factor G 1.20 C/10000Heat Input H (Btu/hr) 1.94E+09 A*C*1000Lime Rate K (ton/hr) 0.61 (0.6702*D2+13.42*D)*A*G/2000

Waste 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*G

Makeup Water Rate N (1000 gph) 11.29 (0.04898*D2+0.5925*D7+55.11)*A*F*G/1000

Lime Cost P ($/ton) 95.00Water Disposal Cost Q ($/ton) 30.00Aux Power Cost R ($/kW) 0.06Makeup Water Cost S ($/1000) 1.00Operating Labor Rate T ($/hr) 60 Labor cost including all benefits

Costs are all based on 2009 dollars

Capital Cost Calculation Include: 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 cost

 BMF ($) = If A> 600 then (A*48700) else 300000*(A0.716)*B*(D*G)0.2 $10,178,000 Base module reagent preparation and waste recycle/handling cost BMB ($) = 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, 

 BM ($) = BMR + BMF + BMB $67,914,000 Total bare module cost including retrofit factor BM ($/kW) $419 Base module cost per kWTotal Project Cost A1 = 10% of BM $6,791,000 Engineering and construction management costs A2 = 10% of BM $6,791,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $6,791,000 Contractor profit and fees CECC($) - excludes owner's costs = BM+A1+A2+A3 $88,287,000 Capital, engineering and construction cost subtotal CECC($/kW) - excludes owner's costs = $545 Capital, engineering and construction cost subtotal per kW B1 = %5 of CECC $4,414,000 Owners costs including "home office" costs (owner engineering, management, and procure TPC ($) - includes owner's costs = CECC + B1 $92,701,000 Total project cost without AFUDC TPC ($/kw) - includes owner's costs = $572 Total project cost per kW without AFUDC B2 = 10% of (CECC + B1) $9,270,000 AFUDC (based on 3 year enginering and construction cycle) TPC ($) - includes owner's costs and AFUDC = CECC + B1 + B2 $101,971,000 Total project cost TPC ($/kw) - includes owner's costs and AFUDC ($/kW) = $629 Total project cost per kW
Corette SDA FGD Capital Cost Estimate Worksheet

Variable Designation Units Value Calculation

Unit Size (Gross) A (MW) 162 Input (Greater than 50 MW)Retrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Gross Heat Rate C (Btu/kWh) 11982 InputSO2 Rate D (lb/MMBtu) 0.461345067 InputType of Coal E PRB InputCoal Factor F 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate Factor G 1.20 C/10000Heat Input H (Btu/hr) 1.94E+09 A*C*1000Lime Rate K (ton/hr) 0.61 (0.6702*D2+13.42*D)*A*G/2000

Waste 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*G

Makeup Water Rate N (1000 gph) 11.29 (0.04898*D2+0.5925*D7+55.11)*A*F*G/1000

Lime Cost P ($/ton) 95.00Water Disposal Cost Q ($/ton) 30.00Aux Power Cost R ($/kW) 0.06Makeup Water Cost S ($/1000 gal) 1.00Operating Labor Rate T ($/hr) 60.00 Labor cost including all benefits

Costs are all based on 2009 dollars

Fixed O&M Cost FOMO ($/kW yr) = (8 additional operators)*2080*T/(A*1000) $6.163 Fixed O&M additional operating labor costs FOMM ($/kW yr) = BM*0.015/(B*A*1000) $6.288 Fixed O&M maintenance material and labor costs FOMA ($/kW yr) = 0.03*(FOMO+0.4*FOMM) $0.260 Fixed O&M additional addministrative labor costs FOM ($/kW yr) = FOMO + FOMM $12.712 Total Fixed O&M costsVariable O&M VOMR ($/MWh) = K*P/A $0.360 Variable O&M costs for lime reagent VOMW ($/MWh)= L*Q/A $0.262 Variable O&M costs for waste disposal VOMP ($/MWh) = M*R*10 $0.984 Variable O&M costs for additional auxillary power requi VOMM ($/MWh) = N*S/A $0.070 Variable O&M costs for makeup water VOM ($/MWh) = VOMR + VOMW + VOMP + VOMM $1.676 Total variable O&M costs
STATE

FACILITY_

NAME

ORISPL 

CODE UNIT ID OP YEAR

SUM OP 

TIME

NUM 

MONTHS 

REPORTED

GROSS 

LOAD 

(MWh) SO2 MASS SO2 RATE NOX RATE

M

MT J E Corette 2187 2 2008 7,314 12 1,086,477 2,817 0.472 0.278 MT J E Corette 2187 2 2009 7,824 12 1,141,292 2,832 0.455 0.261 MT J E Corette 2187 2 2010 7,401 12 1,025,597 2,519 0.457 0.282 

Averages 7,513 1,084,455 2,723 0.461 0.274 

CAMD Data