SCR Capital Costs

Description Formula1 Value

Boiler Size (MMBtu/hr) QB 3982

NOx Removal Efficiency (%) ηNOx 75.0%

Cost Year 2010

Total Direct Capital Costs ($)2

A $55,578,137

Indirect Installation Costs

 General Facilities ($) 0.05 x A $2,778,907

 Engineering and Home Office Fees ($) 0.10 x A $5,557,814

 Process Contingency ($) 0.05 x A $2,778,907

Total Indirect Installation Costs ($) B = A × (0.05 + 0.10 + 0.05) $11,115,627

Project Contingency ($) C = (A + B)× 0.15 $10,004,065

Total Plant Costs ($) D = A + B+ C $76,697,829

Allowance for Funds During Construction ($) E = 0 (Assumed for SCR) $0

Royalty Allowance ($) F = 0 (Assumed for SCR) $0

Preproduction Cost ($) G = 0.02 × (D + E) $1,533,957

Inventory Capital* ($) H = Vol reagent (gal) × Cost reagent ($/gal) $32,275

Initial Catalyst and Chemicals ($) I = 0 (Assumed for SCR) $0

Total Capital Investment (TCI) ($) TCI = D + E + F + G + H + I $78,264,060

Total Capital Investment (TCI) ($) Per kW $235

SCR Annual Costs

Direct Annnual Costs

 Maintenance Cost Eq. 2.46 $1,173,961

 Reagent Cost Eq. 2.47 $641,136

 Electricity Cost Eq. 2.49 $395,582

 Catalyst Cost Eq. 2.50 $253,566

Total Direct Annual Costs DAC (Eq. 2.45) $2,464,244

Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $7,388,127

Total Annual Costs TAC = DAC + IAC (Eq. 2.56) $9,852,372

SOFA Captial Costs

Total Captial Investment for SOFA ($)3

TCI $4,507,528

Total Capital Investment for SOFA ($/kW) Per kW $14

SOFA Annual Costs

Total Direct Annual Costs4 DAC $664,884

Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $425,511

Total Annual Costs TAC = DAC + IAC (Eq. 2.56) $1,090,395

Cost Effectivness

SOFA NOx Removed (tons/yr) Eq. 2.57 1,432

SOFA Cost Effectiveness ($/ton removed) Eq. 2.58 $761

SCR NOx Removed (tons/yr) Eq. 2.57 1,993

SCR Cost Effectiveness ($/ton removed) Eq. 2.58 $4,943

SCR+SOFA NOx Removed (tons/yr) Eq. 2.57 3,425

SCR+SOFA Cost Effectiveness ($/ton removed) Eq. 2.58 $3,195

1

Taken from "EPA Control Cost Manual", Section 4.2, Chapter 2, October 2000.

Colstrip Unit 1 BART Cost Analysis - SCR plus SOFA

2Direct capital costs for SCR were derived from "IPM Model – Revisions to Cost and Performance for APC 

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

3,4Direct capital costs and direct annual costs for SOFA were taken from "Addendum to PPL Montana's Colstrip 

BART Report," TRC for PPL, June 2008. Direct capital costs were escalated to 2010 using the CEPCI.

(2010 Dollars)
Colstrip Unit 1 SCR Capital Cost Estimate Worksheet

Variable Designation Units Value Calculation

Unit Size (Gross) A (MW) 333 InputRetrofit Factor B 1 Input (An "average" retrofit has a factor = 1.0)Heat Rate C (Btu/kWh) 11958 InputNOx Rate D (lb/MMBtu) 0.2 Input

SO2 Rate E (lb/MMBtu) 1.8 Input

Type of Coal F PRB InputCoal Factor G 1.05 Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate Factor H 1.1958 C/10000Heat Input I (Btu/hr) 3.98E+09 A*C*1000Capacity Factor J (%) 76.2 InputNOx Removal Efficiency K (%) 75.0 Input

NOx Removal Factor L 0.9375 K/80

NOx Removed M (lb/hr) 597 D*I/106*K/100

Costs are all based on 2009 dollarsCapital Cost Calculation

 Include: equipment, installation, buildings, foundations, electrical, and retrofit difficulty. BMR ($) = 180000*(B)*(L)0.2*(A*G*H)0.92 $45,841,000 SCR (inlet ductwork, reactor, bypass) island cost BMF ($) = 410000*(M)0.25 $2,027,000 Base reagent preparation cost

 BMA ($) = If E >= 3 then 65000*(B)*(A*G*H)0.78; else 0 $0 Air heater modification / SO3 control (bituminous only & > 3 lb/MMbtu)

 BMB ($) = 380000*(B)*(A*G*H)0.42 $4,794,000 ID or booster fans & auxiliary power modification costs

 BM ($) = BMR + BMF + BMA + BMB $52,662,000 Total bare module cost including retrofit factor BM ($/kW) $158 Base cost per kW

Total Project Cost

 A1 = 10% of BM $5,266,000 Engineering and construction management costs A2 = 10% of BM $5,266,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $5,266,000 Contractor profit and fees

 CECC($) = BM+A1+A2+A3 $68,460,000 Capital, engineering and construction cost subtotal CECC($/kW) = $206 Capital, engineering and construction cost subtotal per kW

 B1 = 5% of CECC $3,423,000 Owners costs including "home office" costs (owners engineering, managem B2 = 6% of (CECC + B1) $4,313,000 AFUDC (based on approximately 3% per year for a 2 year engineering and co

 TPC ($) = CECC + B1 + B2 $76,196,000 Total project cost TPC ($/kW) = $229 Total project cost per kW

Work Sheet adpapted from "IPM Model‐Revisions to Cost And Performance for APC Technologies‐SCR Cost Development Methodology‐FINAL", August 2010 Project 12301‐007prepared by Sargent & Lundy, LLC
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsNew or Retrofit? Retrofit SourceGeneration capacity (MW gross) 333 TRC BART Report Addendum for PPL, p. 1‐1 (6/25/2008)SCR bypass included? No AssumedFuel High Heating Value (Btu/lb) 8,458 From EIA for 1999Maximum Fuel Consumption Rate (lb/hr) 470,797 Calculated from 3,982 MMBtu/hr from TAverage Annual Fuel Consumption (lb) 3.14E+09 Calcuated from 26,578,089 MMBtu/yr averagNumber of SCR Operating Days 365 AssumedPlant Capacity Factor 76% Based on average annual gross load for 2008‐2010 from CAMDUncontrolled NOx Concentration (lb/MMBtu) 0.308 Average for 2008‐2010 from CAMDSOFA Total Capital Cost $ 4,507,528 TRC BART Report for PPL (6/25/2008) adjusted using 2010 CEPCISOFA Total Annual Cost $ 1,090,395 TRC BART Report for PPL (6/25/2008) adjusted using 2010 CEPCILNB/CCOFA/SOFA outlet = SCR inlet NOx Concentration (lb/MMBtu) 0.200Required Controlled NOx Concentration (lb/MMBtu) 0.05 IPM Base Case v4.10 Documentation, Appendix 5‐2A (August 2010)Acceptable Ammonia Slip (ppm) 2.0 OAQPS Control Cost ManualFuel Volume Flow Rate (ft3/min/MMBtu/hr) 516 OAQPS Control Cost ManualFuel Sulfur Content 0.68% TRC BART Report for PPL, p. 2‐1 (8/07/2007)Fuel Ash Content 10.10% From EIA for 1999Number of SCR reactor chambers 2 AssumedNumber of spare catalyst layers 1 AssumedASR 1.05 EPA Control Cost ManualStored Ammonia Concentration 29% EPA Control Cost ManualReagent Molecular Weight (g/mole) 17.03 EPA Control Cost ManualReagent Density (lb/ft3 @ 60F) 56.0 EPA Control Cost ManualReagent Specific Volume (gal/ft3) 7.481 EPA Control Cost ManualNOx Molecular Weight (g/mole) 46.01 EPA Control Cost ManualNumber of Days of Storage for Ammonia 14 EPA Control Cost ManualPressure Drop for SCR Ductwork H2O") 3 EPA Control Cost ManualPressure Drop for each Catalyst Layer (H2O") 1 EPA Control Cost ManualTemperature at SCR Inlet (degrees F) 700 TRC BART Report Addendum for PPL, Table 5.3‐3 (6/25/2008)Equipment Life (years) 20 EPA Control Cost ManualAnnual Interest Rate 7% EPA Control Cost ManualInflation Since 1998 1.41 CEPCI 2010/CEPCI 1998Catalyst Cost, Initial ($/ft3) $ 170 calculated from $ 6,000 Cichanowicz (Jan Catalyst Cost, Replacement ($/ft3) $ 170 calculated from $ 6,000 Cichanowicz (Jan Electrical Power Cost ($/kWh) $ 0.045 Typical29% Aqeous Ammonia ($/lb) $ 0.120 calculated from $ 240 Fuel Tech (Feb 2, Operating Life of Catalyst (hours) 24,000 EPA Control Cost ManualNatural gas unit cost ($/mcf) $ 4.98 EIA 2010 price forecastNatural gas for reheat (mcf) NA
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCRBoiler Calculations (from Section 4.2 of EPA Control Cost Manual)

2.3 QB = HVm‐dotfuel

QB = 8,458 Btu/lb * 470,797 lb/hr

QB = 3,982 Btu/hr

2.7 CFPlant = actual heat input/maximum annual heat input

CFPlant = 76%

2.8 CFSCR = tSCR/365 days

CFSCR = 365 days/ 365 days

CFSCR = 100%

2.6 CFTotal = CFPlant x CFSCR

CFTotal = 76% * 100%

CFTotal = 76%

2.12 qfluegas = qfuelQB(460+T)/(460+700oF)nSCR

qfluegas = 516 ft3/min/(mmBtu/hr)* 3982 mmBtu/hr*( 460 + 700 )/( 460 + 700 )/ 2

qfluegas = 1,027,356 acfm

2.9 ηNOx = (NOxin – NOxout) / NOxin

ηNOx = ( 0.20 lb/mmBtu ‐ 0.05 lb/mmBtu)/ 0.20 lb/mmBtu

ηNOx = 75%

Uncontrolled NOx emissions 4,090 tpy

2.57 NOx Removed = NOxinηNOxQBtop

SOFA NOx Removed = 0.31 * 35% * 3,982 * 6675 / 2000SOFA NOx Removed = 1432 tpySCR NOx Removed = 0.20 * 0.75 * 3,982 * 6675 / 2000SCR NOx Removed = 1993 tpyOverall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc

( 0.31 ‐ 0.05 )/ 0.31 = 84%

Overall NOx removed = 3,425 tpyControlled NOx emissions = 664 tpy
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCRSCR Reactor Calculations (from Section 4.2 of EPA Control Cost Manual)

2.19 Volcatalyst = 2.81 x QB x ηadj x Slipadj x NOxadj x Sadj x Tadj/NSCR

Volcatalyst = 2.81 * 3982 = 11189.42

2.2 ηadj = 0.2869 + (1.058 x η)

ηadj = 0.2869 +( 1.058 * 0.75 )

ηadj = 1.080

2.22 Slipadj = 1.2835 – (0.0567 x Slip)

Slipadj = 1.2835 ‐ ( 0.057 * 2 )

Slipadj = 1.170

2.21 NOxadj = 0.8524 + (0.3208 x NOxin)

NOxadj = 0.8524 + ( 0.321 * 0.20 )

NOxadj = 0.917

2.23 Sadj = 0.9636 + (0.0455 x S)

Sadj = 0.9636 + ( 0.046 * 0.68 )

Sadj = 0.995

2.24 Tadj = 15.16 – (0.03937 x T) + (2.74 x 10‐5 x T2)

Tadj = 15.16 ‐ ( 0.039 * 700 ) + 2.74E‐05 * 490000

Tadj = 1.027Volcatalyst = 6,621 ft3 each =187.6m3 each

2.25 Acatalyst = qfluegas/(16 ft/sec x 60 sec/min)

Acatalyst = 1,027,356 /( 16 * 60 )

Acatalyst = 1,070 ft2

2.26 ASCR = 1.15 x Acatalyst

ASCR = 1.15 * 1070

ASCR = 1,231 ft2

2.27 l = w = ASCR1/2

l = w = 35.1 ft

2.28 nlayer = Volcatalyst/(h’layer x Acatalyst)

nlayer = 6,621 /( 3.1 * 1070 )

nlayer = 2.0

nlayer = 2.0

2.29 hlayer = [Volcatalyst/(nlayer x Acatalyst)] + 1

hlayer = 6,621 /( 2.0 * 1070 ) + 1

hlayer = 4.1

2.3 ntotal = nlayer + nempty

ntotal = 2 + 1

ntotal = 3

2.31 hSCR = ntotal(c1 + hlayer) + c2

hSCR = 3 * ( 7 + 4.1 ) + 9

hSCR = 42 ft
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCRSCR Bypass Calculations (from Section 4.2 of EPA Control Cost Manual)2.41 f(bypass) = $0/(mmBtu/hr) for no bypass

f(bypass) = $ ‐ /mmBtu/hr * inflation = $ ‐ per Btu/hrf(bypass) = $0 each SCR reactor

$0 all SCR reactors
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCRInitial Catalyst Calculations (from Section 4.2 of EPA Control Cost Manual)2.43 f(Volcatalyst) = VolcatalystCCinitial

f(Volcatalyst) = 6621 * 170

f(Volcatalyst) = $1,125,819 each SCR reactor

$2,251,637 all SCR reactors
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCRReagant Calculations (from Section 4.2 of EPA Control Cost Manual)

2.32 m-dotreagent = NOxinQBASRηNOxMreagent/MNOx

m-dotreagent = 0.20 * 3982 * 1.05 * 75% * 17.03 / 46.01

m-dotreagent = 232 lb/hr

2.33 m-dotsol = m-dotreagent/Csol

m-dotsol = 232 / 0.29

m-dotsol = 800 lb/hr

2.34 qsol = (m-dotvol/ρsol)Vsol

qsol = 800 * 7.481 / 56

qsol = 107 gph

2.35 Tank Volume = qsolt

Tank Volume = 107 * 14 * 24Tank Volume = 35,930 gal

2.47 Annual Reagent Cost = qreagentCostreagenttop

2.47a top = CFtotal8760hr/yr

top = 76% * 8760

top = 6675

Annual Reagent Cost = 800 * 6675 * 0.120Annual Reagent Cost = $ 641,136
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCRMaintenance Cost Calculations (from Section 4.2 of EPA Control Cost Manual)

2.46 Annual Maintenance Cost = 0.015 * TCI

Annual Maintenance Cost = 0.015 * 78,264,060 $ 

Annual Maintenance Cost = $ 1,173,961
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCRElectricity Cost Calculations (from Section 4.2 of EPA Control Cost Manual)

2.49 Annual Electricity Cost = Power (Costelect)top2.48 Power = 0.105QB[NOxinηNOx + 0.5(ΔPduct + ntotalΔPcatalyst)]

Power = 0.105 * 3982 *( 0.20 * 75% + 0.50 * ( 3 + 3 * 1 ))Power = 1317 kW

Annual Electricity Cost = 1317 * 6675 * 0.045Annual Electricity Cost = $ 395,582
PPL Colstrip Unit 1

Modified from OAQPS Control Cost Manual Section 4.2, SCRCatalyst Replacement Cost Calculations (from Section 4.2 of EPA Control Cost Manual)

2.51 Annual Catalyst Replacement Cost = (Catalyst Replacement Cost)FWF

2.5 Catalyst Replacement Cost = nSCRVolcatalystCCreplace/Rlayer

Catalyst Replacement Cost = 2 * 6,621 * 170.0 / 2Catalyst Replacement Cost = $ 1,125,819

2.52 FWF = i{1/[(1+i)Y-1]}2.53 Y = hcatalyst/hyear

Y = 24000 /( 76% * 8760 )Y = 3.60

FWF = 0.07 *( 1 /( 1 + 0.07 )^ 4 - 1 )FWF = 0.23

Annual Catalyst Cost = $ 253,566
STATE

FACILITY

_NAME

ORISPL 

CODE UNIT ID OP YEAR

SUM OP 

TIME

NUM 

MONTHS

REPORTED

GROSS 

LOAD 

(MWh)

SO2 

MASS

SO2 

RATE

NOX 

RATE

NOX 

MASS CO2 MASS

HEAT 

(MM

MT Colstrip 6076 1 2008 8,198 12 2,464,601 5,075 0.375 0.316 4,317 2,808,902 27,06

 

MT Colstrip 6076 1 2009 7,519 12 2,417,112 5,885 0.465 0.304 3,854 2,654,975 25,31

 

MT Colstrip 6076 1 2010 8,160 12 2,563,419 5,684 0.416 0.303 4,138 2,868,837 27,35

 

Averages 7,959 2,481,711 5,548 0.418 0.308 4,103 2,777,571 26,57

 

MT Colstrip 6076 2 2008 7,109 12 2,135,046 4,241 0.352 0.310 3,744 2,500,303 24,08

 

MT Colstrip 6076 2 2009 8,590 12 2,573,748 6,152 0.444 0.297 4,117 2,908,431 27,73

 

MT Colstrip 6076 2 2010 7,964 12 2,406,886 5,141 0.389 0.319 4,224 2,771,472 26,42

 

Averages 7,888 2,371,894 5,178 0.395 0.309 4,028 2,726,735 26,07

 

CAMD Emissions Data