# SCR Capital Costs

Description Formula 1 

# Value

Boiler Size (MMBtu/hr) Q B 

# 3982

NOx Removal Efficiency (%) η NOx 

# 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 (A ssumed 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 fo r 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 Costs 4 

# DAC $664,884

Indirect Annual Costs IDAC = TCI x CRF (Eq. 2.54) $42 5,511

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

2 

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

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

3,4 

# Direct capital costs and direct annual costs for SO FA were taken from "Addendum to PPL Montana's Colst rip

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

# (2010 Dollars)Colstrip Unit 1 SCR Capital Cost Estimate WorksheetVariable Designation Units Value CalculationUnit Size (Gross)A(MW)333InputRetrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Heat RateC(Btu/kWh)11958InputNOxRateD (lb/MMBtu) 0.2 InputSO2RateE (lb/MMBtu) 1.8 InputType of CoalFPRBInputCoal FactorG1.05Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate FactorH1.1958C/10000Heat InputI(Btu/hr)3.98E+09A*C*1000Capacity FactorJ(%)76.2InputNOxRemoval EfficiencyK (%) 75.0 InputNOxRemoval FactorL 0.9375 K/80NOxRemovedM (lb/hr) 597D*I/106*K/100Costs are all based on 2009 dollarsCapital Cost CalculationInclude: equipment, installation, buildings, foundations, electrical, and retrofit difficulty.BMR ($) = 180000*(B)*(L)0.2*(A*G*H)0.92$45,841,000 SCR (inlet ductwork, reactor, bypass) island costBMF ($) = 410000*(M)0.25$2,027,000 Base reagent preparation costBMA ($) = If E >= 3 then 65000*(B)*(A*G*H)0.78; else 0$0Air heater modification / SO3control (bituminous only & > 3 lb/MMbtu)BMB ($) = 380000*(B)*(A*G*H)0.42$4,794,000 ID or booster fans & auxiliary power modification costsBM ($) = BMR + BMF + BMA + BMB$52,662,000Total bare module cost including retrofit factorBM ($/kW)$158Base cost per kWTotal Project CostA1 = 10% of BM$5,266,000Engineering and construction management costsA2 = 10% of BM$5,266,000Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 10% of BM$5,266,000Contractor profit and feesCECC($) = BM+A1+A2+A3$68,460,000Capital, engineering and construction cost subtotalCECC($/kW) =$206Capital, engineering and construction cost subtotal per kWB1 = 5% of CECC$3,423,000Owners costs including "home office" costs (owners engineering, management, and procurement activities)B2 = 6% of (CECC + B1)$4,313,000AFUDC (based on approximately 3% per year for a 2 year engineering and construction cycle)TPC ($) = CECC + B1 + B2$76,196,000Total project costTPC ($/kW) =$229Total project cost per kWWork Sheet adpapted from "IPM Model‐Revisions to Cost And Performance for APC Technologies‐SCR Cost Development Methodology‐FINAL", August 2010 Project 12301‐007, Perrin Quarles Associates, Inc.,prepared by Sargent & Lundy, LLCPPL Colstrip Unit 1Modified from OAQPS Control Cost Manual Section 4.2, SCRGiven/AssumptionsNew or Retrofit?RetrofitSourceGeneration capacity (MW gross)333TRC BART Report Addendum for PPL, p. 1‐1 (6/25/2008)SCR bypass included?NoAssumedFuel High Heating Value (Btu/lb)8,458From EIA for 1999Maximum Fuel Consumption Rate (lb/hr)470,797Calculated from3,982MMBtu/hr from TRC Report for PPL (6/25/2008)Average Annual Fuel Consumption (lb)3.14E+09Calcuated from26,578,089MMBtu/yr average for 2008‐2010 from CAMDNumber of SCR Operating Days365AssumedPlant Capacity Factor76%Based on average annual gross load for 2008‐2010 from CAMDUncontrolled NOx Concentration (lb/MMBtu)0.308Average for 2008‐2010 from CAMDSOFA Total Capital Cost4,507,528$TRC BART Report for PPL (6/25/2008) adjusted using 2010 CEPCISOFA Total Annual Cost1,090,395$TRC BART Report for PPL (6/25/2008) adjusted using 2010 CEPCILNB/CCOFA/SOFA outlet = SCR inlet NOx Concentration (lb/MMBtu)0.200Required Controlled NOx Concentration (lb/MMBtu)0.05IPM Base Case v4.10 Documentation, Appendix 5‐2A (August 2010)Acceptable Ammonia Slip (ppm)2.0OAQPS Control Cost ManualFuel Volume Flow Rate (ft3/min/MMBtu/hr)516OAQPS Control Cost ManualFuel Sulfur Content0.68%TRC BART Report for PPL, p. 2‐1 (8/07/2007)Fuel Ash Content10.10%From EIA for 1999Number of SCR reactor chambers2AssumedNumber of spare catalyst layers1AssumedASR1.05EPA Control Cost ManualStored Ammonia Concentration29%EPA Control Cost ManualReagent Molecular Weight (g/mole)17.03EPA Control Cost ManualReagent Density (lb/ft3 @ 60F)56.0EPA Control Cost ManualReagent Specific Volume (gal/ft3)7.481EPA Control Cost ManualNOx Molecular Weight (g/mole)46.01EPA Control Cost ManualNumber of Days of Storage for Ammonia14EPA Control Cost ManualPressure Drop for SCR Ductwork H2O")3EPA Control Cost ManualPressure Drop for each Catalyst Layer (H2O")1EPA Control Cost ManualTemperature at SCR Inlet (degrees F)700TRC BART Report Addendum for PPL, Table 5.3‐3 (6/25/2008)Equipment Life (years)20EPA Control Cost ManualAnnual Interest Rate7%EPA Control Cost ManualInflation Since 19981.41CEPCI 2010/CEPCI 1998Catalyst Cost, Initial ($/ft3)170$calculated from6,000$Cichanowicz (Jan 2010)Catalyst Cost, Replacement ($/ft3)170$calculated from6,000$Cichanowicz (Jan 2010)Electrical Power Cost ($/kWh)0.045$Typical29% Aqeous Ammonia ($/lb)0.120$calculated from240$Fuel Tech (Feb 2, 2012)Operating Life of Catalyst (hours)24,000EPA Control Cost ManualNatural gas unit cost ($/mcf)4.98$EIA 2010 price forecastNatural gas for reheat (mcf)NAPPL Colstrip Unit 1Modified from OAQPS Control Cost Manual Section 4.2, SCRBoiler Calculations (from Section 4.2 of EPA Control Cost Manual)2.3 QB= HVm‐dotfuelQB= 8,458Btu/lb * 470,797lb/hrQB= 3,982Btu/hr2.7 CFPlant= actual heat input/maximum annual heat inputCFPlant =76%2.8 CFSCR= tSCR/365 daysCFSCR= 365 days/ 365 daysCFSCR= 100%2.6 CFTotal= CFPlantx CFSCRCFTotal= 76% * 100%CFTotal= 76%2.12 qfluegas= qfuelQB(460+T)/(460+700oF)nSCRqfluegas= 516 ft3/min/(mmBtu/hr)* 3982 mmBtu/hr*( 460 + 700 )/( 460 + 700 )/ 2qfluegas= 1,027,356acfm2.9 ηNOx= (NOxin– NOxout) / NOxinηNOx= ( 0.20 lb/mmBtu ‐ 0.05 lb/mmBtu)/ 0.20 lb/mmBtuηNOx= 75%Uncontrolled NOx emissions4,090tpy2.57NOx Removed = NOxinηNOxQBtopSOFA NOx Removed =0.31*35%*3,982*6675/2000SOFA NOx Removed =1432tpySCR NOx Removed =0.20*0.75*3,982*6675/2000SCR NOx Removed =1993tpyOverall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc(0.31‐0.05)/0.31=84%Overall NOx removed =3,425tpyControlled NOx emissions =664tpyPPL Colstrip Unit 1Modified 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 QBx ηadjx Slipadjx NOxadjx Sadjx Tadj/NSCRVolcatalyst= 2.81 * 3982 = 11189.422.2 ηadj= 0.2869 + (1.058 x η)ηadj= 0.2869 +( 1.058 * 0.75 )ηadj= 1.0802.22 Slipadj= 1.2835 – (0.0567 x Slip)Slipadj= 1.2835 ‐ ( 0.057 * 2 )Slipadj= 1.1702.21 NOxadj= 0.8524 + (0.3208 x NOxin)NOxadj= 0.8524 + ( 0.321 * 0.20 )NOxadj= 0.9172.23 Sadj= 0.9636 + (0.0455 x S)Sadj= 0.9636 + ( 0.046 * 0.68 )Sadj= 0.9952.24 Tadj= 15.16 – (0.03937 x T) + (2.74 x 10‐5x T2)Tadj= 15.16 ‐ ( 0.039 * 700 ) + 2.74E‐05 * 490000Tadj= 1.027Volcatalyst= 6,621ft3 each =187.6m3 each2.25 Acatalyst= qfluegas/(16 ft/sec x 60 sec/min)Acatalyst= 1,027,356/( 16 * 60 )Acatalyst= 1,070ft22.26 ASCR= 1.15 x AcatalystASCR= 1.15 * 1070ASCR= 1,231ft22.27 l = w = ASCR1/2l = w =35.1ft2.28 nlayer= Volcatalyst/(h’layerx Acatalyst)nlayer= 6,621/( 3.1 * 1070 )nlayer= 2.0nlayer= 2.02.29 hlayer= [Volcatalyst/(nlayerx Acatalyst)] + 1hlayer= 6,621/( 2.0 * 1070 ) + 1hlayer= 4.12.3 ntotal= nlayer+ nemptyntotal= 2 + 1ntotal= 32.31 hSCR= ntotal(c1+ hlayer) + c2hSCR= 3 * ( 7 + 4.1 ) + 9hSCR= 42 ftPPL Colstrip Unit 1Modified from OAQPS Control Cost Manual Section 4.2, SCRSCR Bypass Calculations (from Section 4.2 of EPA Control Cost Manual)2.41f(bypass) = $0/(mmBtu/hr) for no bypassf(bypass) =‐$/mmBtu/hr * inflation =‐$per Btu/hrf(bypass) =$0each SCR reactor$0all SCR reactorsPPL Colstrip Unit 1Modified from OAQPS Control Cost Manual Section 4.2, SCRInitial Catalyst Calculations (from Section 4.2 of EPA Control Cost Manual)2.43 f(Volcatalyst) = VolcatalystCCinitialf(Volcatalyst) = 6621 * 170f(Volcatalyst) = $1,125,819 each SCR reactor$2,251,637all SCR reactors**PPL Colstrip Unit 1 Modified from OAQPS Control Cost Manual Section 4.2, SCR** **Reagant Calculations (from Section 4.2 of EPA Control Cost Manual)**2.32 m-dotreagent= NOxinQBASRηNOxMreagent/MNOxm-dotreagent= 0.20 * 3982 * 1.05 ***75%*** 17.03 / 46.01m-dotreagent= 232 lb/hr2.33 m-dotsol= m-dotreagent/Csolm-dotsol= 232 / 0.29m-dotsol= 800 lb/hr2.34 qsol= (m-dotvol/ρsol)Vsolqsol= 800 * 7.481 / 56qsol= 107 gph2.35 Tank Volume = qsoltTank Volume = 107 * 14 * 24Tank Volume = 35,930gal2.47 Annual Reagent Cost = qreagentCostreagenttop2.47a top= CFtotal8760hr/yrtop= 76% * 8760top= 6675Annual Reagent Cost = 800 * 6675 * 0.120Annual Reagent Cost =**641,136 $** **PPL Colstrip Unit 1 Modified from OAQPS Control Cost Manual Section 4.2, SCR** **Maintenance Cost Calculations (from Section 4.2 of EPA Control Cost Manual)**2.46 Annual Maintenance Cost = 0.015 * TCIAnnual Maintenance Cost = 0.015 * 78,264,060$Annual Maintenance Cost =**1,173,961 $** **PPL Colstrip Unit 1 Modified from OAQPS Control Cost Manual Section 4.2, SCR** **Electricity 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 =1317kWAnnual Electricity Cost =1317*6675*0.045Annual Electricity Cost =**395,582 $** **PPL Colstrip Unit 1 Modified from OAQPS Control Cost Manual Section 4.2, SCR** **Catalyst Replacement Cost Calculations (from Section 4.2 of EPA Control Cost Manual)**2.51Annual Catalyst Replacement Cost = (Catalyst Replacement Cost)FWF2.5 Catalyst Replacement Cost = nSCRVolcatalystCCreplace/RlayerCatalyst Replacement Cost =2*6,621*170.0/2Catalyst Replacement Cost =1,125,819$2.52FWF = i{1/[(1+i)Y-1]}2.53 Y = hcatalyst/hyearY =24000/(76%*8760)Y =3.60FWF =0.07*(1/(1+0.07)^4-1)FWF =0.23Annual Catalyst Cost =**253,566 $** STATEFACILITY_NAMEORISPLCODE UNIT ID OP YEARSUM OPTIMENUMMONTHSREPORTEDGROSSLOAD(MWh)SO2MASSSO2RATENOXRATENOXMASS CO2 MASSHEAT INPUT(MMBtu)HEATINPUT(MMBtu/hr)MT Colstrip 6076 1 2008 8,198122,464,601 5,0750.375 0.316 4,3172,808,90227,066,3473,301MT Colstrip 6076 1 2009 7,519122,417,112 5,8850.465 0.304 3,8542,654,97525,314,4073,367MT Colstrip 6076 1 2010 8,160122,563,419 5,6840.416 0.303 4,1382,868,83727,353,5133,352Averages 7,9592,481,711 5,5480.418 0.308 4,1032,777,57126,578,0893,340MT Colstrip 6076 2 2008 7,109122,135,046 4,2410.352 0.310 3,7442,500,30324,082,8533,388MT Colstrip 6076 2 2009 8,590122,573,748 6,1520.444 0.297 4,1172,908,43127,731,0183,228MT Colstrip 6076 2 2010 7,964122,406,886 5,1410.389 0.319 4,2242,771,47226,425,2083,318Averages 7,8882,371,894 5,1780.395 0.309 4,0282,726,73526,079,6933,311CAMD Emissions Data