NPPD - Gerald Gentleman Unit #2
Given/Assumptions

New or Retrofit? Retrofit Generation capacity (MW) 700 SCR bypass included? No Fuel High Heating Value (Btu/lb) 8,576 Maximum Fuel Consumption Rate (lb/hr) 6.5E+05 Average Annual Fuel Consumption (lb) 5.71E+09 Number of SCR Operating Days 365 Plant Capacity Factor 62% Uncontrolled NOx Concentration (lb/mmBtu) 0.32 Uncontrolled NOx Emissions (tpy) 15,122 LNB + OFA Total Capital Cost 18,465,00 0 $ LNB + OFA Total Annual Cost 1,480,000 $ SCR inlet NOx Concentration (lb/mmBtu) 0.23 Required Controlled NOx Concentration (lb/mmBtu) 0.05 Acceptable Ammonia Slip (ppm) 2.0 Fuel Volume Flow Rate (ft3/min/mmBtu/hr) 547 Fuel Heating Value (Btu/lb) 8,576 Fuel Sulfur Content 0.30 % Fuel Ash Content 4.69 % Number of SCR reactor chambers 1 ASR 1.05 Stored Ammonia Concentration 29% Reagent Molecular Weight (g/mole) 17.03 Reagent Density (lb/ft3 @ 60F) 56.0 Reagent Specific Volume (gal/ft3) 7.481 NOx Molecular Weight (g/mole) 46.01 Number of Days of Storage for Ammonia 14 Pressure Drop for SCR Ductwork H2O") 3 Pressure Drop for each Catalyst Layer (H2O") 1 Temperature at SCR Inlet (degrees F) 650 Equipment Life (years) 20 Annual Interest Rate 7% Inflation Since 1998 1.28 Catalyst Cost, Initial ($/ft3) 240 Catalyst Cost, Replacement ($/ft3) 290 Electrical Power Cost ($/kWh) 0.05 29% Ammonia Solution Cost ($/lb) 0.101 Operating Life of Catalyst (hours) 24,000from EIA 2001 NPS estimate from EIA 2001

Cost Tool annual average from CAM dat a company report company report company report presumptive BAR T NPS estimate OAQPS Control Cost Manual OAQPS Control Cost Manual from EIA 2001 from EIA 2001 from EIA 2001 OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual CPI OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost Manual OAQPS Control Cost ManualUncontrolled NOx emissions (tpy) 15,122
LNB Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet conc ( 0.32 - 0.23 )/

Boiler Calculations



### 2.3 Q B 

### = HVm-dotfuel QB = 8576 Btu/lb * 651,484 lb/hr QB = 5,587 mmBtu/hr



### 2.7 CFPlant 

### = actual mfuel

### /maximum m fuel CFPlant = 5.71E+09 lb/yr / 8760 hr/yr / 651,484 lb/hr CFPlant = 100%



### 2.8 CF SCR 

### = t SCR

### /365 days CFSCR = 365 days/ 365 days CFSCR = 100%



### CF Total 

### = CF Plant 

### x CF SCR CFTotal = 100% * 100% CFTotal = 62% from Given/Assume



### 2.12 q fluegas 

### = q fuel 

### Q B 

### (460+T)/(460+700 o 

### F)n SCR qfluegas = 547 ft3/min/(mmBtu/hr)* 5587 mmBtu/hr*( 460 + qfluegas = 2,924,427 acfm



### 2.9 η NOx

### = (NOx in

### – NOx out 

### ) / NOx in η NOx = ( 0.23 lb/mmBtu - 0.05 lb/mmBtu)/ 0.23 η NOx = 78% Modern NOx controls can achieve 90% N O

Overall Control Efficiency = (Inlet Conc - Outlet Conc)/Inlet con c ( 0.32 - 0.05 )/

NOx removed = 12,764 tpy
Controlled NOx emissions (tpy) = 2,358 tpy0.32 = 28%

650 )/( 460 + 700 )* 1

lb/mmBtu O x reduction.

0.32 = 84%SCR Reactor Calculations



### 2.19 Vol catalyst 

### = 2.81 x Q B 

### x η adj 

### x Slip adj 

### x NOx adj 

### x S adj 

### x T adj 

### /N SCR Volcatalyst = 2.81 * 5587 = 15700 

### 2.2 η adj 

### = 0.2869 + (1.058 x η )
η adj = 0.2869 +( 1.058 * 0.78 ) η adj = 1.115 

### 2.22 Slip adj 

### = 1.2835 – (0.0567 x Slip) Slipadj = 1.2835 - ( 0.057 * 2 ) Slipadj = 1.170 

### 2.21 NOx adj 

### = 0.8524 + (0.3208 x NOx in 

### ) NOxadj = 0.8524 + ( 0.321 * 0.23 ) NOxadj = 0.926 

### 2.23 S adj 

### = 0.9636 + (0.0455 x S) Sadj = 0.9636 + ( 0.046 * 0.3 ) Sadj = 0.977 

### 2.24 T adj 

### = 15.16 – (0.03937 x T) + (2.74 x 10 -5 

### x T 2 

### ) Tadj = 15.16 - ( 0.039 * 650 ) + 2.74E-05 * Tadj = 1.146 Volcatalyst = 21,244 ft3



### 2.25 A catalyst 

### = q fluegas 

### /(16 ft/sec x 60 sec/min) Acatalyst = 2924427 /( 16 * 60 ) Acatalyst = 3046 ft2



### 2.26 A SCR

### = 1.15 x A catalyst ASCR = 1.15 * 3046 ASCR = 3503 ft2



### 2.27 l = w = A SCR 1/2
l = w = 59.2 ft



### 2.28 n layer 

### = Vol catalyst 

### /(h’ layer 

### x A catalyst

### ) nlayer = 21244 /( 3.1 * 3046 ) nlayer = 2.0



### 2.29 h layer 

### = [Vol catalyst 

### /(n layer 

### x A catalyst

### )] + 1 hlayer = 21244 /( 3 * 3046 ) + 1 hlayer = 3.3



### 2.3 n total

### = n layer 

### + n empty ntotal = 2 + 1 ntotal = 3

### 2.31 h SCR

### = n total 

### (c 1 

### + h laye

### r) + c 2 hSCR = 3 * ( 7 + 3.3 ) + 9 hSCR = 40 ft422500SCR Reactor Calculations



### 2.19 Vol catalyst 

### = 2.81 x Q B 

### x η adj 

### x Slip adj 

### x NOx adj 

### x S adj 

### x T adj 

### /N SCR Volcatalyst = 2.81 * 5587 = 15700 

### 2.2 η adj 

### = 0.2869 + (1.058 x η )
η adj = 0.2869 +( 1.058 * 0.78 ) η adj = 1.115 

### 2.22 Slip adj 

### = 1.2835 – (0.0567 x Slip) Slipadj = 1.2835 - ( 0.057 * 2 ) Slipadj = 1.170 

### 2.21 NOx adj 

### = 0.8524 + (0.3208 x NOx in 

### ) NOxadj = 0.8524 + ( 0.321 * 0.23 ) NOxadj = 0.926 

### 2.23 S adj 

### = 0.9636 + (0.0455 x S) Sadj = 0.9636 + ( 0.046 * 0.3 ) Sadj = 0.977 

### 2.24 T adj 

### = 15.16 – (0.03937 x T) + (2.74 x 10 -5 

### x T 2 

### ) Tadj = 15.16 - ( 0.039 * 650 ) + 2.74E-05 * Tadj = 1.146 Volcatalyst = 21,244 ft3



### 2.25 A catalyst 

### = q fluegas 

### /(16 ft/sec x 60 sec/min) Acatalyst = 2924427 /( 16 * 60 ) Acatalyst = 3046 ft2



### 2.26 A SCR

### = 1.15 x A catalyst ASCR = 1.15 * 3046 ASCR = 3503 ft2



### 2.27 l = w = A SCR 1/2
l = w = 59.2 ft



### 2.28 n layer 

### = Vol catalyst 

### /(h’ layer 

### x A catalyst

### ) nlayer = 21244 /( 3.1 * 3046 ) nlayer = 2.0



### 2.29 h layer 

### = [Vol catalyst 

### /(n layer 

### x A catalyst

### )] + 1 hlayer = 21244 /( 3 * 3046 ) + 1 hlayer = 3.3



### 2.3 n total

### = n layer 

### + n empty ntotal = 2 + 1 ntotal = 3

### 2.31 h SCR

### = n total 

### (c 1 

### + h laye

### r) + c 2 hSCR = 3 * ( 7 + 3.3 ) + 9 hSCR = 40 ft422500Reagent Calculations



### 2.32 m-dotreagent 

### = NOx in 

### Q B 

### ASR η NOx

### M reagent 

### /M NOx m-dotreagent = 0.23 * 5587 * 1.05 * 78 % * 17.03 m-dotreagent = 391 lb/hr



### 2.33 m-dot sol 

### = m-dot reagent 

### /C sol m-dotsol = 391 / 0.29 m-dotsol = 1348 lb/hr



### 2.34 q sol 

### = (m-dot vol 

### / ρ sol

### )V sol qsol = 1348 * 7.481 / 56 qsol = 180 gph



### 2.35 Tank Volume = q sol



### t Tank Volume = 180 * 14 * 24 Tank Volume = 60,496 gal/ 46.01Direct Capital Cos t



### 2.36 DC = Q B 

### [($3380/MMBtu/hr) + f(h SCR 

### ) +f(NH 3 

### rate) + f(new) + f(bypass)](35 0 DC = 5587 (( 3,380 $ + 

### 2.37 f(h SCR 

### ) = {[$612/(ft-mmBtu/hr)]h SCR 

### } - $187.9/(mmBtu/hr f(hSCR) = 6.12 * 40 - 187.9 

### f(hSCR) = 57 $ / mmBtu/hr



### 2.38 f(NH 3 

### rate) = [($411/lb/hr)(m-dot reagent 

### /Q B 

### )] - $473/(mmBtu f(NH3rate) = 411 * 391 / 5587 - 

### f(NH3rate) = (19) $ / mmBtu/hr 

### 2.39 f(new) = $0/(mmBtu/hr) for retrofit f(new) = -$ 2.41 f(bypass) = $0/(mmBtu/hr) for no bypass f(bypass) =

- $ /mmBtu/hr 

### 2.43 f(Vol catalyst 

### ) = Vol catalyst 

### CCinitial f(Volcatalyst) = 21244 * 240 f(Volcatalyst) = 5,098,619 $

DC = 5587 * ( 3,380 $ + 57$ + (19) $ DC = 34,706,599 $
Inflation Adjustment = 1.28 DC = 44,424,446 $

### 0 0/ Q B 

### ) 0.35 

### + f(Volcatalyst 

### )

r )

u/hr) 47.3

+ - $ + -$ )*( 3500 / 1000 )^ 0.35 + 5,098,619 $Direct Capital Cos t



### 2.36 DC = Q B 

### [($3380/MMBtu/hr) + f(h SCR 

### ) +f(NH 3 

### rate) + f(new) + f(bypass)](35 0 DC = 5587 (( 3,380 $ + 

### 2.37 f(h SCR 

### ) = {[$612/(ft-mmBtu/hr)]h SCR 

### } - $187.9/(mmBtu/hr f(hSCR) = 6.12 * 40 - 187.9 

### f(hSCR) = 57 $ / mmBtu/hr



### 2.38 f(NH 3 

### rate) = [($411/lb/hr)(m-dot reagent 

### /Q B 

### )] - $473/(mmBtu f(NH3rate) = 411 * 391 / 5587 - 

### f(NH3rate) = (19) $ / mmBtu/hr 

### 2.39 f(new) = $0/(mmBtu/hr) for retrofit f(new) = -$ 2.41 f(bypass) = $0/(mmBtu/hr) for no bypass f(bypass) =

- $ /mmBtu/hr 

### 2.43 f(Vol catalyst 

### ) = Vol catalyst 

### CCinitial f(Volcatalyst) = 21244 * 240 f(Volcatalyst) = 5,098,619 $

DC = 5587 * ( 3,380 $ + 57$ + (19) $ DC = 34,706,599 $
Inflation Adjustment = 1.28 DC = 44,424,446 $

### 0 0/ Q B 

### ) 0.35 

### + f(Volcatalyst 

### )

r )

u/hr) 47.3

+ - $ + -$ )*( 3500 / 1000 )^ 0.35 + 5,098,619 $Indirect Capital Costs
Total Direct Capital Costs, A Indirect Installation Costs General Facilities 0.05 Engineering and Home Office Fees 0.10 Process Contingencies 0.05 Total Indirect Installation Costs, B 0.20 Project Contingency, C = 0.15 Total Plant Cost D = Allowance for Funds During Construction, E = 0 Royalty Allowance, F = 0 Preproduction Cost, G = 0.02 Inventory Capital, H = 0.101 /lb * 1348 lb/r * 24 hr/day * Initial Catalyst and Chemicals, I = Total Capital Investment TCI = D+G+H
Total Capital Investment TCI including LNB + OFA =44,424,446 $

A $2,221,222 A $4,442,445 A $2,221,222 A $8,884,889 (A+B) $7,996,400 A+B+C $61,305,736 $0 $0 (D+E) $1,226,115 14 days = $45,738

- $ +D+E+F+G+H+I $62,577,589
$81,042,589Annual Costs 

### 2.45 DAC = Annual Maintenance Cost + Annual Reagent Cost + Annual Electr 2.46 Annual Maintenance Cost = 0.015 TCI Annual Maintenance Cost = 0.015 * 62,577,589 $ Annual Maintenance Cost = 938,664 $ 

### 2.47 Annual Reagent Cost = q reagent 

### Cost reagent 

### t op 

### 2.47a t o p

### = CF total 

### 8760hr/yr top = 62% * 8760 

### top = 5431 Annual Reagent Cost = 1348 * 5431 * 0.101 Annual Reagent Cost = 739,319 $ 

### 2.49 Annual Electricity Cost = Power (Cost elect) 

### t op 

### 2.48 Power = 0.105Q B 

### [NOxin

### η NOxCFtotal + 0.5( Δ P duc t Power = 0.105 * 5587 *( 0.321 * Power = 1558 kW Annual Electricity Cost = 1558 * 5431 * 0.05 Annual Electricity Cost = 423,063 $ 

### 2.51 Annual Catalyst Replacement Cost = (Catalyst Repl a

2.5 Catalyst Replacement Cost = n SCR

### Volcatalyst 

### CC replace 

### /R Catalyst Replacement Cost = 1 * 21244 * 290 / Catalyst Replacement Cost = 3,080,416 $ 

### 2.52 FWF = i{1/[(1+i) Y 

### -1]} 2.53 Y = h catalyst 

### /hyear Y = 24000 / 5431 Y = 4 FWF = 0.07 *( 1 /( 1 + FWF = 0.23 Annual Catalyst Cost = 693,796 $ 

### DAC = 2,794,842 $



### 2.55 CRF = i(1+i) n 

### /[(1+i) n 

### -1] CRF = 0.07 *( 1 + 0.07 )^ CRF = 0.0944

Indirect Annual Cost = CFR * TCI Indirect Annual Cost = 0.0944 * 81,042,589 $ Indirect Annual Cost = 7,649,847 $



### 2.56 Total Annual Cost = Direct Annual Cost + Indirect A Total Annual Cost = 2,794,842 $ + 7,649,847 $ Total Annual Cost = 10,444,689 $ + 1,480,000 $ for LNB+OFA Total Annual Cost = 11,924,689 $



### 2.57 NOx Removed = NOx in

### η NOx 

### Q B 

### t op NOx Removed = 0.32 * 84% * 5587 *NOx Removed = 12,76 4 data from CAM



### 2.58 Cost effectiveness = TAC/NOx removed Cost effectiveness = 934 $ / ton
Cost effectiveness = 6,179,528 $ / dv

### icity Cost + Annual Water Cost + Annual Catalyst Co s

SRP estimate frm table E-1 936,000 $

t 

### + n total 

### Δ Pcatal y s t

### )] 78% * 62% + 0.5 * ( 3 + 2 * 1 ))



### a cement Cost)FWF Rlayer 2

0.07 )^ 4.00 - 1 )

20 /(( 1 + 0.07 )^ 20 - 1 )



### A nnual Cos t

5431 / 2000