# FGD Capital Costs

Description Formula 1 

# Value

Boiler Size (MMBtu/hr) Q B 

# 1941

SO2 Removal Efficiency (%) η NOx 

# 87.0%

Cost Year 2010

Capital Costs ($) 2



# Base module absorber island cost BMF $23,414,000

Base module reagent preparation and waste

recycle/handling cost BMR $6,075,000

Base module waste hanlding cost BMW $2,925,000

Base module balance of plant cost including ID or

booster fans, new wet chimney, piping, ductwork,

minor WWWT, etc.. BMB $42,288,000

Base module wastewater treatment facility beyond

minor physical/chemical treatment BMWW

-

Total bare module cost including retrofit factor BM=BMR+BMF+BMB+BMWW $74,702,000

Total Project Costs ($)



# Engineering and construction management costs A1 = 10% of BM $7,883,648

Labor adjustment for 6 x 10 hour shift premium, per

diem, etc.. A2 = 10% of BM $7,883,648

Contractor profit and fees A3 = 10% of BM $7,883,648

Total Capital Investment (TCI) ($) BM+A1+A2+A3 $98,352,945

Total Capital Investment (TCI) ($) Per kW $607

FGD Annual Costs

Direct Annnual Costs

Fixed O&M costs for operations staff 

# $1,497,600

Fixed O&M costs for maintenance labor and materi als 

# $2,638,996

Fixed O&M costs for adminstrative labor 

# $74,934

Variable O&M costs for limestone reagent $78,770

Variable O&M costs for waste disposal $475,510

Variable O&M costs for additional auxillary power

required including additional fan power $923,265

Variable O&M costs for makeup water $102,944

Lost Ash Sales $352,200

Total Direct Annual Costs DAC 

# $6,144,220

Indirect Annual Costs IDAC = TCI x CRF 

# $9,284,518

Total Annual Costs TAC = DAC + IAC 

# $15,428,738

Cost Effectivness

SDA FGD SO2 Removed (tons/yr) 

# 2,369

SDA FGD Cost Effectiveness ($/ton removed) 

# $6,514 Corette BART Cost Analysis - Wet FGD

(2010 Dollars)Wet FGD Capital Cost Estimate WorksheetVariableDesignationUnitsValueCalculationWastewater TreatmentMinor physical/chemicalUnit Size (Gross)A(MW)162Input (Greater than 100 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*1000Limestone RateK(ton/hr)0.7817.52*A*D*G/2000Waste RateL(ton/hr)1.421.811*KAux Power M (%) 1.42(1.05*e(0.155*D))*F*GMakeup Water RateN(1000 gph)15.38(1.674*D+74.68)*A*F*G/1000Limestone CostP($/ton)15.00Water Disposal CostQ($/ton)50.00Aux Power CostR($/kW)0.06Makeup Water CostS($/1000)1.00Operating Labor RateT($/hr)60Labor cost including all benefitsCosts are all based on 2009 dollarsCapital Cost CalculationInclude: equipment, installation, buildings, foundations, electrical, and retrofit difficulty.BMR ($) = 550000*(B)*((F*G)0.6)*((D/2)0.02)*(A0.716)$23,414,000 Base module absorber island costBMF ($) = 190000*(B)*((D*G)0.3)*(A0.716)$6,075,000 Base module reagent preparation and waste recycle/handling costBMW ($) = 100000*(B)*((D*G)0.45)*(A0.716)$2,925,000 Base module waste hanlding costBMB ($) = 1010000*(B)*((F*G)0.4)*(A0.716)$42,288,000 Base module balance of plant cost including ID or booster fans, new wet chimney, piping, ductwork, minor WWWT, etc..BMWW ($) =-Base module wastewater treatment facility beyond minor physical/chemical treatmentBM ($) = BMR + BMF + BMW + BMB + BMWW$74,702,000Total bare module cost including retrofit factorBM ($/kW)$461Base module cost per kWTotal Project CostA1 = 10% of BM$7,470,000Engineering and construction management costsA2 = 10% of BM$7,470,000Labor adjustment for 6 x 10 hour shift premium, per diem, etc..A3 = 10% of BM$7,470,000Contractor profit and feesCECC($) - excludes owner's costs = BM+A1+A2+A3$97,112,000Capital, engineering and construction cost subtotalCECC($/kW) - excludes owner's costs =$599Capital, engineering and construction cost subtotal per kWB1 = %5 of CECC$4,856,000Owners costs including "home office" costs (owner engineering, management, and procurement activities)TPC ($) - includes owner's costs = CECC + B1$101,968,000Total project cost without AFUDCTPC ($/kw) - includes owner's costs =$629Total project cost per kW without AFUDCB2 = 10% of (CECC + B1)$10,197,000AFUDC (based on 3 year enginering and construction cycle)TPC ($) - includes owner's costs and AFUDC = CECC + B1 + B2$112,165,000Total project costTPC ($/kw) - includes owner's costs and AFUDC ($/kW) =$692Total project cost per kWWet FGD Capital Cost Estimate WorksheetVariableDesignationUnitsValueCalculationWastewater TreatmentMinor physical/chemicalUnit Size (Gross)A(MW)162Input (Greater than 100 MW)Retrofit FactorB1Input (An "average" retrofit has a factor = 1.0)Gross Heat RateC(Btu/kWh)11982InputSO2RateD (lb/MMBtu) 0.461 InputType of CoalEPRBInputCoal FactorF1.05Bituminous =1.0, PRB=1.05, Lignite=1.07Heat Rate FactorG1.20C/10000Heat InputH(Btu/hr)1.94E+09A*C*1000Limestone RateK(ton/hr)0.7817.52*A*D*G/2000Waste RateL(ton/hr)1.421.811*KAux Power M (%) 1.42(1.05*e(0.155*D))*F*GMakeup Water RateN(1000 gph)15.38(1.674*D+74.68)*A*F*G/1000Limestone CostP($/ton)15.00Water Disposal CostQ($/ton)50.00Aux Power CostR($/kW)0.06Makeup Water CostS($/1000)1.00Operating Labor RateT($/hr)60Labor cost including all benefitsCosts are all based on 2009 dollarsFixed O&M Cost$9.244 Fixed O&M additional operating labor costsFOMM ($/kW yr) = BM*0.015/(B*A*1000)$15.435Fixed O&M maintenance material and labor costsFOMA ($/kW yr) = 0.03*(FOMO+0.4*FOMM)$0.463Fixed O&M additional addministrative labor costsFOMW ($kW yr) =-Fixed O&M costs for wastewater treatment facilityFOM ($/kW yr) = FOMO + FOMM$25.142Total Fixed O&M costsVariable O&MVOMR ($/MWh) = K*P/A$0.073Variable O&M costs for limestone reagentVOMW ($/MWh)= L*Q/A$0.438Variable O&M costs for waste disposalVOMP ($/MWh) = M*R*10$0.851Variable O&M costs for additional auxillary power required including additional fan powerVOMM ($/MWh) = N*S/A$0.095Variable O&M costs for makeup waterVOMWW ($/MWh) =-VOM ($/MWh) = VOMR + VOMM$1.457Total variable O&M costsFOMO ($/kW yr) = (If MW>500 then 16additional operators else 12operators)*2080*T/(A*1000)STATEFACILITY_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