FGD Capital Costs

Description Formula1Value

Boiler Size (MMBtu/hr) QB 1941

SO2 Removal Efficiency (%) ηNOx 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 materials $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 Worksheet

Variable Designation Units Value Calculation

Wastewater Treatment Minor physical/chemical

Unit Size (Gross) A (MW) 162 Input (Greater than 100 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*1000Limestone Rate K (ton/hr) 0.78 17.52*A*D*G/2000Waste Rate L (ton/hr) 1.42 1.811*KAux Power M (%) 1.42 (1.05*e(0.155*D))*F*GMakeup Water Rate N (1000 gph) 15.38 (1.674*D+74.68)*A*F*G/1000Limestone Cost P ($/ton) 15.00Water Disposal Cost Q ($/ton) 50.00Aux 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 ($) = 550000*(B)*((F*G)0.6)*((D/2)0.02)*(A0.716) $23,414,000 Base module absorber island cost

 BMF ($) = 190000*(B)*((D*G)0.3)*(A0.716) $6,075,000 Base module reagent preparation and waste recycle/handling cost

 BMW ($) = 100000*(B)*((D*G)0.45)*(A0.716) $2,925,000 Base module waste hanlding cost

 BMB ($) = 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

 BMWW ($) = - Base module wastewater treatment facility beyond minor physical/chemical treatment BM ($) = BMR + BMF + BMW + BMB + BMWW $74,702,000 Total bare module cost including retrofit factor BM ($/kW) $461 Base module cost per kWTotal Project Cost A1 = 10% of BM $7,470,000 Engineering and construction management costs A2 = 10% of BM $7,470,000 Labor adjustment for 6 x 10 hour shift premium, per diem, etc.. A3 = 10% of BM $7,470,000 Contractor profit and fees CECC($) - excludes owner's costs = BM+A1+A2+A3 $97,112,000 Capital, engineering and construction cost subtotal CECC($/kW) - excludes owner's costs = $599 Capital, engineering and construction cost subtotal per kW B1 = %5 of CECC $4,856,000 Owners costs including "home office" costs (owner engineering, management, and procurement a TPC ($) - includes owner's costs = CECC + B1 $101,968,000 Total project cost without AFUDC TPC ($/kw) - includes owner's costs = $629 Total project cost per kW without AFUDC B2 = 10% of (CECC + B1) $10,197,000 AFUDC (based on 3 year enginering and construction cycle) TPC ($) - includes owner's costs and AFUDC = CECC + B1 + B2 $112,165,000 Total project cost TPC ($/kw) - includes owner's costs and AFUDC ($/kW) = $692 Total project cost per kW
Wet FGD Capital Cost Estimate Worksheet

Variable Designation Units Value Calculation

Wastewater Treatment Minor physical/chemical

Unit Size (Gross) A (MW) 162 Input (Greater than 100 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*1000Limestone Rate K (ton/hr) 0.78 17.52*A*D*G/2000Waste Rate L (ton/hr) 1.42 1.811*KAux Power M (%) 1.42 (1.05*e(0.155*D))*F*GMakeup Water Rate N (1000 gph) 15.38 (1.674*D+74.68)*A*F*G/1000Limestone Cost P ($/ton) 15.00Water Disposal Cost Q ($/ton) 50.00Aux 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

Fixed O&M Cost

$9.244 Fixed O&M additional operating labor costs

 FOMM ($/kW yr) = BM*0.015/(B*A*1000) $15.435 Fixed O&M maintenance material and labor costs FOMA ($/kW yr) = 0.03*(FOMO+0.4*FOMM) $0.463 Fixed O&M additional addministrative labor costs FOMW ($kW yr) = - Fixed O&M costs for wastewater treatment facility FOM ($/kW yr) = FOMO + FOMM $25.142 Total Fixed O&M costsVariable O&M VOMR ($/MWh) = K*P/A $0.073 Variable O&M costs for limestone reagent VOMW ($/MWh)= L*Q/A $0.438 Variable O&M costs for waste disposal VOMP ($/MWh) = M*R*10 $0.851 Variable O&M costs for additional auxillary power required inclu VOMM ($/MWh) = N*S/A $0.095 Variable O&M costs for makeup water VOMWW ($/MWh) = - VOM ($/MWh) = VOMR + VOMM $1.457 Total variable O&M costs FOMO ($/kW yr) = (If MW>500 then 16additional operators else 12 operators)*2080*T/(A*1000)
STATE

FACILITY_NA

ME

ORISPL 

CODE UNIT ID OP YEAR

SUM OP 

TIME

NUM 

MONTHS 

REPORTE

D

GROSS 

LOAD 

(MWh) SO2 MASS SO2 RATE NOX RATE

NO

MA

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