Expected Control - Original Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Original Emission Rate lb/MMBTU 0.849 0.786 0.849 0.786

Original Heat Rate MMBTU/hr 2744 4885 2774 4885

Original Emissions lb/hr (U1 2744 MMBTU/hr; U2 4885 MMBTU/hr) 2330 3840 2355 3840

Original Availability percent 97.30% 93.90% 97.30% 93.90%

Original Annual tons/yr 9928 15792 10037 15792

New Emission Rate lb/MMBTU 0.053 0.049 0.053 0.049

Hourly Emission lbs/hr 145 239 145 239

Control Percentage 93.8% 93.8% 93.8% 93.8%

Annual Emission

Scenario A tons/yr 586 931 589 936

Scenario B tons/yr 533 813 536 813

Emission Reduction

Scenario A tons/yr 9348 14862 9345 14857

Scenario B tons/yr 9401 14980 9398 14980

Source: November 2009 Minnkota Submittals. 

Expected Control - ERG Revision (accounts for changes in availability)

Annual Emission

Scenario 1 tons/yr 612 967 619 967

Scenario 2 tons/yr 616 976 623 976

Scenario 3 tons/yr 620 984 627 984

Scenario 4 Scenario 4 tons/yr 606 963 613 963

Emission Reduction

Scenario 1 tons/yr 9316 14825 9418 14825

Scenario 2 tons/yr 9312 14816 9414 14816

Scenario 3 tons/yr 9309 14807 9410 14807

Scenario 4 tons/yr 9322 14829 9424 14829

Source: Annual cost sheet revisions assumptions. Use new unit availability based on less downtime.

1000$

Capital Costs Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Minnkota Original costs (2018 $) $183,274 $317,429 $240,817 $411,063

Original costs (2009 $) $146,753 $254,175 $192,830 $329,150

Capital_Revised OAQPS

New equipment costs + Hybird of Minnkota and 

OAQPS Assumptions $93,023 $166,346 $123,129 $216,867

Annual Costs Description Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Minnkota (Reported in 2006$) Original costs 

Scenario A 1 layer every 2 years $33,526 $57,351 $39,307 $66,507

Scenario B 1 layer 3-4 times per year $45,245 $86,542 $50,937 $96,268
OAQPS (Reported in 2009$)

New catalyst info + Hybird of Minnkota and OAQPS 

Assumptions

Scenario 1 1 layer every year $20,070 $34,456 $23,372 $39,788

Scenario 2 1 layer every 2 years $19,032 $32,319 $22,569 $38,047

Scenario 3 1 layer every 3 years $18,398 $30,866 $22,015 $36,730

Scenario 4 ASOFA assumption $20,767 $33,712 $24,064 $39,041

Total Annualized Costs (2009$)

Updated cost factor to CEPCI: 2006 = 0.957 * 

2009 (2009 = 521.9; 2006 = 499.6) Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Cost Factor 0.957

Minnkota Original costs

Scenario A 1 layer every 2 years (2009$) $35,033 $59,928 $41,073 $69,495

Scenario B 1 layer 3-4 times per year (2009$) $47,277 $90,430 $53,226 $100,594

North Dakota Avg

OAQPS

New equipment and catalyst info with OAQPS 

assumptions where applicable

Scenario 1 1 layer every year $20,070 $34,456 $23,372 $39,788

Scenario 2 1 layer every 2 years $19,032 $32,319 $22,569 $38,047

Scenario 3 1 layer every 3 years $18,398 $30,866 $22,015 $36,730

Scenario 4 ASOFA assumption $20,767 $33,712 $24,064 $39,041

Assumed Minnkota's annualized cost factors for capital. Total Annualized costs = Annual O&M + Total Capital * 0.08718.

Assumed annual costs are in 2009 dollars.

1000$

Include Cost of Overfire air

Minnkota U1 Document, November 2009, Revised February 2010

ASOFA, Installed Capital 2006$ $4,277,000 Table4-4SF

ASOFA, Annualized Capital 2006$ $373,000 Table4-4SF

ASOFA, Annual O&M 2006$ $1,695,000 Table4-6SF

Minnkota U2 Document, November 2009

ASOFA, Installed Capital 2006$ $10,008,000 Table4-4SF

ASOFA, Annualized Capital 2006$ $873,000 Table4-4SF

ASOFA, Annual O&M 2006$ $2,805,000 Table4-6SF

Total Annualized Costs, 2006$

Unit 1, Annualized 2006$ $2,068,000

Annualized capital + 

annual O&M

Unit 2, Annualized 2006$ $3,678,000

Annualized capital + 

annual O&M
Total Annualized Costs, 2009$ Convert to 2009 $

Unit 1, Annualized 2009$ $2,160,920

Unit 2, Annualized 2009$ $3,843,260

Total Annualized Costs (2009)

Added OFA costs provided by EPA to the total 

annualized costs (added cells B72 or B73 to the 

values in the 2009 annualized cost table) Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Minnkota Original costs

Scenario A 1 layer every 2 years (2009$) $37,194 $63,771 $43,234 $73,338

Scenario B 1 layer 3-4 times per year (2009$) $49,438 $94,273 $55,387 $104,437

North Dakota Avg

ERG

New equipment and catalyst info with OAQPS 

assumptions where applicable

Scenario 1 1 layer every year $22,231 $38,299 $25,533 $43,631

Scenario 2 1 layer every 2 years $21,193 $36,162 $24,730 $41,890

Scenario 3 1 layer every 3 years $20,559 $34,710 $24,176 $40,573

Scenario 4 ASOFA assumption $22,928 $37,555 $26,225 $42,885

Costs in 2006 Dollars (Multiply 2009 costs by B53)

1000$

1000$

Capital Costs Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Minnkota Original costs $140,443 $243,245 $184,538 $314,997

Capital_Revised OAQPS

New equipment costs + Hybird of Minnkota and 

OAQPS Assumptions $89,023 $159,193 $117,834 $207,541

Annual Costs Description Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Minnkota Original costs

Scenario A 1 layer every 2 years $33,526 $57,351 $39,307 $66,507

Scenario B 1 layer 3-4 times per year $45,245 $86,542 $50,937 $96,268

OAQPS

New catalyst info + Hybird of Minnkota and OAQPS 

Assumptions

Scenario 1 1 layer every year $19,207 $32,974 $22,367 $38,077

Scenario 2 1 layer every 2 years $18,213 $30,929 $21,598 $36,411

Scenario 3 1 layer every 3 years $17,607 $29,539 $21,069 $35,151

Scenario 4 ASOFA assumption $19,874 $32,262 $23,029 $37,362

Total Annualized Costs Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

1000$
Minnkota Original costs

Scenario A 1 layer every 2 years $33,526 $57,351 $39,307 $66,507

Scenario B 1 layer 3-4 times per year $45,245 $86,542 $50,937 $96,268

North Dakota Avg

OAQPS

New equipment and catalyst info with OAQPS 

assumptions where applicable

Scenario 1 1 layer every year $19,207 $32,974 $22,367 $38,077

Scenario 2 1 layer every 2 years $18,213 $30,929 $21,598 $36,411

Scenario 3 1 layer every 3 years $17,607 $29,539 $21,069 $35,151

Scenario 4 ASOFA assumption $19,874 $32,262 $23,029 $37,362

Total Annualized Costs (2006)

Added OFA costs provided by EPA to the total 

annualized costs (added cells B102 or B103 to 

the values in the 2006 annualized cost table) Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Minnkota Original costs

Scenario A 1 layer every 2 years $35,594 $61,029 $41,375 $70,185

Scenario B 1 layer 3-4 times per year $47,313 $90,220 $53,005 $99,946

North Dakota Avg

OAQPS

New equipment and catalyst info with OAQPS 

assumptions where applicable

Scenario 1 1 layer every year $21,275 $36,652 $24,435 $41,755

Scenario 2 1 layer every 2 years $20,281 $34,607 $23,666 $40,089

1000$

Scenario 2 1 layer every 2 years $20,281 $34,607 $23,666 $40,089

Scenario 3 1 layer every 3 years $19,675 $33,217 $23,137 $38,829

Scenario 4 ASOFA assumption $21,942 $35,940 $25,097 $41,040
Reduction from Original

Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

36.61% 34.55% 36.15% 34.11%
Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

$3,748 $4,032 $4,395 $4,678

$5,029 $6,037 $5,664 $6,715

$4,388 $5,035 $5,029 $5,696

$2,154 $2,324 $2,482 $2,684

$2,044 $2,181 $2,397 $2,568

$1,976 $2,085 $2,339 $2,481

$2,228 $2,273 $2,553 $2,633

Costs in $/ton removed
Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

$3,979 $4,291 $4,626 $4,936

$5,259 $6,293 $5,893 $6,972

$2,386 $2,583 $2,711 $2,943

$2,276 $2,441 $2,627 $2,827

$2,209 $2,344 $2,569 $2,740

$2,459 $2,533 $2,783 $2,892

Costs in $/ton removed

Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Costs in $/ton removed
$3,586 $3,859 $4,206 $4,476

$4,813 $5,777 $5,420 $6,426

$4,200 $4,818 $4,813 $5,451

$2,062 $2,224 $2,375 $2,568

$1,956 $2,088 $2,294 $2,458

$1,891 $1,995 $2,239 $2,374

$2,132 $2,176 $2,444 $2,520

Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

$3,808 $4,106 $4,427 $4,724

$5,033 $6,023 $5,640 $6,672

$2,284 $2,472 $2,594 $2,817

$2,178 $2,336 $2,514 $2,706

Costs in $/ton removed

$2,114 $2,243 $2,459 $2,622

$2,354 $2,424 $2,663 $2,768
Expected Control - Original Low Dust U1

Original Emission Rate

Original Emissions

Original Annual tons/yr 9,032

New Emission Rate lb/MMBTU 0.053

Hourly Emission lbs/hr

Control Percentage

Annual Emission

Scenario A tons/yr 586

Scenario B tons/yr 533

Emission Reduction

Scenario A tons/yr 8446

Scenario B tons/yr 8499

Source: November 2009 Minnkota Submittals. 

Expected Control - ERG Revision (accounts for changes in availability)

Annual Emission

Scenario 1 tons/yr 612

Scenario 2 tons/yr 616

Scenario 3 tons/yr 620

Scenario 4 tons/yr 606

Emission Reduction

Scenario 1 tons/yr 8420

Scenario 2 tons/yr 8416

Scenario 3 tons/yr 8412

Scenario 4 tons/yr 8426

Source: Annual cost sheet revisions assumptions. Use new unit availability based on less downtime.

1000$

Capital Costs Low Dust U1

Minnkota Original costs (2018 $) $183,274

Original costs (2009 $) $146,753

Capital_Revised OAQPS

New equipment costs + Hybird of Minnkota and 

OAQPS Assumptions $93,023

Annual Costs Description Low Dust U1

Minnkota (Reported in 2006$) Original costs 

Scenario A 1 layer every 2 years $33,526

Scenario B 1 layer 3-4 times per year $45,245

OAQPS (Reported in 2009$)

New catalyst info + Hybird of Minnkota and OAQPS 

Assumptions

Scenario 1 1 layer every year $20,070

Scenario 2 1 layer every 2 years $19,032

Scenario 3 1 layer every 3 years $18,398

Scenario 4 ASOFA assumption $20,767

Total Annualized Costs (2009$)

Updated cost factor to CEPCI: 2006 = 0.957 * 

2009 (2009 = 521.9; 2006 = 499.6) Low Dust U1

Cost Factor 0.957

Minnkota Original costs
Scenario A 1 layer every 2 years (2009$) $35,033

Scenario B 1 layer 3-4 times per year (2009$) $47,277

North Dakota Avg

ERG

New equipment and catalyst info with OAQPS 

assumptions where applicable

Scenario 1 1 layer every year $20,070

Scenario 2 1 layer every 2 years $19,032

Scenario 3 1 layer every 3 years $18,398

Scenario 4 ASOFA assumption $20,767

Assumed Minnkota's annualized cost factors for capital. Total Annualized costs = Annual O&M + Total Capital * 0.08718.

Assumed annual costs are in 2009 dollars.

Include Cost of Overfire air

Minnkota U1 Document, November 2009, Revised February 2010

ASOFA, Installed Capital 2006$ $4,277,000 Table4-4SF

ASOFA, Annualized Capital 2006$ $373,000 Table4-4SF

ASOFA, Annual O&M 2006$ $1,695,000 Table4-6SF

Minnkota U2 Document, November 2009

ASOFA, Installed Capital 2006$ $10,008,000 Table4-4SF

ASOFA, Annualized Capital 2006$ $873,000 Table4-4SF

ASOFA, Annual O&M 2006$ $2,805,000 Table4-6SF

Total Annualized Costs, 2006$

Unit 1, Annualized 2006$ $2,068,000

Annualized capital + 

annual O&M

Unit 2, Annualized 2006$ $3,678,000

Annualized capital + 

annual O&M

Total Annualized Costs, 2009$ Convert to 2009 $

Unit 1, Annualized 2009$ $2,160,920

Unit 2, Annualized 2009$ $3,843,260

Total Annualized Costs (2009)

Added OFA costs provided by EPA to the total 

annualized costs (added cells B72 or B73 to the 

values in the 2009 annualized cost table) Low Dust U1

Minnkota Original costs

Scenario A 1 layer every 2 years (2009$) $37,194

Scenario B 1 layer 3-4 times per year (2009$) $49,438

North Dakota Avg

ERG

New equipment and catalyst info with OAQPS 

assumptions where applicable

Scenario 1 1 layer every year $22,231

Scenario 2 1 layer every 2 years $21,193

Scenario 3 1 layer every 3 years $20,559

Scenario 4 ASOFA assumption $22,928
Costs in 2006 Dollars (Multiply 2009 costs by B53)

1000$

Capital Costs Low Dust U1

Minnkota Original costs $140,443

Capital_Revised OAQPS

New equipment costs + Hybird of Minnkota and 

OAQPS Assumptions $89,023

Annual Costs Description Low Dust U1

Minnkota Original costs

Scenario A 1 layer every 2 years $33,526

Scenario B 1 layer 3-4 times per year $45,245

OAQPS

New catalyst info + Hybird of Minnkota and OAQPS 

Assumptions

Scenario 1 1 layer every year $19,207

Scenario 2 1 layer every 2 years $18,213

Scenario 3 1 layer every 3 years $17,607

Scenario 4 ASOFA assumption $19,874

Total Annualized Costs Low Dust U1

Minnkota Original costs

Scenario A 1 layer every 2 years $33,526

Scenario B 1 layer 3-4 times per year $45,245

North Dakota Avg

ERG

New equipment and catalyst info with OAQPS 

assumptions where applicable

Scenario 1 1 layer every year $19,207

Scenario 2 1 layer every 2 years $18,213

Scenario 3 Scenario 3 1 layer every er every 3 years $17,607 $17,607

Scenario 4 ASOFA assumption $19,874

Total Annualized Costs (2006)

Added OFA costs provided by EPA to the total 

annualized costs (added cells B102 or B103 to 

the values in the 2006 annualized cost table) Low Dust U1

Minnkota Original costs

Scenario A 1 layer every 2 years $35,594

Scenario B 1 layer 3-4 times per year $47,313

North Dakota Avg

ERG

New equipment and catalyst info with OAQPS 

assumptions where applicable

Scenario 1 1 layer every year $21,275

Scenario 2 1 layer every 2 years $20,281

Scenario 3 1 layer every 3 years $19,675

Scenario 4 ASOFA assumption $21,942
Low Dust U2 Tail End U1 Tail End U2

 15,507 9,032 15,507

0.049 0.053 0.049

931 589 936

813 536 813

14576 8443 14571

14694 8496 14694

967 619 967

976 623 976

984 627 984

963 613 963

14540 8413 14540

14531 8409 14531

14523 8405 14523

14544 8419 14544

Reduction from Original

Low Dust U2 Tail End U1 Tail End U2 Low Dust U1 Low Dust U2 Tail End U1

$317,429 $240,817 $411,063

$254,175 $192,830 $329,150

$166,346 $123,129 $216,867 36.61% 34.55% 36.15%

Low Dust U2 Tail End U1 Tail End U2

$57,351 $39,307 $66,507

$86,542 $50,937 $96,268

$34,456 $23,372 $39,788

$32,319 $22,569 $38,047

$30,866 $22,015 $36,730

$33,712 $24,064 $39,041

Low Dust U2 Tail End U1 Tail End U2 Low Dust U1 Low Dust U2 Tail End U1

1000$ Costs in $/ton removed
$59,928 $41,073 $69,495 $4,148 $4,111 $4,865

$90,430 $53,226 $100,594 $5,563 $6,154 $6,265

$4,855 $5,133 $5,565

$34,456 $23,372 $39,788 $2,384 $2,370 $2,778

$32,319 $22,569 $38,047 $2,261 $2,224 $2,684

$30,866 $22,015 $36,730 $2,187 $2,125 $2,619

$33,712 $24,064 $39,041 $2,465 $2,318 $2,858

tal Capital * 0.08718.

Low Dust U2 Tail End U1 Tail End U2 Low Dust U1 Low Dust U2 Tail End U1

$63,771 $43,234 $73,338 $4,404 $4,375 $5,121

$94,273 $55,387 $104,437 $5,817 $6,416 $6,519

$38,299 $25,533 $43,631 $2,640 $2,634 $3,035

$36,162 $24,730 $41,890 $2,518 $2,489 $2,941

$34,710 $24,176 $40,573 $2,444 $2,390 $2,876

$37,555 $26,225 $42,885 $2,721 $2,582 $3,115

1000$ Costs in $/ton removed
Low Dust U2 Tail End U1 Tail End U2

$243,245 $184,538 $314,997

$159,193 $117,834 $207,541

Low Dust U2 Tail End U1 Tail End U2

$57,351 $39,307 $66,507

$86,542 $50,937 $96,268

$32,974 $22,367 $38,077

$30,929 $21,598 $36,411

$29,539 $21,069 $35,151

$32,262 $23,029 $37,362

Low Dust U2 Tail End U1 Tail End U2 Low Dust U1 Low Dust U2 Tail End U1

$57,351 $39,307 $66,507 $3,970 $3,935 $4,656

$86,542 $50,937 $96,268 $5,324 $5,890 $5,995

$4,647 $4,912 $5,325

$32,974 $22,367 $38,077 $2,281 $2,268 $2,659

$30,929 $21,598 $36,411 $2,164 $2,128 $2,568

$29,539 $21,069 $35,151 $2,093 $2,034 $2,507

1000$ Costs in $/ton removed

$29,539 $21,069 $35,151 $2,093 $2,034 $2,507

$32,262 $23,029 $37,362 $2,359 $2,218 $2,735

Low Dust U2 Tail End U1 Tail End U2 Low Dust U1 Low Dust U2 Tail End U1

$61,029 $41,375 $70,185 $4,214 $4,187 $4,900

$90,220 $53,005 $99,946 $5,567 $6,140 $6,239

$36,652 $24,435 $41,755 $2,527 $2,521 $2,904

$34,607 $23,666 $40,089 $2,410 $2,382 $2,814

$33,217 $23,137 $38,829 $2,339 $2,287 $2,753

$35,940 $25,097 $41,040 $2,604 $2,471 $2,981

1000$ Costs in $/ton removed
Tail End U2

34.11%

Tail End U2
$4,769

$6,846

$5,808

$2,736

$2,618

$2,529

$2,684

Tail End U2

$5,033

$7,107

$3,001

$2,883

$2,794

$2,949
Tail End U2

$4,564

$6,552

$5,558

$2,619

$2,506

$2,420

$2,569

Tail End U2

$4,817

$6,802

$2,872

$2,759

$2,674

$2,822
Minnkota Costs - Shared

Item DIRECT CAPITAL COSTS Low Dust U1 Low Dust U2 Tail End U1

(1) Purchased Capital Equipment

(a)

SCR System Equipment - Capital Cost 

of SCR System $29,738,389 $52,565,778 $38,796,814

Capital Cost of Spare Catalyst

(b) Auxillaries/Balance of Plant $23,756,987 $40,894,045 $33,414,080

(c) Instruments and controls

(d) Taxes

(e) Freight

PURCHASED CAPITAL EQUIPMENT 

COSTS - TOTAL $53,495,376 $93,459,823 $72,210,894

(2) Construction Costs

(a) Foundations and supports $15,097,939 $28,304,959 $20,041,826

(b) Urea storage building

(c) Electrical $6,901,578 $13,809,256 $7,690,294

(d) Mechanical/piping $2,411,613 $4,718,286 $2,513,213

(e) Insulation $3,195,016 $4,686,967 $5,350,536

(f) Painting

DIRECT CAPITAL CONSTRUCTION 

COSTS - TOTAL $27,606,146 $51,519,468 $35,595,869

DIRECT CAPITAL COSTS TOTAL $81,101,522 $144,979,291 $107,806,763

INDIRECT CAPITAL COSTS

(3) Indirect Installation Costs

(a) Engineering and Field Support $12,165,228 $21,746,894 $16,171,014

(b) Construction Mgt & Indirects $3,244,061 $5,799,172 $4,312,270

(c) Startup Expenses $1,582,000 $2,938,000 $1,582,000

(d) Scope Contingency $12,486,493 $21,567,604 $16,536,353

(4) Other Indirect Costs

(a) Pricing Contingency $12,486,493 $21,567,604 $16,536,353

INDIRECT INSTALLATION COSTS - 

TOTAL $41,964,275 $73,619,274 $55,137,990

(5) Cost Escalation during Project $26,772,124 $40,212,687 $35,491,483
(6) Interest During Construction $17,441,200 $30,047,900 $23,097,900

(7) Natural Gas Pipeline - Installed $2,362,500 $4,387,500 $2,362,500

(8) Owner's Costs - Other $13,632,335 $24,182,077 $16,920,540

TOTAL CAPITAL INVESTMENT 

(2018$) $183,273,956 $317,428,729 $240,817,176

TOTAL CAPITAL INVESTMENT 

(2009$) $146,752,955 $254,174,706 $192,829,537

SCR COSTS (2009$) $23,812,420 $42,090,995 $31,065,773

1

8

2009 Costs - Minnkota's costs are in 2018 dollars. ERG back-calculated the 2009 costs using the Present Value Factor of 0.80

listed in Minnkota's documentation.

Includes site excavation, structural steel, concrete, and architechtural construction costs. Includes SCR bypass ducts 

and isolation dampers, and interconnecting ductwork construction costs.

Follows SCR Chapter of EPA Cost Control Manual - Minnkota did not use manual for estimating electrical power 

consumption, reagent usage, and catalyst replacements.

Inculdes catalyst, flue gas heat recovery equipment, and flue gas reheat burner equipment and mechanical setting o

equipment.
Tail End U2 Notes Low Dust U1 Low Dust U2 Tail End U1

$70,418,628 1

2

$52,307,775 3 Auxillaries/Balance of Plant 79.9% 77.8% 86.1%

4

5

6

$122,726,403 7

Construction Costs

$39,631,284 8 Foundations and supports 28.2% 30.3% 27.8%

9 Urea storage building

$15,296,131 10 Electrical 12.9% 14.8% 10.6%

$4,995,255 11 Mechanical/piping 4.5% 5.0% 3.5%

$7,143,550 12 Insulation 6.0% 5.0% 7.4%

13 Painting

$67,066,220 14

DIRECT CAPITAL CONSTRUCTION 

COSTS - TOTAL PERCENT 51.6% 55.1% 49.3%

$189,792,623 15

INDIRECT CAPITAL COSTS

Indirect Installation Costs

$28,468,894 16 Engineering and Field Support 15.0% 15.0% 15.0%

$7,591,705 17 Construction Mgt & Indirects 4.0% 4.0% 4.0%

$2,938,000 18 Startup Expenses 2.0% 2.0% 1.5%

$28,151,800 19 Scope Contingency 15.4% 14.9% 15.3%

Other Indirect Costs

$28,151,800 20 Pricing Contingency 15.4% 14.9% 15.3%

$95,302,199

INDIRECT INSTALLATION COSTS - 

TOTAL PERCENT 51.7% 50.8% 51.1%

$52,726,778 22 Cost Escalation during Project 21.8% 18.4% 21.8%

TABLE A. Calculated Percentages Based on Minnkota's Estimate
$39,221,000 23 Interest During Construction 14.2% 13.7% 14.2%

$4,387,500 24 Natural Gas Pipeline - Installed 1.9% 2.0% 1.4%

$29,632,862 25 Owner's Costs - Other 11.1% 11.1% 10.4%

$411,062,962 26 TOTAL CAPITAL INVESTMENT 48.9% 45.2% 47.8%

$329,150,446

$56,386,308

ng the Present Value Factor of 0.80073, 

n costs. Includes SCR bypass ducts 

ating electrical power 

quipment and mechanical setting of 
TABLE B1. EPA Cost Control Manual

Tail End U2 Percent of Avg % Cost Item Percent of

74.3% SCR Equipment 79.5%

32.3% Capital Equipment 29.6%

12.5% Capital Equipment 12.7%

4.1% Capital Equipment 4.3%

5.8% Capital Equipment 6.1%

54.6%

15.0% Total Capital 15.0% Eng & Home Office 10% Total Capital

4.0% Total Capital 4.0% Gen. Facilities 5% Total Capital

1.5% Total Capital 1.7%

14.8% Total Capital 15.1% Process Contingency 5% Total Capital

14.8% Total Capital 15.1%

50.2% Total 20% Applied to Capital

18.5% Capital + Indirect 20.1% Contingency 15% Capital + Indirect
13.8% Capital + Indirect 14.0%

1.5% Capital + Indirect 1.7%

10.4% Capital + Indirect 10.7%

46.5%

44.2% Total 15% Applied to C + I

Preproduction 2%

Total Plant (applied to C 

+ I + Contingency)

Inventory capital (ammonia) vol (gal) x cost ($/gal)
Cost Item

 Percent of 

Equipment Costs Notes

Auxillaries/Balance of Plant 55%

Perry's lists costs as 

percent of total equipment 

(SCR costs)

Construction Costs

Foundations and supports 18%

Urea storage building

Electrical 18%

Mechanical/piping 29%

Insulation 11%

Value from Perry's is 

Insulation painting

Painting

DIRECT CAPITAL 

CONSTRUCTION COSTS - 

TOTAL 76%

Factor to Apply to Equipment 

Costs 131% Equipment*(0.55+0.76)

Total Direct = SCR+SCR*1.31 = SCR(2.31) (Perry's)

Total Direct = (SCR*1.80)+(SCR*1.80*0.50) = SCR(2.7) (Minnkota)

INDIRECT CAPITAL COSTS

Percent of Total Plant 

Costs

Perry's lists costs as 

percent of total equipment 

(SCR costs). 

% of total direct = cost item 

percent*SCR/total direct = 

cost item %/2.31 (direct = 

2.31*SCR)

Indirect Installation Costs

Engineering and Field 

Support 31% 13%

Construction Mgt & Indirects 43% 19%

Startup Expenses 0%

Scope Contingency 39% 17%

Other Indirect Costs 

(Contractor fees) 17% 7%

Pricing Contingency

INDIRECT INSTALLATION 

COSTS - TOTAL 130% 56%

Contingency 39% 17% Assume apply to plant costs

TABLE B2. Perry's Chemical Engineering Handbook 6th Edition (Table 25-53 Typical Factors with 

ERG Calculation - New Vendor Information w/Hybrid Minnkota and OAQPS Assumptions

Item DIRECT CAPITAL COSTS Low Dust U1 Low Dust U2 Tail End U1 Tail End U2 Notes

(1) Purchased Capital Equipment

(a) SCR System Equipment - Capital Cost of SCR System $23,812,420 $42,090,995 $31,065,773 $56,386,308 1

Capital Cost of Spare Catalyst

(b) Auxillaries/Balance of Plant $19,022,932 $32,745,089 $26,755,656 $41,884,405 2

(c) Instruments and controls

(d) Taxes

(e) Freight

PURCHASED CAPITAL EQUIPMENT COSTS - 

TOTAL $42,835,352 $74,836,084 $57,821,429 $98,270,713

(2) Construction Costs

(a) Foundations and supports $12,089,373 $22,664,630 $16,048,091 $31,733,958

(b) Urea storage building

(c) Electrical $5,526,301 $11,057,486 $6,157,849 $12,248,071

(d) Mechanical/piping $1,931,051 $3,778,073 $2,012,405 $3,999,851

(e) Insulation $2,558,345 $3,752,995 $4,284,335 $5,720,055

(f) Painting

DIRECT CAPITAL CONSTRUCTION COSTS - 

TOTAL $22,105,069 $41,253,184 $28,502,680 $53,701,934

DIRECT CAPITAL COSTS - TOTAL $64,940,422 $116,089,268 $86,324,109 $151,972,647

INDIRECT CAPITAL COSTS

(3) Indirect Installation Costs

(a) Engineering and Home Office (OAQPS) $6,494,042 $11,608,927 $8,632,411 $15,197,265

(b) General Facilities (OAQPS) $3,247,021 $5,804,463 $4,316,205 $7,598,632

(c) Startup Expenses

(d) Process Contingency (OAQPS) $3,247,021 $5,804,463 $4,316,205 $7,598,632

(4) Other Indirect Costs

(a) Pricing Contingency

INDIRECT INSTALLATION COSTS - TOTAL $12,988,084 $23,217,854 $17,264,822 $30,394,529

(5) Cost Escalation during Project

(6) Interest During Construction

(7) Natural Gas Pipeline - Installed $1,495,997 $2,796,038 $1,501,913 $2,806,561

(8) Owner's Costs - Other

Contingency - OAQPS $11,689,276 $20,896,068 $15,538,340 $27,355,076
TOTAL PLANT $91,113,779 $162,999,228 $120,629,184 $212,528,814

Preproduction - OAQPS $1,822,276 $3,259,985 $2,412,584 $4,250,576

Initial Reagent Costs $87,126 $87,126 $87,126 $87,126 ERG-1

TOTAL CAPITAL INVESTMENT $93,023,181 $166,346,339 $123,128,894 $216,866,517

1

2

ERG-1 Reagent costs $2006 $379

Minnkota cost, 

$2006

Cost factor ($2006 = CF * $2009) 0.957

See summary row 

52/53

Reagent costs $2009 $ 396

Reagent storage tank size, gallons 40,000

Assumed based 

on FuelTech 

presentation and 

need for 

approximately 1 

month storage

http://www.ftek.co

m/media/enUS/ppts/2011_EU

EC_CUS_ULTRA

.pdf

Density of urea, lb/gal 11

Initial reagent volume, tons 220

Minnkota SCR costs in 2009 dollars calculated based on their reported costs in 2018 dollars.

Includes SCR system w/gas bypass for maintenance, reactor housing, intial catalyst fill, associated fules and internal flow distribution 

devices, ammonia injection grid, hoists and monorails for SCR internal maintenance, sonic horns, natural gas reheater, regenerative gas 

to gas heat exchangers, heat recovery gas to gas heater exchangers (tail end only), associated interconnected piping, freight.

Applied percentage to SCR equipment in Table A. Note this may double count some auxillaries since Minnkota SCR system only

included costs for SCR with initial catalyst, flue gas heat reheater burner, and mechanical setting of equipment. (Freight is included in 

both EPA's vendor estimate and Minnkota's estimate).
TABLE A. Calculated Percentages Based on Minnkota's Estimate

Low Dust U1 Low Dust U2 Tail End U1 Tail End U2 Percent of Cost Item Percent of

79.9% 77.8% 86.1% 74.3% SCR Equipment

28.2% 30.3% 27.8% 32.3% Capital Equipment

12.9% 14.8% 10.6% 12.5% Capital Equipment

4.5% 5.0% 3.5% 4.1% Capital Equipment

6.0% 5.0% 7.4% 5.8% Capital Equipment

Eng & Home 

Office 10% Total Capital

Gen. Facilities 5% Total Capital

Process 

Contingency 5% Total Capital

Contingency 15% Capital + Indirect

1.9% 2.0% 1.4% 1.5% Capital + Indirect

TABLE B1. EPA Cost Control Manual
Total 15% Applied to C + I

Preproduction 2%

Total Plant 

(applied to C + I 

+ Contingency)
Minnkota Costs - Shared

Item DIRECT ANNUAL COSTS Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

(1) Annual Maintenance Costs $4,189,181 $7,514,611 $5,444,530 $9,608,381

(2) Annual Reagent Costs

Scenario A $2,710,313 $4,171,528 $2,709,417 $4,170,150

Scenario B $2,725,539 $4,204,613 $2,724,643 $4,204,613

(3) Annual Electricity Costs

Scenario A $5,929,642 $9,730,376 $6,011,088 $9,740,159

Scenario B $11,939,901 $24,539,279 $11,982,549 $25,083,883

(4) Annual Water Costs
Catalyst Replacement Costs

(5) Scenario A $709,951 $958,131 $709,951 $963,350

Scenario B $4,387,500 $10,260,000 $4,387,500 $10,260,000

(6)

Natural Gas for F.G. 

Reheating & Urea-to-Ammonia 

Conversion sys

Scenario A $3,559,912 $6,064,108 $3,931,511 $6,416,128

Scenario B $3,240,879 $5,296,499 $3,580,852 $5,574,558

(7)

Operating labor for SCR 

equipment and urea-toammonia equipment

DIRECT ANNUAL COSTS - 

TOTAL

Scenario A $17,098,999 $28,438,754 $18,806,497 $30,898,168

Scenario B $26,483,000 $51,815,002 $28,120,074 $54,731,435

INDIRECT ANNUAL COSTS

(8)

Annual costs from capital 

recovery $12,174,396 $21,838,601 $15,822,632 $27,923,414

(9)

Administrative overhead, 

insurance and property taxes 

for SCRs and aux.

INDIRECT ANNUAL COSTS - 

TOTAL $12,174,396 $21,838,601 $15,822,632 $27,923,414

TOTAL ANNUAL COSTS

Scenario A $29,273,395 $50,277,355 $34,629,129 $58,821,582

Scenario B $38,657,396 $73,653,603 $43,942,706 $82,654,849

LEVELIZED TOTAL 

ANNUALIZED COSTS

Scenario A $33,526,429 $57,350,926 $39,306,869 $66,506,883

Scenario B $45,244,513 $86,541,548 $50,937,012 $96,268,199
Notes for this table are Minnkota's unless otherwise noted. See December 2009 submittal for full set of notes.

1

2

3 $35/MW-hr in 2006 $.

5 $7,500/m3 n 2006 $.

6 Replace 1 layer every 2 years. Uses 2.51 and 2.52 in OAQPS Cost Manual

7 Replace 3 layers/yr for U1 and 4 layers/yr for U2. Did not use annualize adjustments in OAQPS manual.

ERG-1

8 $7.98/MMBTU

12 Capital recovery factor is 0.087185

Minnkota's 2/11/10 response noted an error in the NG costs for U1 LDSCR. ERG input correct cost 

values for U1SCR based on 2/11/10 submittal.

Assumed 3% of installed capital cost of SCR equipment and auxillary equipment. Not including catalyst 

replacement cost.

Urea $379.29/ton in 2006 dollars.
TABLE C. Supporting Information for Minnkota Annual Costs

Notes Item Low Dust U1 Low Dust U2 Tail End U1

1 Annual Maintenance 2.85% 3.26% 3.11%

2 Volume of urea (tons)

Scenario A 7146 10998 7143

Scenario B 7191 11094 7189

Electrical Cost Checks

3

Additional Power Demand of System 

(MW) 8.0 12.4 9.7

Reduction in Operating Hours (hr/yr)

4 Scenario A 256 247 213

Scenario B 981 1235 938

Unit baseline availabiltiy 97.3% 93.9% 93.7%

Updated availabilty

Scenario A 92.3% 89.0% 92.8%

Scenario B 84.0% 77.8% 84.5%

Calculated new availabilty

Scenario A 94.4% 91.1% 91.3%

Scenario B 86.1% 79.8% 83.0%

Baseline capacity 96.6% 95.2% 96.6%

Updated capacity

Scenario A 94.2% 92.9% 93.7%

Scenario B 94.2% 92.9% 93.7%

Reduction in Operating Hours (hr/yr)

Scenario A 444 428 401

Scenario B 1,169 1,416 1,126

Calculate electricity costs

MW/yr required for power demand

Scenario A 60932 89811 73886

Scenario B 55453 78509 67278

MW for downtime

Scenario A 108514 188320 98004

Scenario B 285704 623040 275194

Costs

Scenario A $5,930,602 $9,734,599 $6,016,171

Scenario B $11,940,478 $24,554,225 $11,986,529
5 Volume of catalyst replaced

6 Scenario A 1,893 2,555 1,893

7 Scenario B 11,700 27,360 11,700

Volume of catalyst layers

First three layers 146 256 146

Fourth layer 195 342 195

Total 633 1110 633

Calculated number of times full cat vol replaced

Scenario A 3.0 2.3 3.0

Scenario B 18 25 18

Reported number layers replaced

Scenario A 12 12 10

Scenario B 60 80 60

ERG-1,8 Volume of Natural Gas Purchased (MMBTU)

Scenario A 446104 759913 492671

9 Scenario B 406125 663722 448728

10

11

12 Percent of Total Capital 0.0830 0.0859 0.0821

13

14

15 Levelized costs
or full set of notes.

ents in OAQPS manual.

G input correct cost 

. Not including catalyst 
Tail End U2

3.21% % of Total Capital

10995 tons urea @ $379/ton

11094

14.9

206

1235

93.9%

89.5%

77.8%

91.5%

79.8%

95.2%

U1 = 244.4/253

U2 = 440/462

92.4%

92.4%

387

1,416

107941

93830

170280

623040

$9,737,726

$25,090,452

=new operating hours/8760 

[(baseline availability x 8760 -

reduction)/8760]

U1 = 244.4; U2=440
2,569 m3 catalyst @ $7,500/m3

27,360 m3 catalyst @ $7,500/m3

256

342

1110

2.3

25

10

80

804026

698566

0.0848

Calculated as annual costs/capital 

cost

Total Direct * 1.24873 + Indirect

Table D. Comparison with OAQPS Cost Man

Notes Item

Minnkota's documentation stated they used 3%. Annual Maintenance

Calculated based on Minnkota's cost.

Reported in Minnkota's November 2009 submittals for Units 1 and 

2 (p4-22 in both submittals). Annual Electricity Costs

Catalyst Replacement 

Costs

Reported in Minnkota's November 2009 submittals (Tables C.4-1 

and C.4-2).

Reported in Minnkota's November 2009 submittals (Tables C.4-1 

and C.4-2).

Reported in Minnkota's November 2009 submittals (Tables C.4-1 

and C.4-2).

This calculation checks Minnkota's input with the final electrical 

costs.

Reported in Minnkota's November 2009 submittals (text portion). 

Minnkota assumes 2 shifts/day.

Reported in Minnkota's November 2009 submittals (Tables C.4-1 

and C.4-2).

NOTE: ERG's calculated new availability based on the 

reduction in operating hours does not match Minnkota's 

values due to Minnkota including ASOFA.

Reported in Minnkota's November 2009 submittals (Tables C.4-1 

and C.4-2). Minnkota is including outage for ASOFA alternative.
Reported in Minnkota November 2009 submittal.

Minnkota reported 0.087185. Indirect Annual Costs

Levelized Costs

Number of layers replaced by scenario and type reported in 

Minnkota's November and December 2009 response.

Calculated based on reported volume per layer. Note that these 

numbers x 4 layers should equal the number of layer replaced 

below. Numbers are slightly off indicating Minnkota may have 

Calculated based on Minnkota's catalyst costs and assumed 20 

year life. (annual cost * 20/$7500/m3)

parison with OAQPS Cost Manual Procedures

OAQPS Guidance Notes

1.5% of total capital costs Compares to 3% used by Minnkota

Estimated for SCR equipment, ammonia vaporization, 

and additional ID fan power. Based on pressure 

differentials.

Minnkota provided the additional power 

demand required by SCR in MW.

Assumes a catalyst replacement interval of 3 years.

Cataylst cost is multiplied by a future worth factor 

(FWF) to factor in purchases every few years.
Capital recovery factor (CRF) x total capital 

investment. CRF is based on interest rate. At 6% 

interest and a 20 year life, the CRF is 0.087185.

Not included in OAQPS manual.
Revised Costs - New Catalyst Volumes, Costs, and Replacement Time (OAQPS assumptions and new capital costs)

Item DIRECT ANNUAL COSTS Low Dust U1 Low Dust U2 Tail End U1 Tail End U2 Notes

(1) Annual Maintenance Costs $1,395,348 $2,495,195 $1,846,933 $3,252,998 Use OAQPS rate of 1.5%

(2) Annual Reagent Costs $2,838,965 $4,186,476 $2,715,994 $4,185,787

Used avg tons urea of Scenario A 

and B since volumes are similar 

and $379/ton cost.

Reagent costs 2006$ $379 $379 $379 $379

Cost factor (2006 = CF *2009) 0.957 0.957 0.957 0.957 See summary sheet rows 52/53

Reagent costs 20096$ $396 $396 $396 $396

(3) Annual Electricity Costs See computations in Table C1.

Scenario 1 $3,110,338 $5,535,991 $3,567,949 $6,171,540

Scenario 2 $2,679,246 $4,426,227 $3,139,683 $5,067,598

Scenario 3 $2,248,153 $3,316,463 $2,711,417 $3,963,656

Scenario 4 $3,806,718 $4,791,760 $4,259,764 $5,424,712
(4) Annual Water Costs

Catalyst Replacement Costs

(5) Scenario 1 $1,215,000 $2,055,000 $750,000 $1,275,000 $6000/m3

Scenario 2 $607,500 $1,027,500 $375,000 $637,500

Scenario 3 $405,000 $685,000 $250,000 $425,000

Scenario 4 $1,215,000 $2,055,000 $750,000 $1,275,000

(6)

Natural Gas for F.G. 

Reheating & Urea-toAmmonia Conversion sys $3,400,396 $5,680,304 $3,756,182 $5,995,343

Used avg tons urea of Scenario A 

and B since volumes are similar 

and $7.98/MMBTU cost.

(7)

Operating labor for SCR 

equipment and urea-toammonia equipment

DIRECT ANNUAL COSTS - 

TOTAL

Scenario 1 $11,960,047 $19,952,966 $12,637,059 $20,880,668

Scenario 2 $10,921,454 $17,815,701 $11,833,792 $19,139,226

Scenario 3 $10,287,862 $16,363,437 $11,280,526 $17,822,784
Scenario 4 $12,656,427 $19,208,735 $13,328,873 $20,133,841

INDIRECT ANNUAL COSTS

(8)

Annual costs from capital 

recovery $8,110,185 $14,502,832 $10,734,938 $18,907,411

Use OAQPS value of CFR x 

OAQPS capital investment and 6% 

interest rate.

(9)

Administrative overhead, 

insurance and property taxes 

for SCRs and aux.

INDIRECT ANNUAL COSTS - 

TOTAL $8,110,185 $14,502,832 $10,734,938 $18,907,411

TOTAL ANNUAL COSTS

Scenario 1 $20,070,231 $34,455,798 $23,371,997 $39,788,079

Scenario 2 $19,031,639 $32,318,533 $22,568,730 $38,046,637

Scenario 3 $18,398,047 $30,866,269 $22,015,464 $36,730,195

Scenario 4 $20,766,612 $33,711,566 $24,063,811 $39,041,252

LEVELIZED TOTAL 

ANNUALIZED COSTS

OAQPS does not included 

levelized cost factor.

Scenario 1

Scenario 2

Scenario 3

Scenario 4
TABLE E. Supporing Information for Revised Annual Cost Calculations

Item Low Dust U1 Low Dust U2 Tail End U1 Tail End U2

Volume of urea (tons)

Scenario A 7146 10998 7143 10995 tons urea @ $379/ton

Scenario B 7191 11094 7189 11094

Electrical Cost Checks

Additional Power Demand of System 

(MW) 8.0 12.4 9.7 14.9

Reduction in Operating Hours Due to 

Cat Change (hr/yr)

Scenario 1 104 148 104 148 Replace 1 layer/year

Scenario 2 52 74 52 74 Replace 1 layer/2 years

Scenario 3 0 0 0 0 Replace 1 layer/3 years

Scenario 4 188 181 188 181 ASOFA assumptions

Time required to replace layer (hrs)

Reactor cooldown 48 48 48 48

Remove spent catalyst 64 64 64 64

Install fresh catalyst 52 96 52 96

Post changeout time 36 36 36 36

Subtract normal 4 day outage period 96 96 96 96

Total Time 104 148 104 148

Unit baseline availabiltiy 97.3% 93.9% 97.3% 93.9%

Updated availabilty

Calculated new availabilty

Scenario 1 96.1% 92.2% 96.1% 92.2%

Scenario 2 96.7% 93.1% 96.7% 93.1%

Scenario 3 97.3% 93.9% 97.3% 93.9%

Scenario 4 95.2% 91.8% 95.2% 91.8%

Baseline capacity 96.6% 95.2% 96.6% 95.2%

U1 = 244.4/253

U2 = 440/462

Updated capacity 94.2% 92.9% 93.7% 92.4% Used same as Minnkota submittal

=new operating hours/8760 [(baseline availability

x 8760 -reduction)/8760]
Calculate electricity costs

MW hr/yr required for power demand

Scenario 1 63449 93051 76524 111210

Scenario 2 63841 93904 76996 112229

Scenario 3 64233 94756 77469 113247

Scenario 4 62816 92671 75760 110755

MW hr/yr for downtime

Scenario 1 25418 65120 25418 65120

Scenario 2 12709 32560 12709 32560

Scenario 3 0 0 0 0

Scenario 4 45947 44236 45947 44236

Electrical costs - reduced generation

Scenario 1 $2,220,722 $3,256,791 $2,678,333 $3,892,340

Scenario 2 $2,234,438 $3,286,627 $2,694,875 $3,927,998

Scenario 3 $2,248,153 $3,316,463 $2,711,417 $3,963,656

Scenario 4 $2,198,566 $3,243,486 $2,651,612 $3,876,438

Electrical costs - dowtime

Scenario 1 $889,616 $2,279,200 $889,616 $2,279,200

Scenario 2 $444,808 $1,139,600 $444,808 $1,139,600

Scenario 3 $0 $0 $0 $0

Scenario 4 $1,608,152 $1,548,274 $1,608,152 $1,548,274

Volume of catalyst replaced

Scenario 1 203 343 125 213

Scenario 2 101 171 63 106

Scenario 3 68 114 42 71

Scenario 4 203 343 125 213

Volume of catalyst layers

Each layer 202.5 342.5 125 212.5

Volume of Natural Gas Purchased (MMBTU)

Scenario A 446104 759913 492671 804026

Scenario B 406125 663722 448728 698566

Add power demand x availability x capacity x 8760

U1 = 244.4; U2=440

hours downtime x MW

Notes

Minnkota's documentation stated they used 3%.

Calculated based on Minnkota's cost.

Use same assumptions as Minnkota for extra power demand of systems. 

(Reported in Minnkota's November 2009 submittals for Units 1 and 2 (p4-22 in 

both submittals).)

Reported in Minnkota's November 2009 submittals (Tables C.4-1 and C.4-2).

Reported in Minnkota's November 2009 submittals (Tables C.4-1 and C.4-2).

Annualize hours per year based on change out frequency. Did not include 

ASOFA. Assume catalyst replacement performed during major outage for 

every 3 year scenario. Therefore, no additional downtime is due to the catalyst 

outage.

Revised assumptions for catalyst changeout per EPA's analysis.
EPA vendor info. Will have total of three layers.

For catalyst replacement every two or three years, ERG divided the catalysts 

costs equally over the time period.

This calculation checks Minnkota's input with the final electrical costs.

Annualized hours per year based on replacement frequency. Scenario 1: 1 

layer/yr; Scenario 2: 1 layer/2 yrs; Scenario 3: 1 layer/3 yrs;