Document ID: EPA-HQ-OAR-2002-0056-0040
Agency: epa
Document Type: Supporting & Related Material
Title: 
Posted Date: 2004-01-27T05:00Z

Size
acfm
25MW
76400
50MW
152800
70MW
213920
150
MW
458,400
370
MW
1,130,720
700
MW
2,139,200
Costing
equations
Capital
cosAnnual
cosEnergy
usaSolid
waste
generation,
tons/
y
MW
Capital,
$
25
195,087
50
112,540
<
500
MW
­
162853Ln(­
23373Ln(
x
28873
0.163
70
87,525
150
MW
­
24890Ln(
x­
3538.9Ln(
x
28873
0.163
150
52,287
370
MW
370
35,383
700
MW
700
27,732
Capital
cos
y
=
­
16126Ln(
x)
+
132401
R2
=
0.9868
0
20,000
40,000
60,000
0
200
Capital
cost,

2001
$

Annual
cost
y
=
­
2343.3Ln(
x)
+
21235
R2
=
0.9865
0
5,000
10,000
15,000
0
200
Annual
cost,
$/
y­

MW
Capital
costs,
<
7
y
=
­
106654Ln(
x)
+
536270
R2
=
0.9896
0
100,000
200,000
300,000
0
20
Capital
cost,

$/
MW­
y
2001
$
MW
Annual,
$/
yMW
Energy,
KWMW
Solid
waste,
tons/
yr­
MW
MW
25
30,657
25
24,689
25
0.163
25
50
18,455
50
24,689
50
0.163
50
70
14,765
70
24,689
70
0.163
70
150
9,594
150
24,689
150
0.163
150
370
7,134
370
24,689
370
0.163
370
700
6,027
700
24,689
700
0.163
700
Capital
costs,
oil,
$/
MW
+
132401
68
200
400
600
800
Unit
size,
MW
Annual
costs,
oil,
$/
y­
MW
+
21235
5
200
400
600
800
Unit
size,
MW
Energy
usage,
oil,
KWh/
y
y
=
24689x2E­
06
R2
=
0.2376
24,689
24,689
24,689
24,689
0
200
400
600
Unit
size,
Mw
Energy
usage,

kWh/
y
Solid
waste,
oil,
tons/
yr
0.000
0.050
0.100
0.150
0.200
0
200
400
60
Unit
size,
MW
Solid
waste
generation,

tons/
y
tal
costs,
<
70
MW,
oil,
$/
MW­
y
)
+
536270
896
0
20
40
60
80
Unit
size,
MW
Annual
costs,
<
70
MW,
oil,
$/
y­
M
y
=
­
15758Ln(
x)
+
81066
R2
=
0.9895
0
10,000
20,000
30,000
40,000
0
50
100
Unit
size,
MW
Annual
cost,
$/
y­

MW
Capital,
$
MW
Annual,
$/
yMW
Energy,
KWMW
Solid
waste,
tons/
yr­
MW
291,845
25
44,081
25
28,873
25
0.163
166,618
50
26,105
50
28,873
50
0.163
127,392
70
20,479
70
28,873
70
0.163
80,601
150
13,829
150
28,873
150
0.163
54,111
370
10,063
370
28,873
370
0.163
42,749
700
8,447
700
28,873
700
0.163
ave
,
KWh/
y
00
600
800
ze,
Mw
tons/
yr
400
600
800
size,
MW
,
oil,
$/
y­
MW
100
fraction
of
unit
operated
at
70
%
instead
of
80
%
capital
annual
power
solid
waste
0.668463
1
0.695459
1
0.855088
1
1
0.675436
1
0.706951
1
0.85509
1
1
0.687056
1
0.720986
1
0.855088
1
1
0.648717
1
0.693771
1
0.855093
1
1
0.653899
1
0.708868
1
0.855091
1
1
0.648717
1
0.713449
1
0.85509
1
1
0.663715
0.706581
1
0.85509
1
1
ELECTROSTATIC
PRECIPITATORS
Case
Oil
­
700
MW
700
You
supply
data
for
boxed
cells,
see
OAQPS
Control
Cost
Manual
SIZING
PROCEDURE
Flat
Plate
Design
ESP
Type
2
(
Flat
Plate
=
2,
Plate­
Wire=
1)
Design
Efficiency
(
E)
0.8
Penetration
(
p)
0.2
Temperature
(
Tk)
413
Resistivity
(
ohm­
cm)
2.00E+
09
MMD(
i)
3.5
Sneakage
(
Sn)
0.1
Rapping
Reentrainment(
RR)
0.124
MMD(
p)
2
MMD(
r)
3
Loss
Factor
(
LF)
0.2116
E(
bd)
318,194
(
V/
m)
n
(
eta)
2.308E­
05
(
Kg/
md)
e(
0)
8.85E­
12
(
F/
m)
E(
avg)
252,535
Number
of
Sections
(
n)
2
Average
Section
Penetration
(
Ps)
0.45
Collection
Penetration
(
Pc)
0.30
Particle
Size
Change
Factor
(
D)
0.45
MMD(
rp)
0.52
Computed
MMD(
n)
1
3.5
2
2.94
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Computed
SCA
1
12.71
2
15.11
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Total
SCA
27.81
Total
ESCA
141.29
EXHAUST
VOLUME
(
acfm)
2,139,200
acfm
Annual
Dust
Loading
Total
Collection
Area
(
sq.
ft.)
302,258
sq.
ft.
0.10
grains/
cu.
ft.
Annual
Hours
of
Operations
7446
COSTING
PROCEDURE
Prices
include:
ESP
casing,
pyramidal
hoppers,
rigid
electrodes
and
internal
collecting
plates,
transformer­
rectifier
sets
and
microprocessor
controls,
rappers
and
stub­
supports.
(
Options
include
inlet/
outler
nozzles
and
diffusion
plates,
hopper
auxiliaries
and
level
detectors,
weather
enclosure
and
stair
access,
structural
supports,
and
3
in.
of
fiberglass
insulation
encased
in
a
metal
skin.
Costs
also
include
auxiliary
equipment.)

"
Your
year"
dollars
are
based
on
the
Chemical
Engineering
cost
index
value
you
specify
below.
The
base
year
value
(
mid
1987)
is
320,
which
should
be
entered
if
you
do
not
have
a
cost
index
value.
In
this
case
you
should
not
use
"
your
year"
values
for
direct
annual
costs
and
should
not
enter
1
in
the
second
line
of
the
box
below.

"
CRF"
is
a
capital
recovery
factor
calculated
as
described
in
Chapter
2
of
the
OAQPS
Control
Cost
Manual
and
based
on
interest
rate
and
equipment
lifetime.

Supply
the
following
data
to
be
used
in
the
costing
procedure:

Chemical
Engineering
cost
index
value
for
your
year
(
enter
base
year
value
of
320
if
no
other
value)
394.3
If
using
your
year
dollar
values
for
direct
annual
costs,
enter
1
1
Operating
labor
hourly
cost
without
overheads
($
12/
hr
base
year)
17.26
Cost
of
electricity
($
0.06/
kWh
for
base
year)
0.06
Tipping
fee
for
waste
disposal
($
20/
ton
for
base
year)
50
Fractional
interest
rate
for
capital
(
0.07
for
base
year)
0.07
Equipment
lifetime
(
20
years
for
base
case)
20
Additional
auxiliary
costs,
base
year
(
1987)
0.00E+
00
Retrofit
factor
(
1.2
to
1.5
typical,
use
1
for
new
installation)
1.40
Capital
Cost
Factors
for
ESPs
Direct
Costs
in
base
year
dollars
Purchased
Equipment
Costs
ESP
+
auxiliary
equipment
$
6,303,659
Auxiliary
equipment
$
2,801,626
ESP
$
3,502,033
$
11.59
Instrumentation
(
0.1
x
EC)
$
630,366
$
5.00
Sales
taxes
(
0.03
x
EC)
$
189,110
Freight
(
0.05
x
EC)
$
315,183
Purchased
equipment
cost,
PEC
$
7,438,318
Direct
installation
costs
in
base
year
dollars
Foundations
&
supports
(
0.04
x
PEC)
$
297,533
Handling
&
erection
().
5
x
PEC)
$
3,719,159
Electrical
(
0.08
x
PEC)
$
595,065
Piping
(
0.01
x
PEC)
$
74,383
Insulation
for
ductwork
(
0.02
x
PEC)
$
148,766
Painting
(
0.02
x
PEC)
$
148,766
Direct
installation
costs
$
4,983,672
Site
preparation
Buildings
Total
Direct
Costs,
DC
$
7,013,388
Indirect
Costs
(
installation,
in
base
year
dollars)
Engineering
(
0.2
x
PEC)
$
1,487,664
Construction
and
field
expenses
(
0.2
x
PEC)
$
1,487,664
Contractor
fees
(
0.1
x
PEC)
$
743,832
Start­
up
(
0.01
x
PEC)
$
74,383
Performance
test
(
0.01
x
PEC
$
74,383
Model
study
(
0.02
x
PEC)
$
148,766
Contingencies
(
0.03
x
PEC)
$
223,150
Total
Indirect
Costs,
IC
$
4,239,842
Total
Capital
Investment
(
TCI=
(
DC
+
IC)
x
retrofit)
$
15,754,522
TCI
in
your
year
dollars
$
19,412,525
9.07
27.73
Annual
Costs
For
ESP
Systems
27,732
Direct
Annual
Costs,
DC
Operating
labor
Operator
(
3
hrs/
day
x
labor
cost
)
$
16,065
Supervisor
(
15
%
of
operator)
$
2,410
Coordinator
(
1/
3
of
operator)
$
5,355
Operating
materials
Maintenance
Labor
(
based
on
collector
area)
$
30,726
Materials
(
1%
of
PEC)
$
74,383
Utilities
Electricity
­
fan
$
774,965
24,689
kWh/
y­
MW
(
0.000181
x
flue
x
pres.
drp.
x
hrs
x
power
cost)
Electricity
­
operating
$
261,971
(
0.00194
x
col.
area
x
hrs
x
power
cost)
Waste
disposal
2
mile
haul
$
348,499
0.163
tons/
y­
MW
(
tipping
fee
+
$
0.50/
ton­
mi)
Total
DC,
your
year
dollars
$
1,514,374
Indirect
Annual
Costs,
IC
Overhead
(
60%
of
labor
&
maint.
materials)
$
95,326
Administrative
charges
(
0.02
x
TCI)
$
388,251
Property
tax
(
0.01
x
TCI)
$
194,125
Insurance
(
0.01
x
TCI)
$
194,125
Capital
recovery
(
CRF
x
TCI)*
$
1,832,405
Total
IC
your
year
dollars
$
2,704,232
Total
Annual
Cost,
your
year
dollars
$
4,218,606
$
9.20
$
6.03
6,027
0.5
0.75
0.9
0.95
0.99
0.995
0.999
$
308,802
$
378,309
$
416,839
$
517,794
$
673,798
$
589,425
$
680,192
Total
Annual
Cost
vs.
Efficiency
for
Electrostatic
Precipatators
0
2
0.5
0.7
0.9
1.1
REMOVAL
EFFICIENCY
COSTS
Throughpu
acf
Flat
Plate
Design
$/
ft2
plate
area,
1987
$,
ESP
only
$/
kW,
1987
$,
ESP
only
$/
acfm
$/
kW
$/
MW
$/
acfm
$/
kW
$/
MW
ELECTROSTATIC
PRECIPITATORS
Case
Oil
­
370
MW
370
You
supply
data
for
boxed
cells,
see
OAQPS
Control
Cost
Manual
SIZING
PROCEDURE
Flat
Plate
Design
ESP
Type
2
(
Flat
Plate
=
2,
Plate­
Wire=
1)
Design
Efficiency
(
E)
0.8
Penetration
(
p)
0.2
Temperature
(
Tk)
413
Resistivity
(
ohm­
cm)
2.00E+
09
MMD(
i)
3.5
Sneakage
(
Sn)
0.1
Rapping
Reentrainment(
RR)
0.124
MMD(
p)
2
MMD(
r)
3
Loss
Factor
(
LF)
0.2116
E(
bd)
318,194
(
V/
m)
n
(
eta)
2.308E­
05
(
Kg/
md)
e(
0)
8.85E­
12
(
F/
m)
E(
avg)
252,535
Number
of
Sections
(
n)
2
Average
Section
Penetration
(
Ps)
0.45
Collection
Penetration
(
Pc)
0.30
Particle
Size
Change
Factor
(
D)
0.45
MMD(
rp)
0.52
Computed
MMD(
n)
1
3.5
2
2.94
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Computed
SCA
1
12.71
2
15.11
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Total
SCA
27.81
Total
ESCA
141.29
EXHAUST
VOLUME
(
acfm)
1,130,720
acfm
Annual
Dust
Loading
Total
Collection
Area
(
sq.
ft.)
159,765
sq.
ft.
0.10
grains/
cu.
ft.
Annual
Hours
of
Operations
7446
COSTING
PROCEDURE
Prices
include:
ESP
casing,
pyramidal
hoppers,
rigid
electrodes
and
internal
collecting
plates,
transformer­
rectifier
sets
and
microprocessor
controls,
rappers
and
stub­
supports.
(
Options
include
inlet/
outler
nozzles
and
diffusion
plates,
hopper
auxiliaries
and
level
detectors,
weather
enclosure
and
stair
access,
structural
supports,
and
3
in.
of
fiberglass
insulation
encased
in
a
metal
skin.
Costs
also
include
auxiliary
equipment.)

"
Your
year"
dollars
are
based
on
the
Chemical
Engineering
cost
index
value
you
specify
below.
The
base
year
value
(
mid
1987)
is
320,
which
should
be
entered
if
you
do
not
have
a
cost
index
value.
In
this
case
you
should
not
use
"
your
year"
values
for
direct
annual
costs
and
should
not
enter
1
in
the
second
line
of
the
box
below.

"
CRF"
is
a
capital
recovery
factor
calculated
as
described
in
Chapter
2
of
the
OAQPS
Control
Cost
Manual
and
based
on
interest
rate
and
equipment
lifetime.

Supply
the
following
data
to
be
used
in
the
costing
procedure:

Chemical
Engineering
cost
index
value
for
your
year
(
enter
base
year
value
of
320
if
no
other
value)
394.3
If
using
your
year
dollar
values
for
direct
annual
costs,
enter
1
1
Operating
labor
hourly
cost
without
overheads
($
12/
hr
base
year)
17.26
Cost
of
electricity
($
0.06/
kWh
for
base
year)
0.06
Tipping
fee
for
waste
disposal
($
20/
ton
for
base
year)
50
Fractional
interest
rate
for
capital
(
0.07
for
base
year)
0.07
Equipment
lifetime
(
20
years
for
base
case)
20
Additional
auxiliary
costs,
base
year
(
1987)
0.00E+
00
Retrofit
factor
(
1.2
to
1.5
typical,
use
1
for
new
installation)
1.40
Capital
Cost
Factors
for
ESPs
Direct
Costs
in
base
year
dollars
Purchased
Equipment
Costs
ESP
+
auxiliary
equipment
$
3,799,489
Auxiliary
equipment
$
1,688,662
ESP
$
2,110,827
$
13.21
Instrumentation
(
0.1
x
EC)
$
379,949
$
5.70
Sales
taxes
(
0.03
x
EC)
$
113,985
Freight
(
0.05
x
EC)
$
189,974
Purchased
equipment
cost,
PEC
$
4,483,397
Direct
installation
costs
in
base
year
dollars
Foundations
&
supports
(
0.04
x
PEC)
$
179,336
Handling
&
erection
().
5
x
PEC)
$
2,241,698
Electrical
(
0.08
x
PEC)
$
358,672
Piping
(
0.01
x
PEC)
$
44,834
Insulation
for
ductwork
(
0.02
x
PEC)
$
89,668
Painting
(
0.02
x
PEC)
$
89,668
Direct
installation
costs
$
3,003,876
Site
preparation
Buildings
Total
Direct
Costs,
DC
$
5,033,592
Indirect
Costs
(
installation,
in
base
year
dollars)
Engineering
(
0.2
x
PEC)
$
896,679
Construction
and
field
expenses
(
0.2
x
PEC)
$
896,679
Contractor
fees
(
0.1
x
PEC)
$
448,340
Start­
up
(
0.01
x
PEC)
$
44,834
Performance
test
(
0.01
x
PEC
$
44,834
Model
study
(
0.02
x
PEC)
$
89,668
Contingencies
(
0.03
x
PEC)
$
134,502
Total
Indirect
Costs,
IC
$
2,555,536
Total
Capital
Investment
(
TCI=
(
DC
+
IC)
x
retrofit)
$
10,624,779
TCI
in
your
year
dollars
$
13,091,720
11.58
35.38
Annual
Costs
For
ESP
Systems
35,383
Direct
Annual
Costs,
DC
Operating
labor
Operator
(
3
hrs/
day
x
labor
cost
)
$
16,065
Supervisor
(
15
%
of
operator)
$
2,410
Coordinator
(
1/
3
of
operator)
$
5,355
Operating
materials
Maintenance
Labor
(
based
on
collector
area)
$
16,241
Materials
(
1%
of
PEC)
$
44,834
Utilities
Electricity
­
fan
$
409,625
24,689
kWh/
y­
MW
(
0.000181
x
flue
x
pres.
drp.
x
hrs
x
power
cost)
Electricity
­
operating
$
138,471
(
0.00194
x
col.
area
x
hrs
x
power
cost)
Waste
disposal
2
mile
haul
$
184,207
0.163
tons/
y­
MW
(
tipping
fee
+
$
0.50/
ton­
mi)
Total
DC,
your
year
dollars
$
817,208
Indirect
Annual
Costs,
IC
Overhead
(
60%
of
labor
&
maint.
materials)
$
62,771
Administrative
charges
(
0.02
x
TCI)
$
261,834
Property
tax
(
0.01
x
TCI)
$
130,917
Insurance
(
0.01
x
TCI)
$
130,917
Capital
recovery
(
CRF
x
TCI)*
$
1,235,766
Total
IC
your
year
dollars
$
1,822,205
Total
Annual
Cost,
your
year
dollars
$
2,639,413
$
5.76
$
7.13
7,134
0.5
0.75
0.9
0.95
0.99
0.995
0.999
$
308,802
$
378,309
$
416,839
$
517,794
$
673,798
$
589,425
$
680,192
Total
Annual
Cost
vs.
Efficiency
for
Electrostatic
Precipatators
0
2
0.5
0.7
0.9
1.1
REMOVAL
EFFICIENCY
COSTS
Throughpu
acf
Flat
Plate
Design
$/
ft2
plate
area,
1987
$,
ESP
only
$/
kW,
1987
$,
ESP
only
$/
acfm
$/
kW
$/
MW
$/
acfm
$/
kW
$/
MW
ELECTROSTATIC
PRECIPITATORS
Case
Oil
­
150
MW
150
You
supply
data
for
boxed
cells,
see
OAQPS
Control
Cost
Manual
SIZING
PROCEDURE
Flat
Plate
Design
ESP
Type
2
(
Flat
Plate
=
2,
Plate­
Wire=
1)
Design
Efficiency
(
E)
0.8
Penetration
(
p)
0.2
Temperature
(
Tk)
413
Resistivity
(
ohm­
cm)
2.00E+
09
MMD(
i)
3.5
Sneakage
(
Sn)
0.1
Rapping
Reentrainment(
RR)
0.124
MMD(
p)
2
MMD(
r)
3
Loss
Factor
(
LF)
0.2116
E(
bd)
318,194
(
V/
m)
n
(
eta)
2.308E­
05
(
Kg/
md)
e(
0)
8.85E­
12
(
F/
m)
E(
avg)
252,535
Number
of
Sections
(
n)
2
Average
Section
Penetration
(
Ps)
0.45
Collection
Penetration
(
Pc)
0.30
Particle
Size
Change
Factor
(
D)
0.45
MMD(
rp)
0.52
Computed
MMD(
n)
1
3.5
2
2.94
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Computed
SCA
1
12.71
2
15.11
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Total
SCA
27.81
Total
ESCA
141.29
EXHAUST
VOLUME
(
acfm)
458,400
acfm
Annual
Dust
Loading
Total
Collection
Area
(
sq.
ft.)
64,770
sq.
ft.
0.10
grains/
cu.
ft.
Annual
Hours
of
Operations
7446
dwcgi­
5273­
1075236774­
948100000.
xls
22
1/
28/
04
1:
43
PM
COSTING
PROCEDURE
Prices
include:
ESP
casing,
pyramidal
hoppers,
rigid
electrodes
and
internal
collecting
plates,
transformer­
rectifier
sets
and
microprocessor
controls,
rappers
and
stub­
supports.
(
Options
include
inlet/
outler
nozzles
and
diffusion
plates,
hopper
auxiliaries
and
level
detectors,
weather
enclosure
and
stair
access,
structural
supports,
and
3
in.
of
fiberglass
insulation
encased
in
a
metal
skin.
Costs
also
include
auxiliary
equipment.)

"
Your
year"
dollars
are
based
on
the
Chemical
Engineering
cost
index
value
you
specify
below.
The
base
year
value
(
mid
1987)
is
320,
which
should
be
entered
if
you
do
not
have
a
cost
index
value.
In
this
case
you
should
not
use
"
your
year"
values
for
direct
annual
costs
and
should
not
enter
1
in
the
second
line
of
the
box
below.

"
CRF"
is
a
capital
recovery
factor
calculated
as
described
in
Chapter
2
of
the
OAQPS
Control
Cost
Manual
and
based
on
interest
rate
and
equipment
lifetime.

Supply
the
following
data
to
be
used
in
the
costing
procedure:

Chemical
Engineering
cost
index
value
for
your
year
(
enter
base
year
value
of
320
if
no
other
value)
394.3
If
using
your
year
dollar
values
for
direct
annual
costs,
enter
1
1
Operating
labor
hourly
cost
without
overheads
($
12/
hr
base
year)
17.26
Cost
of
electricity
($
0.06/
kWh
for
base
year)
0.06
Tipping
fee
for
waste
disposal
($
20/
ton
for
base
year)
50
Fractional
interest
rate
for
capital
(
0.07
for
base
year)
0.07
Equipment
lifetime
(
20
years
for
base
case)
20
Additional
auxiliary
costs,
base
year
(
1987)
0.00E+
00
Retrofit
factor
(
1.2
to
1.5
typical,
use
1
for
new
installation)
1.40
dwcgi­
5273­
1075236774­
948100000.
xls
23
1/
28/
04
1:
43
PM
Capital
Cost
Factors
for
ESPs
Direct
Costs
in
base
year
dollars
Purchased
Equipment
Costs
ESP
+
auxiliary
equipment
$
1,720,098
Auxiliary
equipment
$
764,488
ESP
$
955,610
$
14.75
Instrumentation
(
0.1
x
EC)
$
172,010
$
6.37
Sales
taxes
(
0.03
x
EC)
$
51,603
Freight
(
0.05
x
EC)
$
86,005
Purchased
equipment
cost,
PEC
$
2,029,716
Direct
installation
costs
in
base
year
dollars
Foundations
&
supports
(
0.04
x
PEC)
$
81,189
Handling
&
erection
().
5
x
PEC)
$
1,014,858
Electrical
(
0.08
x
PEC)
$
162,377
Piping
(
0.01
x
PEC)
$
20,297
Insulation
for
ductwork
(
0.02
x
PEC)
$
40,594
Painting
(
0.02
x
PEC)
$
40,594
Direct
installation
costs
$
1,359,909
Site
preparation
Buildings
Total
Direct
Costs,
DC
$
3,389,625
Indirect
Costs
(
installation,
in
base
year
dollars)
Engineering
(
0.2
x
PEC)
$
405,943
Construction
and
field
expenses
(
0.2
x
PEC)
$
405,943
Contractor
fees
(
0.1
x
PEC)
$
202,972
Start­
up
(
0.01
x
PEC)
$
20,297
Performance
test
(
0.01
x
PEC
$
20,297
Model
study
(
0.02
x
PEC)
$
40,594
Contingencies
(
0.03
x
PEC)
$
60,891
Total
Indirect
Costs,
IC
$
1,156,937
Total
Capital
Investment
(
TCI=
(
DC
+
IC)
x
retrofit)
$
6,365,187
dwcgi­
5273­
1075236774­
948100000.
xls
24
1/
28/
04
1:
43
PM
TCI
in
your
year
dollars
$
7,843,104
17.11
52.29
Annual
Costs
For
ESP
Systems
52,287
Direct
Annual
Costs,
DC
Operating
labor
Operator
(
3
hrs/
day
x
labor
cost
)
$
16,065
Supervisor
(
15
%
of
operator)
$
2,410
Coordinator
(
1/
3
of
operator)
$
5,355
Operating
materials
Maintenance
Labor
(
based
on
collector
area)
$
6,584
Materials
(
1%
of
PEC)
$
20,297
Utilities
Electricity
­
fan
$
166,064
24,689
kWh/
y­
MW
(
0.000181
x
flue
x
pres.
drp.
x
hrs
x
power
cost)
Electricity
­
operating
$
56,137
(
0.00194
x
col.
area
x
hrs
x
power
cost)
Waste
disposal
2
mile
haul
$
74,678
0.163
tons/
y­
MW
(
tipping
fee
+
$
0.50/
ton­
mi)
Total
DC,
your
year
dollars
$
347,590
Indirect
Annual
Costs,
IC
Overhead
(
60%
of
labor
&
maint.
materials)
$
37,491
Administrative
charges
(
0.02
x
TCI)
$
156,862
Property
tax
(
0.01
x
TCI)
$
78,431
Insurance
(
0.01
x
TCI)
$
78,431
Capital
recovery
(
CRF
x
TCI)*
$
740,333
Total
IC
your
year
dollars
$
1,091,548
Total
Annual
Cost,
your
year
dollars
$
1,439,138
$
3.14
$
9.59
dwcgi­
5273­
1075236774­
948100000.
xls
25
1/
28/
04
1:
43
PM
ELECTROSTATIC
PRECIPITATORS
Case
Oil
­
70
MW
70
You
supply
data
for
boxed
cells,
see
OAQPS
Control
Cost
Manual
SIZING
PROCEDURE
Flat
Plate
Design
ESP
Type
2
(
Flat
Plate
=
2,
Plate­
Wire=
1)
Design
Efficiency
(
E)
0.8
Penetration
(
p)
0.2
Temperature
(
Tk)
413
Resistivity
(
ohm­
cm)
2.00E+
09
MMD(
i)
3.5
Sneakage
(
Sn)
0.1
Rapping
Reentrainment(
RR)
0.124
MMD(
p)
2
MMD(
r)
3
Loss
Factor
(
LF)
0.2116
E(
bd)
318,194
(
V/
m)
n
(
eta)
2.308E­
05
(
Kg/
md)
e(
0)
8.85E­
12
(
F/
m)
E(
avg)
252,535
Number
of
Sections
(
n)
2
Average
Section
Penetration
(
Ps)
0.45
Collection
Penetration
(
Pc)
0.30
Particle
Size
Change
Factor
(
D)
0.45
MMD(
rp)
0.52
Computed
MMD(
n)
1
3.5
2
2.94
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Computed
SCA
1
12.71
2
15.11
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Total
SCA
27.81
Total
ESCA
141.29
EXHAUST
VOLUME
(
acfm)
213,920
acfm
Annual
Dust
Loading
Total
Collection
Area
(
sq.
ft.)
30,226
sq.
ft.
0.10
grains/
cu.
ft.
Annual
Hours
of
Operations
7446
COSTING
PROCEDURE
Prices
include:
ESP
casing,
pyramidal
hoppers,
rigid
electrodes
and
internal
collecting
plates,
transformer­
rectifier
sets
and
microprocessor
controls,
rappers
and
stub­
supports.
(
Options
include
inlet/
outler
nozzles
and
diffusion
plates,
hopper
auxiliaries
and
level
detectors,
weather
enclosure
and
stair
access,
structural
supports,
and
3
in.
of
fiberglass
insulation
encased
in
a
metal
skin.
Costs
also
include
auxiliary
equipment.)

"
Your
year"
dollars
are
based
on
the
Chemical
Engineering
cost
index
value
you
specify
below.
The
base
year
value
(
mid
1987)
is
320,
which
should
be
entered
if
you
do
not
have
a
cost
index
value.
In
this
case
you
should
not
use
"
your
year"
values
for
direct
annual
costs
and
should
not
enter
1
in
the
second
line
of
the
box
below.

"
CRF"
is
a
capital
recovery
factor
calculated
as
described
in
Chapter
2
of
the
OAQPS
Control
Cost
Manual
and
based
on
interest
rate
and
equipment
lifetime.

Supply
the
following
data
to
be
used
in
the
costing
procedure:

Chemical
Engineering
cost
index
value
for
your
year
(
enter
base
year
value
of
320
if
no
other
value)
394.3
If
using
your
year
dollar
values
for
direct
annual
costs,
enter
1
1
Operating
labor
hourly
cost
without
overheads
($
12/
hr
base
year)
17.26
Cost
of
electricity
($
0.06/
kWh
for
base
year)
0.06
Tipping
fee
for
waste
disposal
($
20/
ton
for
base
year)
50
Fractional
interest
rate
for
capital
(
0.07
for
base
year)
0.07
Equipment
lifetime
(
20
years
for
base
case)
20
Additional
auxiliary
costs,
base
year
(
1987)
0.00E+
00
Retrofit
factor
(
1.2
to
1.5
typical,
use
1
for
new
installation)
1.40
Capital
Cost
Factors
for
ESPs
Direct
Costs
in
base
year
dollars
Purchased
Equipment
Costs
ESP
+
auxiliary
equipment
$
1,040,121
Auxiliary
equipment
$
462,276
ESP
$
577,845
$
19.12
Instrumentation
(
0.1
x
EC)
$
104,012
$
8.25
Sales
taxes
(
0.03
x
EC)
$
31,204
Freight
(
0.05
x
EC)
$
52,006
Purchased
equipment
cost,
PEC
$
1,227,343
Direct
installation
costs
in
base
year
dollars
Foundations
&
supports
(
0.04
x
PEC)
$
49,094
Handling
&
erection
().
5
x
PEC)
$
613,672
Electrical
(
0.08
x
PEC)
$
98,187
Piping
(
0.01
x
PEC)
$
12,273
Insulation
for
ductwork
(
0.02
x
PEC)
$
24,547
Painting
(
0.02
x
PEC)
$
24,547
Direct
installation
costs
$
822,320
Site
preparation
Buildings
Total
Direct
Costs,
DC
$
2,852,036
Indirect
Costs
(
installation,
in
base
year
dollars)
Engineering
(
0.2
x
PEC)
$
245,469
Construction
and
field
expenses
(
0.2
x
PEC)
$
245,469
Contractor
fees
(
0.1
x
PEC)
$
122,734
Start­
up
(
0.01
x
PEC)
$
12,273
Performance
test
(
0.01
x
PEC
$
12,273
Model
study
(
0.02
x
PEC)
$
24,547
Contingencies
(
0.03
x
PEC)
$
36,820
Total
Indirect
Costs,
IC
$
699,585
Total
Capital
Investment
(
TCI=
(
DC
+
IC)
x
retrofit)
$
4,972,269
TCI
in
your
year
dollars
$
6,126,768
28.64
87.53
Annual
Costs
For
ESP
Systems
87,525
Direct
Annual
Costs,
DC
Operating
labor
Operator
(
3
hrs/
day
x
labor
cost
)
$
16,065
Supervisor
(
15
%
of
operator)
$
2,410
Coordinator
(
1/
3
of
operator)
$
5,355
Operating
materials
Maintenance
Labor
(
based
on
collector
area)
$
5,083
Materials
(
1%
of
PEC)
$
12,273
Utilities
Electricity
­
fan
$
77,497
24,689
kWh/
y­
MW
(
0.000181
x
flue
x
pres.
drp.
x
hrs
x
power
cost)
Electricity
­
operating
$
26,197
(
0.00194
x
col.
area
x
hrs
x
power
cost)
Waste
disposal
2
mile
haul
$
34,850
0.163
tons/
y­
MW
(
tipping
fee
+
$
0.50/
ton­
mi)
Total
DC,
your
year
dollars
$
179,730
Indirect
Annual
Costs,
IC
Overhead
(
60%
of
labor
&
maint.
materials)
$
30,449
Administrative
charges
(
0.02
x
TCI)
$
122,535
Property
tax
(
0.01
x
TCI)
$
61,268
Insurance
(
0.01
x
TCI)
$
61,268
Capital
recovery
(
CRF
x
TCI)*
$
578,324
Total
IC
your
year
dollars
$
853,844
Total
Annual
Cost,
your
year
dollars
$
1,033,574
$
2.25
$
14.77
14,765
0.5
0.75
0.9
0.95
0.99
0.995
0.999
$
308,802
$
378,309
$
416,839
$
517,794
$
673,798
$
589,425
$
680,192
Total
Annual
Cost
vs.
Efficiency
for
Electrostatic
Precipatators
0
2
0
0.5
1
1.5
Throughp
acf
Flat
Plate
Design
$/
ft2
plate
area,
1987
$,
ESP
only
$/
kW,
1987
$,
ESP
only
$/
acfm
$/
kW
$/
MW
$/
acfm
$/
kW
$/
MW
ELECTROSTATIC
PRECIPITATORS
Case
Oil
­
50
MW
50
You
supply
data
for
boxed
cells,
see
OAQPS
Control
Cost
Manual
SIZING
PROCEDURE
Flat
Plate
Design
ESP
Type
2
(
Flat
Plate
=
2,
Plate­
Wire=
1)
Design
Efficiency
(
E)
0.8
Penetration
(
p)
0.2
Temperature
(
Tk)
413
Resistivity
(
ohm­
cm)
2.00E+
09
MMD(
i)
3.5
Sneakage
(
Sn)
0.1
Rapping
Reentrainment(
RR)
0.124
MMD(
p)
2
MMD(
r)
3
Loss
Factor
(
LF)
0.2116
E(
bd)
318,194
(
V/
m)
n
(
eta)
2.308E­
05
(
Kg/
md)
e(
0)
8.85E­
12
(
F/
m)
E(
avg)
252,535
Number
of
Sections
(
n)
2
Average
Section
Penetration
(
Ps)
0.45
Collection
Penetration
(
Pc)
0.30
Particle
Size
Change
Factor
(
D)
0.45
MMD(
rp)
0.52
Computed
MMD(
n)
1
3.5
2
2.94
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Computed
SCA
1
12.71
2
15.11
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Total
SCA
27.81
Total
ESCA
141.29
EXHAUST
VOLUME
(
acfm)
152,800
acfm
Annual
Dust
Loading
Total
Collection
Area
(
sq.
ft.)
21,590
sq.
ft.
0.10
grains/
cu.
ft.
Annual
Hours
of
Operations
7446
COSTING
PROCEDURE
Prices
include:
ESP
casing,
pyramidal
hoppers,
rigid
electrodes
and
internal
collecting
plates,
transformer­
rectifier
sets
and
microprocessor
controls,
rappers
and
stub­
supports.
(
Options
include
inlet/
outler
nozzles
and
diffusion
plates,
hopper
auxiliaries
and
level
detectors,
weather
enclosure
and
stair
access,
structural
supports,
and
3
in.
of
fiberglass
insulation
encased
in
a
metal
skin.
Costs
also
include
auxiliary
equipment.)

"
Your
year"
dollars
are
based
on
the
Chemical
Engineering
cost
index
value
you
specify
below.
The
base
year
value
(
mid
1987)
is
320,
which
should
be
entered
if
you
do
not
have
a
cost
index
value.
In
this
case
you
should
not
use
"
your
year"
values
for
direct
annual
costs
and
should
not
enter
1
in
the
second
line
of
the
box
below.

"
CRF"
is
a
capital
recovery
factor
calculated
as
described
in
Chapter
2
of
the
OAQPS
Control
Cost
Manual
and
based
on
interest
rate
and
equipment
lifetime.

Supply
the
following
data
to
be
used
in
the
costing
procedure:

Chemical
Engineering
cost
index
value
for
your
year
(
enter
base
year
value
of
320
if
no
other
value)
394.3
If
using
your
year
dollar
values
for
direct
annual
costs,
enter
1
1
Operating
labor
hourly
cost
without
overheads
($
12/
hr
base
year)
17.26
Cost
of
electricity
($
0.06/
kWh
for
base
year)
0.06
Tipping
fee
for
waste
disposal
($
20/
ton
for
base
year)
50
Fractional
interest
rate
for
capital
(
0.07
for
base
year)
0.07
Equipment
lifetime
(
20
years
for
base
case)
20
Additional
auxiliary
costs,
base
year
(
1987)
0.00E+
00
Retrofit
factor
(
1.2
to
1.5
typical,
use
1
for
new
installation)
1.40
Capital
Cost
Factors
for
ESPs
Direct
Costs
in
base
year
dollars
Purchased
Equipment
Costs
ESP
+
auxiliary
equipment
$
842,121
Auxiliary
equipment
$
374,276
ESP
$
467,845
$
21.67
Instrumentation
(
0.1
x
EC)
$
84,212
$
9.36
Sales
taxes
(
0.03
x
EC)
$
25,264
Freight
(
0.05
x
EC)
$
42,106
Purchased
equipment
cost,
PEC
$
993,703
Direct
installation
costs
in
base
year
dollars
Foundations
&
supports
(
0.04
x
PEC)
$
39,748
Handling
&
erection
().
5
x
PEC)
$
496,852
Electrical
(
0.08
x
PEC)
$
79,496
Piping
(
0.01
x
PEC)
$
9,937
Insulation
for
ductwork
(
0.02
x
PEC)
$
19,874
Painting
(
0.02
x
PEC)
$
19,874
Direct
installation
costs
$
665,781
Site
preparation
Buildings
Total
Direct
Costs,
DC
$
2,695,497
Indirect
Costs
(
installation,
in
base
year
dollars)
Engineering
(
0.2
x
PEC)
$
198,741
Construction
and
field
expenses
(
0.2
x
PEC)
$
198,741
Contractor
fees
(
0.1
x
PEC)
$
99,370
Start­
up
(
0.01
x
PEC)
$
9,937
Performance
test
(
0.01
x
PEC
$
9,937
Model
study
(
0.02
x
PEC)
$
19,874
Contingencies
(
0.03
x
PEC)
$
29,811
Total
Indirect
Costs,
IC
$
566,411
Total
Capital
Investment
(
TCI=
(
DC
+
IC)
x
retrofit)
$
4,566,671
TCI
in
your
year
dollars
$
5,626,995
36.83
112.54
Annual
Costs
For
ESP
Systems
112,540
Direct
Annual
Costs,
DC
Operating
labor
Operator
(
3
hrs/
day
x
labor
cost
)
$
16,065
Supervisor
(
15
%
of
operator)
$
2,410
Coordinator
(
1/
3
of
operator)
$
5,355
Operating
materials
Maintenance
Labor
(
based
on
collector
area)
$
5,083
Materials
(
1%
of
PEC)
$
9,937
Utilities
Electricity
­
fan
$
55,355
24,689
kWh/
y­
MW
(
0.000181
x
flue
x
pres.
drp.
x
hrs
x
power
cost)
Electricity
­
operating
$
18,712
(
0.00194
x
col.
area
x
hrs
x
power
cost)
Waste
disposal
2
mile
haul
$
24,893
0.163
tons/
y­
MW
(
tipping
fee
+
$
0.50/
ton­
mi)
Total
DC,
your
year
dollars
$
137,810
Indirect
Annual
Costs,
IC
Overhead
(
60%
of
labor
&
maint.
materials)
$
28,722
Administrative
charges
(
0.02
x
TCI)
$
112,540
Property
tax
(
0.01
x
TCI)
$
56,270
Insurance
(
0.01
x
TCI)
$
56,270
Capital
recovery
(
CRF
x
TCI)*
$
531,149
Total
IC
your
year
dollars
$
784,951
Total
Annual
Cost,
your
year
dollars
$
922,761
$
2.01
$
18.46
18,455
0.5
0.75
0.9
0.95
0.99
0.995
0.999
$
308,802
$
378,309
$
416,839
$
517,794
$
673,798
$
589,425
$
680,192
Total
Annual
Cost
vs.
Efficiency
for
Electrostatic
Precipatators
0
2
0
0.5
1
1.5
Throughp
acf
Flat
Plate
Design
$/
ft2
plate
area,
1987
$,
ESP
only
$/
kW,
1987
$,
ESP
only
$/
acfm
$/
kW
$/
MW
$/
acfm
$/
kW
$/
MW
ELECTROSTATIC
PRECIPITATORS
Case
Oil
­
25
MW
25
You
supply
data
for
boxed
cells,
see
OAQPS
Control
Cost
Manual
SIZING
PROCEDURE
Flat
Plate
Design
ESP
Type
2
(
Flat
Plate
=
2,
Plate­
Wire=
1)
Design
Efficiency
(
E)
0.8
Penetration
(
p)
0.2
Temperature
(
Tk)
413
Resistivity
(
ohm­
cm)
2.00E+
09
MMD(
i)
3.5
Sneakage
(
Sn)
0.1
Rapping
Reentrainment(
RR)
0.124
MMD(
p)
2
MMD(
r)
3
Loss
Factor
(
LF)
0.2116
E(
bd)
318,194
(
V/
m)
n
(
eta)
2.308E­
05
(
Kg/
md)
e(
0)
8.85E­
12
(
F/
m)
E(
avg)
252,535
Number
of
Sections
(
n)
2
Average
Section
Penetration
(
Ps)
0.45
Collection
Penetration
(
Pc)
0.30
Particle
Size
Change
Factor
(
D)
0.45
MMD(
rp)
0.52
Computed
MMD(
n)
1
3.5
2
2.94
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Computed
SCA
1
12.71
2
15.11
3
0.00
4
0.00
5
0.00
6
0.00
7
0.00
Total
SCA
27.81
Total
ESCA
141.29
EXHAUST
VOLUME
(
acfm)
76,400
acfm
Annual
Dust
Loading
Total
Collection
Area
(
sq.
ft.)
10,795
sq.
ft.
0.10
grains/
cu.
ft.
Annual
Hours
of
Operations
7446
COSTING
PROCEDURE
Prices
include:
ESP
casing,
pyramidal
hoppers,
rigid
electrodes
and
internal
collecting
plates,
transformer­
rectifier
sets
and
microprocessor
controls,
rappers
and
stub­
supports.
(
Options
include
inlet/
outler
nozzles
and
diffusion
plates,
hopper
auxiliaries
and
level
detectors,
weather
enclosure
and
stair
access,
structural
supports,
and
3
in.
of
fiberglass
insulation
encased
in
a
metal
skin.
Costs
also
include
auxiliary
equipment.)

"
Your
year"
dollars
are
based
on
the
Chemical
Engineering
cost
index
value
you
specify
below.
The
base
year
value
(
mid
1987)
is
320,
which
should
be
entered
if
you
do
not
have
a
cost
index
value.
In
this
case
you
should
not
use
"
your
year"
values
for
direct
annual
costs
and
should
not
enter
1
in
the
second
line
of
the
box
below.

"
CRF"
is
a
capital
recovery
factor
calculated
as
described
in
Chapter
2
of
the
OAQPS
Control
Cost
Manual
and
based
on
interest
rate
and
equipment
lifetime.

Supply
the
following
data
to
be
used
in
the
costing
procedure:

Chemical
Engineering
cost
index
value
for
your
year
(
enter
base
year
value
of
320
if
no
other
value)
394.3
If
using
your
year
dollar
values
for
direct
annual
costs,
enter
1
1
Operating
labor
hourly
cost
without
overheads
($
12/
hr
base
year)
17.26
Cost
of
electricity
($
0.06/
kWh
for
base
year)
0.06
Tipping
fee
for
waste
disposal
($
20/
ton
for
base
year)
50
Fractional
interest
rate
for
capital
(
0.07
for
base
year)
0.07
Equipment
lifetime
(
20
years
for
base
case)
20
Additional
auxiliary
costs,
base
year
(
1987)
0.00E+
00
Retrofit
factor
(
1.2
to
1.5
typical,
use
1
for
new
installation)
1.40
Capital
Cost
Factors
for
ESPs
Direct
Costs
in
base
year
dollars
Purchased
Equipment
Costs
ESP
+
auxiliary
equipment
$
545,063
Auxiliary
equipment
$
242,250
ESP
$
302,813
$
28.05
Instrumentation
(
0.1
x
EC)
$
54,506
$
12.11
Sales
taxes
(
0.03
x
EC)
$
16,352
Freight
(
0.05
x
EC)
$
27,253
Purchased
equipment
cost,
PEC
$
643,174
Direct
installation
costs
in
base
year
dollars
Foundations
&
supports
(
0.04
x
PEC)
$
25,727
Handling
&
erection
().
5
x
PEC)
$
321,587
Electrical
(
0.08
x
PEC)
$
51,454
Piping
(
0.01
x
PEC)
$
6,432
Insulation
for
ductwork
(
0.02
x
PEC)
$
12,863
Painting
(
0.02
x
PEC)
$
12,863
Direct
installation
costs
$
430,926
Site
preparation
Buildings
Total
Direct
Costs,
DC
$
2,460,642
Indirect
Costs
(
installation,
in
base
year
dollars)
Engineering
(
0.2
x
PEC)
$
128,635
Construction
and
field
expenses
(
0.2
x
PEC)
$
128,635
Contractor
fees
(
0.1
x
PEC)
$
64,317
Start­
up
(
0.01
x
PEC)
$
6,432
Performance
test
(
0.01
x
PEC
$
6,432
Model
study
(
0.02
x
PEC)
$
12,863
Contingencies
(
0.03
x
PEC)
$
19,295
Total
Indirect
Costs,
IC
$
366,609
Total
Capital
Investment
(
TCI=
(
DC
+
IC)
x
retrofit)
$
3,958,151
TCI
in
your
year
dollars
$
4,877,185
63.84
195.09
Annual
Costs
For
ESP
Systems
195,087
Direct
Annual
Costs,
DC
Operating
labor
Operator
(
3
hrs/
day
x
labor
cost
)
$
16,065
Supervisor
(
15
%
of
operator)
$
2,410
Coordinator
(
1/
3
of
operator)
$
5,355
Operating
materials
Maintenance
Labor
(
based
on
collector
area)
$
5,083
Materials
(
1%
of
PEC)
$
6,432
Utilities
Electricity
­
fan
$
27,677
24,689
kWh/
y­
MW
(
0.000181
x
flue
x
pres.
drp.
x
hrs
x
power
cost)
Electricity
­
operating
$
9,356
(
0.00194
x
col.
area
x
hrs
x
power
cost)
Waste
disposal
2
mile
haul
$
12,446
0.163
tons/
y­
MW
(
tipping
fee
+
$
0.50/
ton­
mi)
Total
DC,
your
year
dollars
$
84,824
Indirect
Annual
Costs,
IC
Overhead
(
60%
of
labor
&
maint.
materials)
$
26,131
Administrative
charges
(
0.02
x
TCI)
$
97,544
Property
tax
(
0.01
x
TCI)
$
48,772
Insurance
(
0.01
x
TCI)
$
48,772
Capital
recovery
(
CRF
x
TCI)*
$
460,372
Total
IC
your
year
dollars
$
681,591
Total
Annual
Cost,
your
year
dollars
$
766,415
$
1.67
$
30.66
30,657
0.5
0.75
0.9
0.95
0.99
0.995
0.999
$
308,802
$
378,309
$
416,839
$
517,794
$
673,798
$
589,425
$
680,192
Total
Annual
Cost
vs.
Efficiency
for
Electrostatic
Precipatators
0
2
0
0.5
1
1.5
Throughp
acf
Flat
Plate
Design
$/
ft2
plate
area,
1987
$,
ESP
only
$/
kW,
1987
$,
ESP
only
$/
acfm
$/
kW
$/
MW
$/
acfm
$/
kW
$/
MW