Integrated Air Pollution Control System Costing Program

APPENDIX B

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IAPCS VERSION 5a 3/17/2005 15:32:19

INTEGRATED AIR POLLUTION CONTROL SYSTEM COSTING PROGRAM------

Gascoyne CFB

USER INPUT SUMMARY

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BOILER SIZE: 175. MW TANGENTIALLY FIRED, DRY BOTTOM

CAPACITY FACTOR: 90.0 % 310. DEG.F

CONSTRUCTION STATUS OF CONTROL SYSTEM: NEW

COAL CLEANING LEVEL: RUN-OF-MINE SORTED AND SCREENED

COAL CHARACTERISTICS AT THIS CLEANING LEVEL:

HHV (BTU/#): 5749.0

SULFUR CONTENT (%): 1.00

ASH CONTENT (%):12.09

COST ($/TON): .00

CHLORINE CONTENT (%): .00

MOISTURE CONTENT (%): 6.00

VOLATILE MATTER CONTENT (%):36.20

FIXED CARBON CONTENT (%):48.70

ASH CHARACTERISTICS AT THIS CLEANING LEVEL:

NA20 CONTENT (%): .90

ALKALINITY (%): 5.10

FE2O3 CONTENT (%):20.20

CONTROL SYSTEM CONFIGURATION:

1 - SELECTIVE NONCATALYTIC REDUCTION

2 - ATMOSPHERIC FLUIDIZED BED (AFBC)

3 - LIMESPRAY DRYING (LSD)

4 - FABRIC FILTER (FF)

Warning: Control devices should be entered in the

correct gas path order from the boiler to the stack.

Results for this run may not be correct.

ECONOMIC PREMISES (TVA/EPRI):

+ EPRI

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INTEGRATED AIR POLLUTION CONTROL SYSTEM COSTING PROGRAM

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USER INPUT SUMMARY (CONTINUED)

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PARAMETER FILE USED: C:\OLDCOM~1\D\DONS\POWERP~1\IAPCS_5A\GSCYNCFB.EPR

BATCH DATA FILE USED: C:\OLDCOM~1\D\DONS\POWERP~1\IAPCS_5A\GSCYNCFB.EPR

THE FOLLOWING CHANGES WERE MADE TO THE PARAMETER FILE FOR THIS RUN:

NEW VALUE DESCRIPTION

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59.00 SO2 Removal Efficiency %, (LSD)

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UREA-BASED SNCR SYSTEM

IN THE SNCR SYSTEM, UREA IS INJECTED INTO

THE UPPER FURNACE USING WALL INJECTORS.

NOx REDUCTION EFFICIENCY IS 50.00 % AT A

N:NOx STOICHIOMETRIC RATIO OF 1.13 YIELDING

AN AMMONIA SLIP RATE OF 8.94 PPM

OR 4.47%.

SPRAY DRYING ABSORBER

OVERALL STOICHIOMETRIC RATIO 1.45

SPRAY-DOWN TEMPERATURE 175. DEG F

OVERALL SO2 REMOVAL EFFICIENCY 59.0 %

NUMBER OF OPERATING DRYER UNITS 3

NUMBER OF SPARE DRYER UNITS 0

DESIGN L/G .197 GAL/1000 CU FT

AVERAGE PRESSURE DROP 2. IN H20

FLUE GAS TREATED 100.00%

FABRIC FILTER

THE FABRIC FILTER IS DESIGNED TO REMOVE 99.7 % OF THE

PARTICULATE LOADING WITH AN AIR-TO-CLOTH RATIO OF ***.

.0 % OF THE FLUE GAS IS BYPASSING THE FABRIC FILTER.

THE FABRIC FILTER REFLECTS A REVERSE AIR CLEANING

CONFIGURATION AND TEFLON-COATED FIBERGLASS BAGS.

FANS

THE TOTAL SYSTEM PRESSURE DROP IS 10.0 IN. H20.

THE SYSTEM REQUIRES 3 FAN(S) RATED AT 995. HP EACH.

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BOILER/SYSTEM PERFORMANCE

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0 PARASITIC DEMAND (W/O CONTROL)...... -4.5%

STEAM CYCLE HEAT RATE...... 8277.0 BTU/KWH

BOILER THERMAL EFFICIENCY...... 79.2%

BOILER GROSS HEAT RATE...... 10451.8 BTU/KWH

BOILER NET HEAT RATE W/O CONTROL SYSTEM.. 10000.0 BTU/KWH

BOILER NET HEAT RATE W/ CONTROL SYSTEM... 11004.0 BTU/KWH

HEAT INPUT...... 1750.0 MMBTU/H

COAL USE...... 152.2 TONS/H

ANNUAL COAL CONSUMPTION...... 1.1999E+06 TONS/YR

IAPCS ENERGY PENALTY...... 1004.0 BTU/KWH

IAPCS ENERGY PENALTY...... 10.0 %

SYSTEM NET GENERATION...... 159.0 MW

SYSTEM MATERIAL BALANCE

(100% CAPACITY CONDITION)

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AIR

UNCONT- HEATER

ROLLED EXIT

+ LSD FF

------

FLUE GAS, 1000 LB/H : 4269. 4285. 4426. 4426.

FLUE GAS, 1000 ACFM : 1428. 1432. 1241. 1241.

TEMPERATURE,DEG.F : 310. 310. 175. 175.

MOISTURE, LB/H : 301671. 303133. 444466. 444466.

ALKALINITY, LB/H : 1740. 2473. 2267. 7.

PARTICULATE, LB/H : 34111. 51. 296. 1.

SO2, LB/H : 6473. 617. 253. 114.

NO2, LB/H : 2489. 1050. 1050. 1050.

CO2, LB/H : 620231. 568791. 568791. 568791.

EMISSION SUMMARY

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PERCENT

POLLUTANT LB/HR REDUCTION LB/MMBTU PPM(V)

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PARTICULATE 1. 99.9 .001

SO2 114. 98.2 .065 12.

NO2 1050. 57.8 .600 229.

CO2 568791. 8.3 325.023

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INSTALLED CAPITAL COSTS JUNE, 1995

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TOTAL WEIGHTED AVERAGE RETROFIT FACTOR: 1.00

FABRIC FILTER------$ 3779800

RETROFIT FACTOR: 1.00

FF AND DUCTING------$ 3318600

FF ASH DISPOSAL------$ 461300

------

LIMESPRAY DRYING------$ 21861300

RETROFIT FACTOR: 1.00

ATMOSPHERIC FLUIDIZED BED (AFBC)------$ 209287300

RETROFIT FACTOR: 1.00

STEAM GENERATOR------$ 41857300

PM CONTROLS------$ 17915400

STEAM/FEED WATER/COND.----$ 29802800

STEAM TURBINE------$ 21543600

COAL HANDLING/PREP.------$ 18515400

LIMESTONE/MISC. EQUIP.----$ 79652800

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SELECTIVE NONCATALYTIC REDUCTION------$ 1846400

RETROFIT FACTOR: 1.00

AIR HEATER MOD(SNCR)------$ 770200

NH3 STORAGE (SNCR)------$ 432500

NH3 INJECTION (SNCR)------$ 475500

CONTROLS/MISC. (SNCR)-----$ 168200

------

FANS------$ 808100

RETROFIT FACTOR: 1.00

TOTAL DIRECT CAPITAL COSTS W/O SCOPE ADDERS>$ 237582900

TOTAL DIRECT CAPITAL COSTS WITH SCOPE ADDERS>$ 237582900

DIRECT COSTS INCLUDE SALES TAX OF .0%

INDIRECT AND STARTUP COSTS------$ 198088804

GENERAL FACILITIES (10.0%)...$ 23758301

ENGINEERING (10.0%)...... $ 23758301

PROJECT CONTINGENCY (17.5%)..$ 41681400

PROCESS CONTINGENCY (27.0%)..$ 64095501

TOTAL PLANT COST (TPC)...... $ 390876403

INTEREST DURING CONSTRUCTION (10.4%)...... $ 24812701

TOTAL PLANT INVESTMENT ( 3.0yr)...... $ 415689100

ROYALTY ALLOWANCE ( .4%)....$ 1055700

PREPRODUCTION COSTS ( 4.8%)..$ 11433000

INVENTORY CAPITAL ( 1.5%)....$ 3614900

INITIAL CATALYST ( .0%).....$ 78700

LAND ( 1.6%)...... $ 3800300

*************

TOTAL CAPITAL REQUIREMENT>*$ 435671700*

*************

TOTAL SYSTEM COST>$ 2489.55/KW

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ANNUAL OPERATING COSTS JUNE, 1995

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INFLATION RATE...... 5.0%

BOOK LIFE ...... 30.0 YEARS

DISCOUNT RATE...... 11.5%

DEPRECIATION METHOD...... 3

1=accelerated, 2=straight line, 3=straightline based on ACRS class

CALCULATED CAPITAL CARRYING CHARGE FACTOR...... 0.1655

CALCULATED O&M LEVELIZATION FACTOR...... 1.6116

NOTE: CAPITAL CARRYING CHARGE FACTOR AND O&M

LEVELIZATION FACTORS WERE CALCULATED FROM THE

ECONOMIC FACTORS LISTED ABOVE AND OTHER FACTORS

LISTED IN THE ECONOMIC SECTION.

ITEM QUANTITY RATE ANNUAL COST

======

OPERATING AND SUPERVISORY LABOR

+______

SYSTEM .162E+06 MANHR 25.86 $/HR $ 4187500

MAINTENANCE LABOR .919E+07 $ .40 $ 3677700

MAINTENANCE MATERIAL .919E+07 $ .60 $ 5516500

PERCENT OF TPC = 2.35

ADMIN. & SUPPORT LABOR .787E+07 $ .30 $ 2359600

CONSUMABLES

+______

COAL USE .120E+07 TONS .00 $/TON $ 0

SOLIDS DISPOSAL, DRY .299E+06 TONS 12.19 $/TON $ 3646000

WATER .949E+06 K GAL .79 $/K GAL $ 747600

ELECTRICITY .139E+09 KWH 65.63 mil/KWH $ 9090800

LIMESTONE .128E+06 TONS 19.69 $/TON $ 2525900

LIME .353E+03 TONS 72.19 $/TON $ 25500

UREA .721E+04 TONS 483.02 $/TON $ 3484400

0

FIXED COMPONENT .175E+06 KWY 89.95 $/KWY $ 15741300

VARIABLE COMPONENT .138E+10 KWH 14.15 mil/KWH $ 19520200

TOTAL FIRST YEAR O&M EXPENSE $ 35261500

LEVELIZED CARRYING CHARGES 435671700 $ 16.55 % $ 72101800

BUSBAR COST OF POWER $ 107363300

LEVELIZED FIRST YEAR O&M 35261500 $ 1.61 $ 56827200

LEVELIZED CARRYING CHARGES 435671700 $ 16.55 % $ 72101800

LEVELIZED ANNUAL REQUIREMENTS $ 128929000

FIRST YEAR BUSBAR COST OF POWER 77.82 MILLS/KWH

LEVELIZED ANNUAL BUSBAR COST OF POWER 93.45 MILLS/KWH

COST/TON OF PARTICULATE REMOVED 958.86 $/TON

COST/TON OF SO2 REMOVED 5143.43 $/TON

COST/TON OF NOX REMOVED 22721.13 $/TON

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