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Economic I nputs
Cost Basis -Year Dollars Year 1998 2009 2009 2009 2009 2009
Sevice Life (levelization period) Years 30 20 20 20 20 20
Inflation Rate % 3.00% 3.00% 3.00% 3.00% 3.00% 3.00%
After Tax Discount Rate (current $'s) % 9.20% 9.20% 9.20% 9.20% 9.20% 9.20%
AFDC Rate (current $'s) % 10.80% 10.80% 10.80% 10.80% 10.80% 10.80%
First-year Carrying Charge (current $'s) % 22.30% 22.30% 22.30% 22.30% 22.30% 22.30%
Levelized Carrying Charge (current $'s) % 16.90% 16.90% 16.90% 16.90% 16.90% 16.90%
First-year Carrying Charge (constant $'s) % 15.70% 15.70% 15.70% 15.70% 15.70% 15.70%
Levelized Carrying Charge (constant $'s) % 11.70% 11.70% 11.70% 11.70% 11.70% 11.70%
Sales Tax % 6% 6.5% 6.5% 6.5% 6.5% 6.5%
Escalation Rates:
Consumables (O&M) % 3% 3% 3% 3% 3% 3%
Capital Costs:
Is Chem. Eng. Cost Index available? Yes / No Yes Yes Yes Yes Yes Yes
If "Yes" input cost basis CE Plant Index. Integer 388 561 561 561 561 561
If "No" input escalation rate. % 3% 3% 3% 3% 3% 3%
Construction Labor Rate $/hr $35 $35 $35 $35 $35 $35
Prime Contractor's Markup % 3% 3% 3% 3% 3% 3%
Operating Labor Rate $/hr $30 $35 $35 $35 $35 $35
Power Cost Mills/kWh 25 53.3 53.3 53.5 53.3 53.3
Steam Cost $/1000 lbs 3.5 3.5 3.5 3.5 3.5 3.5
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APC Technology Choices
Description Units Input 1 Input 2 Input 3 Input 4 Input 5
FGD Process Integer 1 1 2 2 2
(1 = LSFO, 2 = LSD)
Particulate Control Integer 2 2 2 2 2
(1 = Fabric Filter, 2 = ESP)
NOx Control Integer 1 2 1 2 4
(1 = SCR, 2 = SNCR, 3 = LNBs, 4 = NGR)
INPUTS
Description Units Input 1 Input 2 Input 3 Input 4 Input 5
General Plant Technical I nputs
Location - State Abbrev. WA WA WA WA Wa
MW Equivalent of Flue Gas to Control System MW 22.5 22.5 22.5 22.5 22.5
Net Plant Heat Rate Btu/kWhr 10,500 10,500 10,500 10,500 10,500
Plant Capacity Factor % 95% 95% 95% 95% 95%
Total Air Downstream of Economizer % 120% 120% 120% 120% 120%
Air Heater Leakage % 12% 12% 12% 12% 12%Air Heater Outlet Gas Temperature F 300 300 300 300 300
Inlet Air Temperature F 55 55 55 55 55
Ambient Absolute Pressure In. of Hg 29.4 29.4 29.4 29.4 29.4
Pressure After Air Heater In. of H2O -12 -12 -12 -12 -12
Moisture in Air lb/lb dry air 0.013 0.013 0.013 0.013 0.013
Ash Split:
Fly Ash % 80% 80% 80% 80% 80%
Bottom Ash % 20% 20% 20% 20% 20%
Seismic Zone Integer 3 3 3 3 3
Retrofit Factor Integer 1.6 1.6 1.6 1.6 1.6
(1.0 = new, 1.3 = medium, 1.6 = difficult)
Select Coal Integer 6 6 6 6 8
Is Selected Coal a Powder River Basin Coal? Yes / No Yes yes Yes Yes yes
Economic I nputs
Cost Basis -Year Dollars Year 2009 2009 2009 2009 2009
Sevice Life (levelization period) Years 20 20 20 20 20
Inflation Rate % 3% 3% 3% 3% 3%
After Tax Discount Rate (current $'s) % 9% 9% 9% 9% 9%
AFDC Rate (current $'s) % 11% 11% 11% 11% 11%
First-year Carrying Charge (current $'s) % 22% 22% 22% 22% 22%
Levelized Carrying Charge (current $'s) % 17% 17% 17% 17% 17%
First-year Carrying Charge (constant $'s) % 16% 16% 16% 16% 16%
Levelized Carrying Charge (constant $'s) % 12% 12% 12% 12% 12%
Sales Tax % 7% 7% 7% 7% 7%
Escalation Rates:
Consumables (O&M) % 3% 3% 3% 3% 3%
Capital Costs:
Is Chem. Eng. Cost Index available? Yes / No Yes Yes Yes Yes Yes If "Yes" input cost basis CE Plant Index. Integer 561 561 561 561 561
If "No" input escalation rate. % 3% 3% 3% 3% 3%
Construction Labor Rate $/hr $35 $35 $35 $35 $35
Prime Contractor's Markup % 3% 3% 3% 3% 3%
Operating Labor Rate $/hr $35 $35 $35 $35 $35
Power Cost Mills/kWh 53.3 53.3 53.5 53.3 53.3
Steam Cost $/1000 lbs 3.5 3.5 3.5 3.5 3.5
L imestone Forced Oxidation (LSFO) I nputs
SO2 Removal Required % 95% 95% 95% 95% 95%
L/G Ratio gal / 1000 acf 125 125 125 125 125
Design Scrubber with Dibasic Acid Addition? Integer 2 1 2 2 2
(1 = yes, 2 = no)
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Adiabatic Saturation Temperature F 127 127 127 127 127
Reagent Feed Ratio Factor 1.05 1.05 1.05 1.05 1.05
(Mole CaCO3 / Mole SO2 removed)
Scrubber Slurry Solids Concentration Wt. % 15% 15% 15% 15% 15%
Stacking, Landfill, Wallboard Integer 1 1 1 1 1
(1 = stacking, 2 = lanfill, 3 = wallboard)
Number of Absorbers Integer 1 1 1 1 1
(Max. Capacity = 700 MW per absorber)
Absorber Material Integer 1 1 1 1 1
(1 = alloy, 2 = RLCS)Absorber Pressure Drop in. H2O 6 6 6 6 6
Reheat Required ? Integer 2 2 2 2 2
(1 = yes, 2 = no)
Amount of Reheat F 0 0 0 0 0
Reagent Bulk Storage Days 60 60 60 60 60
Reagent Cost (delivered) $/ton $15 $15 $15 $15 $15
Landfill Disposal Cost $/ton $30 $30 $30 $30 $30
Stacking Disposal Cost $/ton $6 $6 $6 $6 $6
Credit for Gypsum Byproduct $/ton $2 $2 $2 $2 $2
Maintenance Factors by Area (% of Installed Cost)
Reagent Feed % 5% 5% 5% 5% 5%
SO2 Removal % 5% 5% 5% 5% 5%
Flue Gas Handling % 5% 5% 5% 5% 5%
Waste / Byproduct % 5% 5% 5% 5% 5%
Support Equipment % 5% 5% 5% 5% 5%Contingency by Area (% of Installed Cost)
Reagent Feed % 20% 20% 20% 20% 20%
SO2 Removal % 20% 20% 20% 20% 20%
Flue Gas Handling % 20% 20% 20% 20% 20%
Waste / Byproduct % 20% 20% 20% 20% 20%
Support Equipment % 20% 20% 20% 20% 20%
General Facilities by Area (% of Installed Cost)
Reagent Feed % 10% 10% 10% 10% 10%
SO2 Removal % 10% 10% 10% 10% 10%
Flue Gas Handling % 10% 10% 10% 10% 10%
Waste / Byproduct % 10% 10% 10% 10% 10%
Support Equipment % 10% 10% 10% 10% 10%
Engineering Fees by Area (% of Installed Cost)
Reagent Feed % 10% 10% 10% 10% 10%
SO2 Removal % 10% 10% 10% 10% 10% Flue Gas Handling % 10% 10% 10% 10% 10%
Waste / Byproduct % 10% 10% 10% 10% 10%
Support Equipment % 10% 10% 10% 10% 10%
Lime Spray Dryer (L SD) I nputs
SO2 Removal Required % 30% 30% 30% 30% 25%
Adiabatic Saturation Temperature F 127 127 127 127 127
Flue Gas Approach to Saturation F 20 20 20 20 20
Spray Dryer Outlet Temperature F 147 147 147 147 147
Reagent Feed Ratio Factor 0.31 0.31 0.31 0.31 0.26
(Mole CaO / Mole Inlet SO2)
Recycle Rate Factor 19.5 19.5 19.5 19.5 30
(lb recycle / lb lime feed)
Recycle Slurry Solids Concentration Wt. % 50% 50% 50% 50% 50%Number of Absorbers Integer 1 1 1 1 1
(Max. Capacity = 300 MW per spray dryer)
Absorber Material Integer 1 1 1 1 1
(1 = alloy, 2 = RLCS)
Spray Dryer Pressure Drop in. H2O 5 5 5 5 1
Reagent Bulk Storage Days 60 60 60 60 60
Reagent Cost (delivered) $/ton $0 $0 $0 $0 $0
Dry Waste Disposal Cost $/ton $0 $0 $0 $0 $0
Maintenance Factors by Area (% of Installed Cost)
Reagent Feed % 5% 5% 5% 5% 5%
SO2 Removal % 5% 5% 5% 5% 5%
Flue Gas Handling % 5% 5% 5% 5% 0%
Waste / Byproduct % 5% 5% 5% 5% 0%
Support Equipment % 5% 5% 5% 5% 5%
Contingency by Area (% of Installed Cost)
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Reagent Feed % 20% 20% 20% 20% 20%
SO2 Removal % 20% 20% 20% 20% 20%
Flue Gas Handling % 20% 20% 20% 20% 0%
Waste / Byproduct % 20% 20% 20% 20% 0%
Support Equipment % 20% 20% 20% 20% 20%
General Facilities by Area (% of Installed Cost)
Reagent Feed % 10% 10% 10% 10% 10%
SO2 Removal % 10% 10% 10% 10% 0%
Flue Gas Handling % 10% 10% 10% 10% 0%
Waste / Byproduct % 10% 10% 10% 10% 10% Support Equipment % 10% 10% 10% 10% 10%
Engineering Fees by Area (% of Installed Cost)
Reagent Feed % 10% 10% 10% 10% 10%
SO2 Removal % 10% 10% 10% 10% 10%
Flue Gas Handling % 10% 10% 10% 10% 10%
Waste / Byproduct % 10% 10% 10% 10% 10%
Support Equipment % 10% 10% 10% 10% 10%
Particulate Control I nputs
Outlet Particulate Emission Limit lbs/MMBtu 0.001 0.001 0.001 0.001 0.001
Fabric Filter:
Pressure Drop in. H2O 6 6 6 6 6
Type (1 = Reverse Gas, 2 = Pulse Jet) Integer 2 2 2 2 2
Gas-to-Cloth Ratio ACFM/ft2 3.5 3.5 3.5 3.5 3.5 Bag Material (RGFF fiberglass only) Integer 2 2 2 2 2
(1 = Fiberglass, 2 = Nomex, 3 = Ryton)
Bag Diameter inches 6 6 6 6 6
Bag Length feet 20 20 20 20 20
Bag Reach 3 3 3 3 3
Compartments out of Service % 10% 10% 10% 10% 10%
Bag Life Years 5 5 5 5 5
Maintenance (% of installed cost) % 5% 5% 5% 5% 5%
Contingency (% of installed cost) % 20% 20% 20% 20% 20%
General Facilities (% of installed cost) % 10% 10% 10% 10% 10%
Engineering Fees (% of installed cost) % 10% 10% 10% 10% 10%
ESP:
Strength of the electric field in the ESP =E kV/cm 10.0 10.0 10.0 10.0 10.0
Plate Spacing in. 12 12 12 12 12
Plate Height ft. 36 36 36 36 36 Pressure Drop in. H2O 3 3 3 3 3
Maintenance (% of installed cost) % 5% 5% 5% 5% 5%
Contingency (% of installed cost) % 20% 20% 20% 20% 20%
General Facilities (% of installed cost) % 10% 10% 10% 10% 10%
Engineering Fees (% of installed cost) % 10% 10% 10% 10% 10%
NOx Control Inputs
Selective Catalytic Reduction (SCR) Inputs
NH3/NOX Stoichiometric Ratio NH3/NOX 0.9 0.9 0.9 0.9 0.9
NOX Reduction Efficiency Fraction 0.90 0.90 0.90 0.90 0.90
Inlet NOx lbs/MMBtu 6.93 6.93 6.93 6.93 6.93
Space Velocity (Calculated if zero) 1/hr 0 0 0 0 0
Overall Catalyst Life years 3 3 3 3 3Ammonia Cost $/ton 280 280 280 280 282
Catalyst Cost $/ft3 356.34 356.34 356.34 356.34 356.34
Solid Waste Disposal Cost $/ton 11.48 11.48 11.48 11.48 11.48
Maintenance (% of installed cost) % 1.5% 1.5% 1.5% 1.5% 1.5%
Contingency (% of installed cost) % 20% 20% 20% 20% 20%
General Facilities (% of installed cost) % 5% 5% 5% 5% 5%
Engineering Fees (% of installed cost) % 10% 10% 10% 10% 10%
Number of Reactors integer 2 2 2 2 2
Number of Air Preheaters integer 1 1 1 1 1
Selective NonCatal ytic Reduction (SNCR) I nputs
Reagent 1:Urea 2:Ammonia 2 2 2 2 2
Number of Injector Levels integer 3 3 3 3 3
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Number of Injectors integer 18 18 18 18 18
Number of Lance Levels integer 0 0 0 0 0
Number of Lances integer 0 0 0 0 0
Steam or Air Injection for Ammonia integer 2 2 2 2 2
NOX Reduction Efficiency Fraction 0.40 0.40 0.40 0.40 0.40
Inlet NOx lbs/MMBtu 6.93 6.93 6.93 6.93 6.93
NH3/NOX Stoichiometric Ratio NH3/NOX 1.2 1.2 1.2 1.2 1.2
Urea/NOX Stoichiometric Ratio Urea/NOX 1.2 1.2 1.2 1.2 1.2
Urea Cost $/ton 225 224.95 224.95 224.95 224.95
Ammonia Cost $/ton 280 280 280 280 280Water Cost $/1,000 gal 0.407 0.407 0.407 0.407 0.407
Maintenance (% of installed cost) % 1.5% 1.5% 1.5% 1.5% 1.5%
Contingency (% of installed cost) % 20% 20% 20% 20% 20%
General Facilities (% of installed cost) % 5% 5% 5% 5% 5%
Engineering Fees (% of installed cost) % 10% 10% 10% 10% 10%
Low NOX Burner Technology I nputs
NOX Reduction Efficiency fraction 0.35 0.35 0.35 0.35 0.35
Boiler Type T:T-fired, W:Wall T T T T T
Retrofit Difficulty
L:Low, A:Average,
H:High A A A A A
Maintenance Labor (% of installed cost) % 0.8% 0.8% 0.8% 0.8% 0.8%
Maintenance Materials (% of installed cost) % 1.2% 1.2% 1.2% 1.2% 1.2%
Natural Gas Reburn ing I nputs
NOX Reduction Efficiency fraction 0.61 0.61 0.61 0.61 0.61
Gas Reburn Fraction fraction 0.15 0.15 0.15 0.15 0.15
Waste Disposal Cost $/ton 11.48 11.48 11.48 11.48 11.48
Natural Gas Cost $/MMBtu 1.04 1.04 1.04 1.04 1.04
Maintenance (% of installed cost) % 1.5% 1.5% 1.5% 1.5% 1.5%
Contingency (% of installed cost) % 20% 20% 20% 20% 20%
General Facilities (% of installed cost) % 2% 2% 2% 2% 2%
Engineering Fees (% of installed cost) % 10% 10% 10% 10% 10%
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SCR (high-dust) - Preliminary Case1 Case2 Case3 Case4 Case5
Ammonia Injection Rate lb/hr 545 545 545 545
Space Velocity 1/hr 2,673 2,673 2,673 2,673 2,
Gross Catalyst Volume ft3
1,163 1,163 1,163 1,163 1,
SCR Capital Costs Case1 Case2 Case3 Case4 Case5Cost Basis (Year) 2009 2009 2009 2009 2009
Reactor Housing and Installation $ 1,316,707 1,316,707 1,316,707 1,316,707 1,316,485
Ammonia Handling and Injection $ 1,663,119 1,663,119 1,663,119 1,663,119 1,663,119
Flue Gas Handling:Ductwork and Fans $ 851,019 851,019 851,019 851,019 850,815
Air Preheater Modifications $ 145,068 145,068 145,068 145,068 145,028
Misc. Other Direct Capital Costs $ 226,217 226,217 226,217 226,217 226,217 Equipment Capital Cost Subtotal $ $4,202,130 $4,202,130 $4,202,130 $4,202,130 $4,201,664
Instruments & Controls $ $84,043 $84,043 $84,043 $84,043 $84,033
Taxes $ $273,138 $273,138 $273,138 $273,138 $273,108
Freight $ $210,107 $210,107 $210,107 $210,107 $210,083
Total Di rect Cost $4,769,418 $4,769,418 $4,769,418 $4,769,418 $4,768,888
Total Direct Cost with Retrofit Factor $ $7,631,069 $7,631,069 $7,631,069 $7,631,069 $7,630,221
General Facilities $ $381,553 $381,553 $381,553 $381,553 $381,511
Engineering Fees $ $763,107 $763,107 $763,107 $763,107 $763,022
Contingency $ $1,526,214 $1,526,214 $1,526,214 $1,526,214 $1,526,044
Total Plant Cost (TPC) $ $10,301,943 $10,301,943 $10,301,943 $10,301,943 $10,300,799
Total Plant Cost (TPC) w/ Prime Contractor's Markup $ $10,611,001 $10,611,001 $10,611,001 $10,611,001 $10,609,823
Total Cash Expended (TCE) $ $10,611,001 $10,611,001 $10,611,001 $10,611,001 $10,609,823
All ow. for Funds Dur ing Constr. (AFDC) $ $0 $0 $0 $0 $0
Total Plant I nvestment (TPI) $ $10,611,001 $10,611,001 $10,611,001 $10,611,001 $10,609,823
Preproduction Costs $ $285,109 $285,109 $285,109 $285,109 $285,483
Inventory Capital
Initial Ammonia(60 days) $ $104,472 $104,472 $104,472 $104,472 $105,218
Initial Catalyst $ $414,396 $414,396 $414,396 $414,396 $414,252
Total Capital Requir ement (TCR) $ $11,414,978 $11,414,978 $11,414,978 $11,414,978 $11,414,776
$/kW $507 $507 $507 $507 $507
SCR O&M Costs Case1 Case2 Case3 Case4 Case5
Cost Basis (Year) 2009 2009 2009 2009 2009
Ammonia $/yr 635,535 635,535 635,535 635,535 640,
Catalyst Replacement $/yr 138,132 138,132 138,132 138,132 138,
Catalyst Disposal $/yr 107 107 107 107
Electricity $/yr (2,342) (2,342) (2,351) (2,342) (2,
High-dust SCR Steam $/yr 60,327 60,327 60,327 60,327 60,
Operating Labor $/yr 51,158 51,158 51,158 51,158 51,Maintenance $/yr 154,529 154,529 154,529 154,529 154,
Total O&M Costs $/yr 1,037,447 1,037,447 1,037,438 1,037,447 1,041,
SNCR - Preliminary Case1 Case2 Case3 Case4 Case5
Number of Wall Injectors integer 18 18 18 18 18
Number of Lances integer 0 0 0 0 0
Urea Injection Rate lb/hr 1277 1277 1277 1277 1277
Ammonia Injection Rate lb/hr 727 727 727 727 727
SNCR Capital Costs Case1 Case2 Case3 Case4 Case5Cost Basis (Year) 2009 2009 2009 2009 2009
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Urea Based SNCR Costs
Urea Storage & Handling $ $0 $0 $0 $0 $0
Urea Injection $ $0 $0 $0 $0 $0
Controls/Miscellaneous $ $0 $0 $0 $0 $0
Air Heater Modifications $ $0 $0 $0 $0 $0
Ammonia Based SNCR Costs
Ammonia Storage, Handling, Injection, Controls $ $424,704 $424,704 $424,704 $424,704 $424,704
Air Heater Modifications $ $92,417 $92,417 $92,417 $92,417 $92,378
Total Di rect Cost $ $517,121 $517,121 $517,121 $517,121 $517,082
Total Direct Cost with Retrofit Factor $ $827,394 $827,394 $827,394 $827,394 $827,331
General Facilities $ $41,370 $41,370 $41,370 $41,370 $41,367
Engineering Fees $ $82,739 $82,739 $82,739 $82,739 $82,733
Contingency $ $165,479 $165,479 $165,479 $165,479 $165,466
Total Pl ant Cost (TPC) $ $1,116,982 $1,116,982 $1,116,982 $1,116,982 $1,116,897
Total Plant Cost (TPC) w/ Prime Contractor' s Markup $ $1,150,492 $1,150,492 $1,150,492 $1,150,492 $1,150,404
Total Cash Expended (TCE) $ $1,150,492 $1,150,492 $1,150,492 $1,150,492 $1,150,404
All ow. for Funds Dur ing Constr. (AFDC) $ $0 $0 $0 $0 $0
Total Plant I nvestment (TPI) $ $1,150,492 $1,150,492 $1,150,492 $1,150,492 $1,150,404
Preproduction Costs $ $105,125 $105,125 $105,125 $105,125 $105,123
Inventory Capital $ $139,295 $139,295 $139,295 $139,295 $139,295
Total Capital Requirement (TCR) $ $1,394,913 $1,394,913 $1,394,913 $1,394,913 $1,394,822
$/kW $62.0 $62.0 $62.0 $62.0 $62.0
SNCR O&M Costs Case1 Case2 Case3 Case4 Case5
Cost Basis (Year) 2009 2009 2009 2009 2009
Operating and Supervisory Labor $/yr 76,650 76,650 76,650 76,650 76
Maintenance Labor and Materials $/yr 16,755 16,755 16,755 16,755 16
Reagent $/yr 847,380 847,380 847,380 847,380 847
Electricity $/yr 42,216 42,216 42,374 42,216 42
Water $/yr - - - -
Steam (for steam atomization) $/yr - - - -
Total O&M Costs $/yr 983,001 983,001 983,160 983,001 983
Low NOX Burner Technology Capital Costs Case1 Case2 Case3 Case4 Case5
Cost Basis (Year) 2009 2009 2009 2009 2009
Total Capital Requirement with Retrofit (TCR) $ $1,852,731 $1,852,731 $1,852,731 $1,852,731 $1,852,731
$/kW $82.3 $82.3 $82.3 $82.3 $82.3
Low NOX Burner Technology O&M Costs Case1 Case2 Case3 Case4 Case5
Cost Basis (Year) 2009 2009 2009 2009 2009
Maintenance Labor $/yr 14,822 14,822 14,822 14,822 14
Maintenance Materials $/yr 22,233 22,233 22,233 22,233 22
Control, Administration, Overhead $/yr 4,447 4,447 4,447 4,447 4
Total O&M Costs $/yr 41,501 41,501 41,501 41,501 41
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Natural Gas Reburn ing - Preliminary Case1 Case2 Case3 Case4 Case5
Fraction of heat input as reburn fuel fraction 0.15 0.15 0.15 0.15 0.15
Bottom Ash Rate tons/yr 91 91 91 91 94
Natur al Gas Reburning Capital Costs Case1 Case2 Case3 Case4 Case5
Cost Basis (Year) 2009 2009 2009 2009 2009
Gas Pipeline from Fenceline to Boiler $ $501,678 $501,678 $501,678 $501,678 $501,678Fuel Injectors, Overfire Air Ports and Associated Piping, Valves, Windbox and
Control Dampers $ $1,274,466 $1,274,466 $1,274,466 $1,274,466 $1,274,466
Total Di rect Cost $ $1,776,145 $1,776,145 $1,776,145 $1,776,145 $1,776,145
Total Direct Cost with Retrofit Factor $ $2,841,832 $2,841,832 $2,841,832 $2,841,832 $2,841,832
General Facilities $ $56,837 $56,837 $56,837 $56,837 $56,837
Engineering Fees $ $284,183 $284,183 $284,183 $284,183 $284,183
Contingency $ $568,366 $568,366 $568,366 $568,366 $568,366
Total Plant Cost (TPC) $ $3,751,218 $3,751,218 $3,751,218 $3,751,218 $3,751,218
Total Plant Cost (TPC) w/ Prime Contractor's Markup $ $3,863,754 $3,863,754 $3,863,754 $3,863,754 $3,863,754
Total Cash Expended (TCE) $ $3,863,754 $3,863,754 $3,863,754 $3,863,754 $3,863,754
All ow. for Funds Duri ng Constr. (AFDC) $ $0 $0 $0 $0 $0
Total Plant I nvestment (TPI) $ $3,863,754 $3,863,754 $3,863,754 $3,863,754 $3,863,754
Preproduction Costs $ $80,823 $80,823 $80,823 $80,823 $80,793
Inventory Capital $ $0 $0 $0 $0 $0
Total Capital Requirement (TCR) $ $3,944,577 $3,944,577 $3,944,577 $3,944,577 $3,944,547
$/kW $175.3 $175.3 $175.3 $175.3 $175.3
Natural Gas Reburning O&M Costs Case1 Case2 Case3 Case4 Case5
Cost Basis (Year) 2009 2009 2009 2009 2009
Electrical Consumption Savings $/yr (19,416) (19,416) (19,489) (19,416) (19,4
Maintenance $/yr 56,236 56,236 56,236 56,236 56,2
Waste Disposal Savings $/yr (12,981) (12,981) (12,981) (12,981) (13,3
Natural Gas Consumption $/yr (134,479) (134,479) (134,479) (134,479) (134,4
Total O&M Costs (110,641) (110,641) (110,714) (110,641) (110,9
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LSFO Materi al Balance - Preliminary Case1 Case 2 Case 3 Case 4 Case 5
Fl ue Gas, Downstream of I D F ans
Temperature F 295 295 295 295 295
Pressure in. H2O 10 10 10 10 10
Flow Rate SCFM 58,015 58,015 58,015 58,015 57,995
Flow Rate ACFM 83,634 83,634 83,634 83,634 83,605
CO2 lb/hr 50,489 50,489 50,489 50,489 50,535 N2 lb/hr 184,042 184,042 184,042 184,042 183,960
SO2 lb/hr 301 301 301 301 188
O2 lb/hr 14,693 14,693 14,693 14,693 14,687
HCl lb/hr 28 28 28 28 28
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 17,793 17,793 17,793 17,793 17,805
Fly Ash lb/hr 0 0 0 0 0
Total (gas only) lb/hr 267,412 267,412 267,412 267,412 267,269
Flue Gas, to Absorber
Temperature F 295 295 295 295 295
Pressure in. H2O 10 10 10 10 10
Flow Rate SCFM 58,015 58,015 58,015 58,015 57,995
Flow Rate ACFM 83,634 83,634 83,634 83,634 83,605
CO2 lb/hr 50,489 50,489 50,489 50,489 50,535 N2 lb/hr 184,042 184,042 184,042 184,042 183,960
SO2 lb/hr 301 301 301 301 188
O2 lb/hr 14,693 14,693 14,693 14,693 14,687
HCl lb/hr 28 28 28 28 28
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 17,793 17,793 17,793 17,793 17,805
Fly Ash lb/hr 0 0 0 0 0
Total (gas only) lb/hr 267,412 267,412 267,412 267,412 267,269
Flue Gas, from Absorbers (total)
Temperature F 127 127 127 127 127
Pressure in. H2O 4 4 4 4 4
Flow Rate SCFM 60,374 60,374 60,374 60,374 60,249
Flow Rate ACFM 68,672 68,672 68,672 68,672 68,531
CO2 lb/hr 50,702 50,702 50,702 50,702 50,675 N2 lb/hr 184,988 184,988 184,988 184,988 184,552
SO2 lb/hr 15 15 15 15 9
O2 lb/hr 14,907 14,907 14,907 14,907 14,821
HCl lb/hr 0 0 0 0 0
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 23,773 23,773 23,773 23,773 23,762
Fly Ash lb/hr 0 0 0 0 0
Total (gas only) lb/hr 274,451 274,451 274,451 274,451 273,884
Heat Capacities
O2 Btu/lbmolF 7.203 7.203 7.203 7.203 7.203
CO2 Btu/lbmolF 9.263 9.263 9.263 9.263 9.263
N2 Btu/lbmolF 6.990 6.990 6.990 6.990 6.990
H2O Btu/lbmolF 8.048 8.048 8.048 8.048 8.048
NO Btu/lbmolF 7.151 7.151 7.151 7.151 7.151
SO2 Btu/lbmolF 9.771 9.771 9.771 9.771 9.771 HCl Btu/lbmolF 6.951 6.951 6.951 6.951 6.951
O2 Btu/lbF 0.225 0.225 0.225 0.225 0.225
CO2 Btu/lbF 0.210 0.210 0.210 0.210 0.210
N2 Btu/lbF 0.249 0.249 0.249 0.249 0.249
H2O Btu/lbF 0.447 0.447 0.447 0.447 0.447
NO Btu/lbF 0.238 0.238 0.238 0.238 0.238
SO2 Btu/lbF 0.153 0.153 0.153 0.153 0.153
HCl Btu/lbF 0.191 0.191 0.191 0.191 0.191
Reheated Gas Temperature: C 52.8 52.8 52.8 52.8 52.8
K 325.8 325.8 325.8 325.8 325.8
FGD Outlet Temperature: C 52.8 52.8 52.8 52.8 52.8
K 325.8 325.8 325.8 325.8 325.8
Total Btu/hr Btu/hr 0 0 0 0 0
Hot Reheat Air
Temperature F 440 440 440 440 440
Pressure in. H2O 1 1 1 1 1
Flow Rate SCFM 0 0 0 0 0
Flow Rate ACFM 0 0 0 0 0
N2 lb/hr 0 0 0 0 0
O2 lb/hr 0 0 0 0 0
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H2O lb/hr 0 0 0 0 0
Total lb/hr 0 0 0 0 0
Heat Capacities of Hot Reheat Ai r
O2 Btu/lbmolF 7.322 7.322 7.322 7.322 7.322
N2 Btu/lbmolF 7.104 7.104 7.104 7.104 7.104
H2O Btu/lbmolF 8.316 8.316 8.316 8.316 8.316
O2 Btu/lbF 0.229 0.229 0.229 0.229 0.229
N2 Btu/lbF 0.254 0.254 0.254 0.254 0.254
H2O Btu/lbF 0.462 0.462 0.462 0.462 0.462
Heated Temperature: C 226.7 226.7 226.7 226.7 226.7
K 499.7 499.7 499.7 499.7 499.7
FGD Outlet Temperature: C 52.8 52.8 52.8 52.8 52.8
K 325.8 325.8 325.8 325.8 325.8
Heat Capacities of I nlet Reheat Ai r
O2 Btu/lbmolF 7.295 7.295 7.295 7.295 7.295
N2 Btu/lbmolF 7.077 7.077 7.077 7.077 7.077
H2O Btu/lbmolF 8.254 8.254 8.254 8.254 8.254
O2 Btu/lbF 0.228 0.228 0.228 0.228 0.228
N2 Btu/lbF 0.253 0.253 0.253 0.253 0.253
H2O Btu/lbF 0.458 0.458 0.458 0.458 0.458
Heated Temperature: C 226.7 226.7 226.7 226.7 226.7
K 499.7 499.7 499.7 499.7 499.7
Inlet Air Temperature: C 12.8 12.8 12.8 12.8 12.8
K 285.8 285.8 285.8 285.8 285.8
Requir ed Heat Btu/hr 0 0 0 0 0
Oxidation Air (total)
Temperature F 60 60 60 60 60
Pressure in. H2O 0 0 0 0 0
Flow Rate SCFM 276 276 276 276 173
Flow Rate ACFM 281 281 281 281 176
N2 lb/hr 946 946 946 946 592
O2 lb/hr 285 285 285 285 179
H2O lb/hr 16 16 16 16 10
Total (gas only) lb/hr 1,248 1,248 1,248 1,248 781
Limestone to Ball M il l
Temperature F 55 55 55 55 55
Wt.% Solids wt. % 100% 100% 100% 100% 100%
Inerts lb/hr 25 25 25 25 16
CaCO3 lb/hr 507 507 507 507 331
Total lb/hr 532 532 532 532 348
L imestone Slurr y to L imestone Slurr y Tank
Temperature F 90 90 90 90 90
Flow Rate GPM 1.9 1.9 1.9 1.9 1.2
Wt.% Solids wt. % 40% 40% 40% 40% 40%
Inerts lb/hr 25 25 25 25 16
CaCO3 lb/hr 507 507 507 507 331
H2O lb/hr 797 797 797 797 521
Total lb/hr 1,329 1,329 1,329 1,329 869
Limestone Slur ry to Reaction M ix Tank (total)
Temperature F 68 68 68 68 68
Flow Rate GPM 4.4 4.4 4.4 4.4 2.9
Wt.% Solids wt. % 20% 20% 20% 20% 20%
Inerts lb/hr 25 25 25 25 16
CaCO3 lb/hr 507 507 507 507 331
H2O lb/hr 2,127 2,127 2,127 2,127 1,390
Total lb/hr 2,658 2,658 2,658 2,658 1,738
Slurr y to Absorber
Temperature F 126 126 126 126 126
Flow Rate GPM 8,479 4,748 8,479 8,479 8,462
Wt.% Solids wt. % 15% 15% 15% 15% 15%
CaSO3*1/2H2O lb/hr 0 0 0 0 0
CaSO4*2H2O lb/hr 655,593 367,132 655,593 655,593 634,723
Inerts lb/hr 21,333 11,947 21,333 21,333 21,582
CaCl2 lb/hr 35,923 20,117 35,923 35,923 55,648
CaCO3 lb/hr 19,056 10,671 19,056 19,056 18,449 H2O lb/hr 4,147,468 2,322,582 4,147,468 4,147,468 4,138,947
Total lb/hr 4,879,374 2,732,449 4,879,374 4,879,374 4,869,350
Slur ry fr om Rxn Tank to Thickener
Temperature F 126 126 126 126 126
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Flow Rate GPM 9.9 9.9 9.9 9.9 6.4
Wt.% Solids wt. % 15% 15% 15% 15% 15%
CaSO3*1/2H2O lb/hr 0 0 0 0 0
CaSO4*2H2O lb/hr 768 768 768 768 480
Inerts lb/hr 25 25 25 25 16
CaCl2 lb/hr 42 42 42 42 42
CaCO3 lb/hr 22 22 22 22 14
H2O lb/hr 4,858 4,858 4,858 4,858 3,132
Total lb/hr 5,715 5,715 5,715 5,715 3,685
LSFO Equipment Capital Costs Case1 Case 2 Case 3 Case 4 Case 5Cost Basis (Year) 2009 2009 2009 2009 2009
Sizing Criteria
Reagent Feed System $ kpph Reag. $10,344,623 $10,344,623 $10,344,623 $10,344,623 $10,326,592
Ball Mill & Hydroclone System $ TPH Reag. $2,690,576 $2,690,576 $2,690,576 $2,690,576 $2,687,591
DBA Acid Tank (pump, heater, agitator) $ gpm DBA $0 $108,960 $0 $0 $0
SO2 Removal System $ kpph SO2 $2,769,943 $2,769,943 $2,769,943 $2,769,943 $2,764,290
Absorber Tower $ kACFM $4,034,765 $4,034,765 $4,034,765 $4,034,765 $4,033,979
Spray Pumps $ slurry gpm $287,420 $203,511 $287,420 $287,420 $287,068
Flue Gas Handling System $ * $2,132,534 $2,132,534 $2,132,534 $2,132,534 $2,132,196
ID Fans $ ACFM $397,788 $397,788 $397,788 $397,788 $397,694
Waste / Byproduct Handling System $ kpph SO2 $117,459 $117,459 $117,459 $117,459 $117,168
Thickener System $ TPH solids $171,232 $171,232 $171,232 $171,232 $169,247
Support Equipment $ MW $1,766,858 $1,766,858 $1,766,858 $1,766,858 $1,766,858
Chimney $ ACFM $2,624,233 $2,624,233 $2,624,233 $2,624,233 $2,622,125
TOTAL $ $27,337,430 $27,362,481 $27,337,430 $27,337,430 $27,304,808* Based on flue gas flow and reheat temperature.
Capital Costs with Retrof it F actors
Reagent Feed System $ $16,551,396 $16,551,396 $16,551,396 $16,551,396 $16,522,547
Ball Mill & Hydroclone System $ $4,304,922 $4,304,922 $4,304,922 $4,304,922 $4,300,146
DBA Acid Tank (pump, heater, agitator) $ $0 $174,336 $0 $0 $0
SO2 Removal System $ $4,431,909 $4,431,909 $4,431,909 $4,431,909 $4,422,865
Absorber Tower $ $6,455,625 $6,455,625 $6,455,625 $6,455,625 $6,454,367 Spray Pumps $ $459,872 $325,618 $459,872 $459,872 $459,309
Flue Gas Handling System $ $3,412,054 $3,412,054 $3,412,054 $3,412,054 $3,411,514
ID Fans $ $636,460 $636,460 $636,460 $636,460 $636,310
Waste / Byproduct Handling System $ $187,935 $187,935 $187,935 $187,935 $187,469
Thickener System $ $273,971 $273,971 $273,971 $273,971 $270,794
Support Equipment $ $2,826,972 $2,826,972 $2,826,972 $2,826,972 $2,826,972
Chimney $ $4,198,773 $4,198,773 $4,198,773 $4,198,773 $4,195,400
TOTAL $ $43,739,888 $43,779,970 $43,739,888 $43,739,888 $43,687,693
General Facili ties
Reagent Feed System $ $1,655,140 $1,655,140 $1,655,140 $1,655,140 $1,652,255
Ball Mill & Hydroclone System $ $430,492 $430,492 $430,492 $430,492 $430,015
DBA Acid Tank (pump, heater, agitator) $ $0 $17,434 $0 $0 $0
SO2 Removal System $ $443,191 $443,191 $443,191 $443,191 $442,286
Absorber Tower $ $645,562 $645,562 $645,562 $645,562 $645,437
Spray Pumps $ $45,987 $32,562 $45,987 $45,987 $45,931
Flue Gas Handling System $ $341,205 $341,205 $341,205 $341,205 $341,151
ID Fans $ $63,646 $63,646 $63,646 $63,646 $63,631
Waste / Byproduct Handling System $ $18,793 $18,793 $18,793 $18,793 $18,747
Thickener System $ $27,397 $27,397 $27,397 $27,397 $27,079
Support Equipment $ $282,697 $282,697 $282,697 $282,697 $282,697
Chimney $ $419,877 $419,877 $419,877 $419,877 $419,540
TOTAL $ $4,373,989 $4,377,997 $4,373,989 $4,373,989 $4,368,769
Engineeri ng Fees
Reagent Feed System $ $1,655,140 $1,655,140 $1,655,140 $1,655,140 $1,652,255
Ball Mill & Hydroclone System $ $430,492 $430,492 $430,492 $430,492 $430,015 DBA Acid Tank (pump, heater, agitator) $ $0 $17,434 $0 $0 $0
SO2 Removal System $ $443,191 $443,191 $443,191 $443,191 $442,286
Absorber Tower $ $645,562 $645,562 $645,562 $645,562 $645,437
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Spray Pumps $ $45,987 $32,562 $45,987 $45,987 $45,931
Flue Gas Handling System $ $341,205 $341,205 $341,205 $341,205 $341,151
ID Fans $ $63,646 $63,646 $63,646 $63,646 $63,631
Waste / Byproduct Handling System $ $18,793 $18,793 $18,793 $18,793 $18,747
Thickener System $ $27,397 $27,397 $27,397 $27,397 $27,079
Support Equipment $ $282,697 $282,697 $282,697 $282,697 $282,697
Chimney $ $419,877 $419,877 $419,877 $419,877 $419,540
TOTAL $ $4,373,989 $4,377,997 $4,373,989 $4,373,989 $4,368,769
Contingency
Reagent Feed System $ $3,310,279 $3,310,279 $3,310,279 $3,310,279 $3,304,509
Ball Mill & Hydroclone System $ $860,984 $860,984 $860,984 $860,984 $860,029
DBA Acid Tank (pump, heater, agitator) $ $0 $34,867 $0 $0 $0
SO2 Removal System $ $886,382 $886,382 $886,382 $886,382 $884,573
Absorber Tower $ $1,291,125 $1,291,125 $1,291,125 $1,291,125 $1,290,873
Spray Pumps $ $91,974 $65,124 $91,974 $91,974 $91,862
Flue Gas Handling System $ $682,411 $682,411 $682,411 $682,411 $682,303
ID Fans $ $127,292 $127,292 $127,292 $127,292 $127,262
Waste / Byproduct Handling System $ $37,587 $37,587 $37,587 $37,587 $37,494
Thickener System $ $54,794 $54,794 $54,794 $54,794 $54,159
Support Equipment $ $565,394 $565,394 $565,394 $565,394 $565,394
Chimney $ $839,755 $839,755 $839,755 $839,755 $839,080TOTAL $ $8,747,978 $8,755,994 $8,747,978 $8,747,978 $8,737,539
Total Plant Cost (TPC) $ $61,235,843 $61,291,958 $61,235,843 $61,235,843 $61,162,771
Total Plant Cost (TPC) w/ Prime Contractor's M arku $ $63,072,918 $63,130,717 $63,072,918 $63,072,918 $62,997,654
Total Cash Expended (TCE) $ $63,072,918 $63,130,717 $63,072,918 $63,072,918 $62,997,654
All ow. for F unds Duri ng Constr. (AFDC) $ $0 $0 $0 $0 $0
Total Plant I nvestment (TPI) $ $63,072,918 $63,130,717 $63,072,918 $63,072,918 $62,997,654
Preproduction Costs $ $1,494,583 $1,490,904 $1,494,649 $1,494,583 $1,491,184
Inventory Capital $ $5,742 $5,742 $5,742 $5,742 $3,753
Total Capital Requir ement (TCR) $ $64,573,243 $64,627,363 $64,573,309 $64,573,243 $64,492,591$/kW $2,870 $2,872 $2,870 $2,870 $2,866
Maintenance Cost by Area Case1 Case 2 Case 3 Case 4 Case 5
TPC w/o Retrofi t F actor
Reagent Feed System $ $14,896,256 $14,896,256 $14,896,256 $14,896,256 $14,870,292
Ball Mill & Hydroclone System $ $3,874,430 $3,874,430 $3,874,430 $3,874,430 $3,870,131
DBA Acid Tank (pump, heater, agitator) $ $0 $156,903 $0 $0 $0
SO2 Removal System $ $3,988,718 $3,988,718 $3,988,718 $3,988,718 $3,980,578
Absorber Tower $ $5,810,062 $5,810,062 $5,810,062 $5,810,062 $5,808,930
Spray Pumps $ $413,885 $293,056 $413,885 $413,885 $413,378
Flue Gas Handling System $ $3,070,848 $3,070,848 $3,070,848 $3,070,848 $3,070,363
ID Fans $ $572,814 $572,814 $572,814 $572,814 $572,679
Waste / Byproduct Handling System $ $169,141 $169,141 $169,141 $169,141 $168,722
Thickener System $ $246,574 $246,574 $246,574 $246,574 $243,715
Support Equipment $ $2,544,275 $2,544,275 $2,544,275 $2,544,275 $2,544,275
Chimney $ $3,778,895 $3,778,895 $3,778,895 $3,778,895 $3,775,860
TOTAL $ $39,365,899 $39,401,973 $39,365,899 $39,365,899 $39,318,924
Fir st Year M aintenance Costs
Reagent Feed System $ $744,813 $744,813 $744,813 $744,813 $743,515
Ball Mill & Hydroclone System $ $193,721 $193,721 $193,721 $193,721 $193,507
DBA Acid Tank (pump, heater, agitator) $ $0 $7,845 $0 $0 $0
SO2 Removal System $ $199,436 $189,464 $199,436 $199,436 $199,029
Absorber Tower $ $290,503 $275,978 $290,503 $290,503 $290,447
Spray Pumps $ $20,694 $13,920 $20,694 $20,694 $20,669Flue Gas Handling System $ $153,542 $153,542 $153,542 $153,542 $153,518
ID Fans $ $28,641 $28,641 $28,641 $28,641 $28,634
Waste / Byproduct Handling System $ $8,457 $8,457 $8,457 $8,457 $8,436
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Thickener System $ $12,329 $12,329 $12,329 $12,329 $12,186
Support Equipment $ $127,214 $127,214 $127,214 $127,214 $127,214
Chimney $ $188,945 $188,945 $188,945 $188,945 $188,793
TOTAL $ $1,968,295 $1,944,869 $1,968,295 $1,968,295 $1,965,946
LSFO O&M Data and Costs Case1 Case 2 Case 3 Case 4 Case 5Cost Basis (Year) 2009 2009 2009 2009 2009
Parameters
Reagent Required lbs/hr 532 532 532 532 348
lbs/MMBtu 2.250 2.250 2.250 2.250 1.471
DBA Required lbs/hr 0.0 2.9 0.0 0.0 0.0
Percent SO2 Removal % 95% 95% 95% 95% 95%
FGD Sludge to Disposal lbs/hr, dry 857 857 857 857 553
Steam to FGD System lbs/hr 0 0 0 0 0
Total FGD Power Consumption kW 450 370 450 450 450
FGD Byproduct lbs/hr 0 0 0 0 0
Fixed O&M Costs
Number of Operators 3 3 3 3 3
(40 hrs/week) Operating Labor Cost ** $/yr $250,341 $250,341 $250,341 $250,341 $250,341
Maint. Labor & Matls. Cost $/yr $1,968,295 $1,944,869 $1,968,295 $1,968,295 $1,965,946
Admin. & Support Labor $/yr $311,298 $308,487 $311,298 $311,298 $311,016
TOTAL $/yr $2,529,934 $2,503,697 $2,529,934 $2,529,934 $2,527,303
Variable Operating Costs **
Reagent Costs $/yr $33,182 $33,182 $33,182 $33,182 $21,691
DBA Costs $/yr $0 $5,112 $0 $0 $0
Disposal Costs $/yr $21,402 $21,402 $21,402 $21,402 $13,800
Credit for Byproduct $/yr $0 $0 $0 $0 $0
Steam Costs $/yr $0 $0 $0 $0 $0
Power Costs $/yr $199,603 $164,293 $200,352 $199,603 $199,603
TOTAL $/yr $254,188 $223,990 $254,937 $254,188 $235,094
** These costs assume inputs are in current dollars (no escalation included).
I ntermediate Materi al Balance Calcs. Case1 Case 2 Case 3 Case 4 Case 5
Sulfi te Reaction
SO2 lbmole/hr 4.46 4.46 4.46 4.46 2.79
CaCO3 lbmole/hr 4.46 4.46 4.46 4.46 2.79
H2O lbmole/hr 2.23 2.23 2.23 2.23 1.39
CaSO3*1/2H2O lbmole/hr 4.46 4.46 4.46 4.46 2.79
CO2 lbmole/hr 4.46 4.46 4.46 4.46 2.79
SO2 lb/hr 286 286 286 286 179
CaCO3 lb/hr 446 446 446 446 279
H2O lb/hr 40 40 40 40 25 CaSO3*1/2H2O lb/hr 576 576 576 576 360
CO2 lb/hr 196 196 196 196 123
Sulfate Reaction
CaSO3*1/2H2O lbmole/hr 4.46 4.46 4.46 4.46 2.79
O2 lbmole/hr 2.23 2.23 2.23 2.23 1.39
H2O lbmole/hr 6.69 6.69 6.69 6.69 4.18
CaSO4*2H2O lbmole/hr 4.46 4.46 4.46 4.46 2.79
CaSO3*1/2H2O lb/hr 576 576 576 576 360
O2 lb/hr 71 71 71 71 45
H2O lb/hr 121 121 121 121 75
CaSO4*2H2O lb/hr 768 768 768 768 480
Water in Absorber
Mole Fraction H2O in Absorber % 0.1389 0.1389 0.1389 0.1389 0.1389
Moles H2O in Absorber lbmole 1,319.20 1,319.20 1,319.20 1,319.20 1,318.58
DBA Feed Calculations
SO2 Removed lbs/hr 286 286 286 286 179
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CUECost - Air Pollution Control Systems Economics Spreadsheet
DBA Added lbs/hr 0.00 2.86 0.00 0.00 0.00
DBA Added GPM 0.00 0.00 0.00 0.00 0.00
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CUECost - Air Pollution Control Systems Economics Spreadsheet
LSD Material Balance - Preliminary Case1 Case 2 Case 3 Case 4 Case 5
F lue Gas, Downstream of A ir Heater
Temperature F 300 300 300 300 300
Pressure in. H2O -12 -12 -12 -12 -12
Flow Rate SCFM 58,015 58,015 58,015 58,015 57,995
Flow Rate ACFM 88,958 88,958 88,958 88,958 88,927
CO2 lb/hr 50,489 50,489 50,489 50,489 50,535 N2 lb/hr 184,042 184,042 184,042 184,042 183,960
SO2 lb/hr 301 301 301 301 188
O2 lb/hr 14,693 14,693 14,693 14,693 14,687
HCl lb/hr 28 28 28 28 28
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 17,793 17,793 17,793 17,793 17,805
Fly Ash lb/hr 1,808 1,808 1,808 1,808 1,855
Total (gas only) lb/hr 267,412 267,412 267,412 267,412 267,269
F lue Gas, to Spray Dryer
Temperature F 300 300 300 300 300
Pressure in. H2O -12 -12 -12 -12 -12
Flow Rate SCFM 58,015 58,015 58,015 58,015 57,995
Flow Rate ACFM 88,958 88,958 88,958 88,958 88,927
CO2 lb/hr 50,489 50,489 50,489 50,489 50,535 N2 lb/hr 184,042 184,042 184,042 184,042 183,960
SO2 lb/hr 301 301 301 301 188
O2 lb/hr 14,693 14,693 14,693 14,693 14,687
HCl lb/hr 28 28 28 28 28
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 17,793 17,793 17,793 17,793 17,805
Fly Ash lb/hr 1,808 1,808 1,808 1,808 1,855
Total (gas only) lb/hr 267,412 267,412 267,412 267,412 267,269
F lue Gas, fr om Spray Dr yers (total)
Temperature F 147 147 147 147 147
Pressure in. H2O -17 -17 -17 -17 -13
Flow Rate SCFM 63,810 63,810 63,810 63,810 63,627
Flow Rate ACFM 79,166 79,166 79,166 79,166 78,124
CO2 lb/hr 50,489 50,489 50,489 50,489 50,535
N2 lb/hr 184,042 184,042 184,042 184,042 183,960
SO2 lb/hr 229 229 229 229 151
O2 lb/hr 14,689 14,689 14,689 14,689 14,685
HCl lb/hr 0 0 0 0 0
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 34,317 34,317 34,317 34,317 33,854
Fly Ash lb/hr 3,356 3,356 3,356 3,356 3,006
Total (gas only) lb/hr 283,831 283,831 283,831 283,831 283,250
F lue Gas Downstream of Particul ate Control Device
Temperature F 147 147 147 147 147
Pressure in. H2O -20 -20 -20 -20 -16
Flow Rate SCFM 63,784 63,784 63,784 63,784 63,605
Flow Rate ACFM 79,758 79,758 79,758 79,758 78,706
CO2 lb/hr 50,489 50,489 50,489 50,489 50,535
N2 lb/hr 184,042 184,042 184,042 184,042 183,960 SO2 lb/hr 211 211 211 211 141
O2 lb/hr 14,688 14,688 14,688 14,688 14,684
HCl lb/hr 0 0 0 0 0
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 34,248 34,248 34,248 34,248 33,793
Fly Ash lb/hr 0 0 0 0 0
Total (gas only) lb/hr 283,744 283,744 283,744 283,744 283,179
F lue Gas Downstream of I D F ans
Temperature F 152 152 152 152 152
Pressure in. H2O 1 1 1 1 1
Flow Rate SCFM 63,784 63,784 63,784 63,784 63,605
Flow Rate ACFM 76,207 76,207 76,207 76,207 75,992
CO2 lb/hr 50,489 50,489 50,489 50,489 50,535
N2 lb/hr 184,042 184,042 184,042 184,042 183,960 SO2 lb/hr 211 211 211 211 141
O2 lb/hr 14,688 14,688 14,688 14,688 14,684
HCl lb/hr 0 0 0 0 0
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 34,248 34,248 34,248 34,248 33,793
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Fly Ash lb/hr 0 0 0 0 0
Total (gas only) lb/hr 283,744 283,744 283,744 283,744 283,179
Lime to Ball M ill
Temperature F 60 60 60 60 60
Wt.% Solids wt. % 100% 100% 100% 100% 100%
Inerts lb/hr 9 9 9 9 5
CaO lb/hr 81 81 81 81 42
Total lb/hr 90 90 90 90 47
Water to Ball M ill
Temperature F 60 60 60 60 60
Flow Rate GPM 1 1 1 1 0
Wt.% Solids wt. % 0% 0% 0% 0% 0%
H2O lb/hr 296 296 296 296 154
Total lb/hr 296 296 296 296 154
L ime Slurr y to Head Tanks (Total)
Temperature F 110 110 110 110 110
Flow Rate GPM 1 1 1 1 0
Wt.% Solids wt. % 30% 30% 30% 30% 30%
Ca(OH)2 lb/hr 107 107 107 107 56
Inerts lb/hr 9 9 9 9 5
H2O lb/hr 270 270 270 270 140
Total lb/hr 386 386 386 386 201
Lime Slur ry from Head Tank
Temperature F 110 110 110 110 110
Flow Rate GPM 5 5 5 5 4
Wt.% Solids wt. % 49% 49% 49% 49% 50%
CaSO3*1/2H2O lb/hr 112 112 112 112 48
CaSO4*2H2O lb/hr 50 50 50 50 21
Flyash / Inerts lb/hr 1,541 1,541 1,541 1,541 1,283
Ca(OH)2 lb/hr 87 87 87 87 38
CaCl2 lb/hr 82 82 82 82 59
H2O lb/hr 1,945 1,945 1,945 1,945 1,471
Total lb/hr 3,818 3,818 3,818 3,818 2,920
L ime Slurr y to Atomizer
Temperature F 104 104 104 104 104
Flow Rate GPM 33 33 33 33 32
Wt.% Solids wt. % 10% 10% 10% 10% 8%
CaSO3*1/2H2O lb/hr 112 112 112 112 48
CaSO4*2H2O lb/hr 50 50 50 50 21
Flyash / Inerts lb/hr 1,541 1,541 1,541 1,541 1,283
Ca(OH)2 lb/hr 87 87 87 87 38
CaCl2 lb/hr 82 82 82 82 59
H2O lb/hr 16,515 16,515 16,515 16,515 16,041
Total lb/hr 18,388 18,388 18,388 18,388 17,490
Solids fr om Spray Dryers (Total)
Temperature F 150 150 150 150 150
Wt.% Solids wt. % 98% 98% 98% 98% 98%
CaSO3*1/2H2O lb/hr 22 22 22 22 10
CaSO4*2H2O lb/hr 10 10 10 10 5 Flyash / Inerts lb/hr 301 301 301 301 280
Ca(OH)2 lb/hr -2 -2 -2 -2 -3
CaCl2 lb/hr 42 42 42 42 42
H2O lb/hr 8 8 8 8 7
Total lb/hr 380 380 380 380 341
Baghouse/ESP Soli ds to Recycle
Particulate Removal Efficiency % 99.99% 99.99% 99.99% 99.99% 99.99%
Temperature F 150 150 150 150 150
Wt.% Solids wt. % 98% 98% 98% 98% 98%
CaSO3*1/2H2O lb/hr 90 90 90 90 37
CaSO4*2H2O lb/hr 40 40 40 40 17
Flyash / Inerts lb/hr 1,230 1,230 1,230 1,230 999
Ca(OH)2 lb/hr -17 -17 -17 -17 -14
CaCl2 lb/hr 40 40 40 40 17 H2O lb/hr 27 27 27 27 21
Total lb/hr 1,371 1,371 1,371 1,371 1,060
Recycle Soli ds to Slu rry Tank
Temperature F 150 150 150 150 150
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Wt.% Solids wt. % 98% 98% 98% 98% 98%
CaSO3*1/2H2O lb/hr 112 112 112 112 48
CaSO4*2H2O lb/hr 50 50 50 50 21
Flyash / Inerts lb/hr 1,532 1,532 1,532 1,532 1,279
Ca(OH)2 lb/hr -19 -19 -19 -19 -18
CaCl2 lb/hr 82 82 82 82 59
H2O lb/hr 35 35 35 35 28
Total lb/hr 1,792 1,792 1,792 1,792 1,417
Blowdown Water to Recycle Solids Tank Temperature F 60 60 60 60 60
Flow Rate GPM 3 3 3 3 3
Wt.% Solids wt. % 0% 0% 0% 0% 0%
H2O lb/hr 1,640 1,640 1,640 1,640 1,302
Total lb/hr 1,640 1,640 1,640 1,640 1,302
Recycle Slurry to Head Tanks (Total )
Temperature F 110 110 110 110 110
Flow Rate GPM 5 5 5 5 4
Wt.% Solids wt. % 50% 50% 50% 50% 50%
CaSO3*1/2H2O lb/hr 112 112 112 112 48
CaSO4*2H2O lb/hr 50 50 50 50 21
Flyash / Inerts lb/hr 1,532 1,532 1,532 1,532 1,279
Ca(OH)2 lb/hr -19 -19 -19 -19 -18
CaCl2 lb/hr 82 82 82 82 59 H2O lb/hr 1,675 1,675 1,675 1,675 1,330
Total lb/hr 3,432 3,432 3,432 3,432 2,719
Dry Solids
Temperature F 100 100 100 100 100
Wt.% Solids wt. % 98% 98% 98% 98% 98%
CaSO3*1/2H2O lb/hr 136 136 136 136 71
CaSO4*2H2O lb/hr 61 61 61 61 32
Flyash / Inerts lb/hr 1,817 1,817 1,817 1,817 1,859
Ca(OH)2 lb/hr -26 -26 -26 -26 -27
CaCl2 lb/hr 84 84 84 84 84
H2O lb/hr 41 41 41 41 40
Total lb/hr 2,114 2,114 2,114 2,114 2,060
Solids to Landfi ll Temperature F 100 100 100 100 100
Wt.% Solids wt. % 80% 80% 80% 80% 80%
CaSO3*1/2H2O lb/hr 136 136 136 136 71
CaSO4*2H2O lb/hr 61 61 61 61 32
Flyash / Inerts lb/hr 1,817 1,817 1,817 1,817 1,859
Ca(OH)2 lb/hr -26 -26 -26 -26 -27
CaCl2 lb/hr 84 84 84 84 84
H2O lb/hr 518 518 518 518 505
Total lb/hr 2,590 2,590 2,590 2,590 2,524
LSD Equipment Capital Costs Case1 Case 2 Case 3 Case 4 Case 5Cost Basis (Year) 2009 2009 2009 2009 2009
Sizing CriteriaReagent Feed System $ * $5,553,775 $5,553,775 $5,553,775 $5,553,775 $5,526,459
SO2 Removal System $ Wt. % S $1,834,342 $1,834,342 $1,834,342 $1,834,342 $1,907,952
Spray Dryers $ kACFM $3,120,143 $3,120,143 $3,120,143 $3,120,143 $3,119,624
Flue Gas Handling System $ kACFM $834,503 $834,503 $834,503 $834,503 $829,836
ID Fans $ ACFM $297,927 $297,927 $297,927 $297,927 $295,232
Waste / Byproduct Handling System $ kpph SO2 $1,565,513 $1,565,513 $1,565,513 $1,565,513 $1,513,201
Support Equipment $ MW $2,045,839 $2,045,839 $2,045,839 $2,045,839 $2,045,839
Chimney $ ACFM $2,733,206 $2,733,206 $2,733,206 $2,733,206 $2,730,198
TOTAL $ $17,985,249 $17,985,249 $17,985,249 $17,985,249 $17,968,343
* Based on lbs/hr of lime feed and GPM of lime slurry.
Capital Costs with Retrofit Factors
Reagent Feed System $ $8,886,041 $8,886,041 $8,886,041 $8,886,041 $8,842,335
SO2 Removal System $ $2,934,947 $2,934,947 $2,934,947 $2,934,947 $3,052,724
Spray Dryers $ $4,992,229 $4,992,229 $4,992,229 $4,992,229 $4,991,399
Flue Gas Handling System $ $1,335,206 $1,335,206 $1,335,206 $1,335,206 $1,327,738
ID Fans $ $476,683 $476,683 $476,683 $476,683 $472,371
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Waste / Byproduct Handling System $ $2,504,820 $2,504,820 $2,504,820 $2,504,820 $2,421,121
Support Equipment $ $3,273,343 $3,273,343 $3,273,343 $3,273,343 $3,273,343
Chimney $ $4,373,130 $4,373,130 $4,373,130 $4,373,130 $4,368,317
TOTAL $ $28,776,398 $28,776,398 $28,776,398 $28,776,398 $28,749,348
General Facil iti es
Reagent Feed System $ $888,604 $888,604 $888,604 $888,604 $884,233
SO2 Removal System $ $293,495 $293,495 $293,495 $293,495 $0
Spray Dryers $ $499,223 $499,223 $499,223 $499,223 $0Flue Gas Handling System $ $133,521 $133,521 $133,521 $133,521 $0
ID Fans $ $47,668 $47,668 $47,668 $47,668 $0
Waste / Byproduct Handling System $ $250,482 $250,482 $250,482 $250,482 $242,112
Support Equipment $ $327,334 $327,334 $327,334 $327,334 $327,334
Chimney $ $437,313 $437,313 $437,313 $437,313 $436,832
TOTAL $ $2,877,640 $2,877,640 $2,877,640 $2,877,640 $1,890,512
Engineeri ng Fees
Reagent Feed System $ $888,604 $888,604 $888,604 $888,604 $884,233
SO2 Removal System $ $293,495 $293,495 $293,495 $293,495 $305,272
Spray Dryers $ $499,223 $499,223 $499,223 $499,223 $499,140
Flue Gas Handling System $ $133,521 $133,521 $133,521 $133,521 $132,774
ID Fans $ $47,668 $47,668 $47,668 $47,668 $47,237
Waste / Byproduct Handling System $ $250,482 $250,482 $250,482 $250,482 $242,112
Support Equipment $ $327,334 $327,334 $327,334 $327,334 $327,334
Chimney $ $437,313 $437,313 $437,313 $437,313 $436,832
TOTAL $ $2,877,640 $2,877,640 $2,877,640 $2,877,640 $2,874,935
Contingency
Reagent Feed System $ $1,777,208 $1,777,208 $1,777,208 $1,777,208 $1,768,467
SO2 Removal System $ $586,989 $586,989 $586,989 $586,989 $610,545
Spray Dryers $ $998,446 $998,446 $998,446 $998,446 $998,280
Flue Gas Handling System $ $267,041 $267,041 $267,041 $267,041 $0
ID Fans $ $95,337 $95,337 $95,337 $95,337 $0
Waste / Byproduct Handling System $ $500,964 $500,964 $500,964 $500,964 $0
Support Equipment $ $654,669 $654,669 $654,669 $654,669 $654,669
Chimney $ $874,626 $874,626 $874,626 $874,626 $873,663TOTAL $ $5,755,280 $5,755,280 $5,755,280 $5,755,280 $4,905,624
Total Plant Cost (TPC) $ $40,286,957 $40,286,957 $40,286,957 $40,286,957 $38,420,418
Total Plant Cost (TPC) w/ Prime Contractor' s $ $41,495,566 $41,495,566 $41,495,566 $41,495,566 $39,573,031
Total Cash Expended (TCE) $ $41,495,566 $41,495,566 $41,495,566 $41,495,566 $39,573,031
All ow. for F unds Duri ng Constr. (AFD $ $0 $0 $0 $0 $0
Total Plant I nvestment (TPI ) $ $41,495,566 $41,495,566 $41,495,566 $41,495,566 $39,573,031
Preproduction Costs $ $976,715 $976,715 $976,738 $976,715 $917,598
Inventory Capital $ $0 $0 $0 $0 $0
Total Capital Requirement (TCR) $ $42,472,280 $42,472,280 $42,472,303 $42,472,280 $40,490,629$/kW $1,888 $1,888 $1,888 $1,888 $1,800
Maintenance Cost by Area Case1 Case 2 Case 3 Case 4 Case 5
TPC w/o Retrof it Factor
Reagent Feed System $ $7,997,437 $7,997,437 $7,997,437 $7,997,437 $7,958,101
SO2 Removal System $ $2,641,452 $2,641,452 $2,641,452 $2,641,452 $2,518,497
Spray Dryers $ $4,493,006 $4,493,006 $4,493,006 $4,493,006 $4,117,904
Flue Gas Handling System $ $1,201,685 $1,201,685 $1,201,685 $1,201,685 $912,820
ID Fans $ $429,015 $429,015 $429,015 $429,015 $324,755
Waste / Byproduct Handling System $ $2,254,338 $2,254,338 $2,254,338 $2,254,338 $1,815,841
Support Equipment $ $2,946,008 $2,946,008 $2,946,008 $2,946,008 $2,946,008
Chimney $ $3,935,817 $3,935,817 $3,935,817 $3,935,817 $3,931,486
TOTAL $ $25,898,758 $25,898,758 $25,898,758 $25,898,758 $24,525,413
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F ir st Year M aintenance Costs
Reagent Feed System $ $399,872 $399,872 $399,872 $399,872 $397,905
SO2 Removal System $ $132,073 $132,073 $132,073 $132,073 $125,925
Spray Dryers $ $224,650 $224,650 $224,650 $224,650 $205,895
Flue Gas Handling System $ $60,084 $60,084 $60,084 $60,084 $0
ID Fans $ $21,451 $21,451 $21,451 $21,451 $0
Waste / Byproduct Handling System $ $112,717 $112,717 $112,717 $112,717 $0
Support Equipment $ $147,300 $147,300 $147,300 $147,300 $147,300
Chimney $ $196,791 $196,791 $196,791 $196,791 $196,574
TOTAL $ $1,294,938 $1,294,938 $1,294,938 $1,294,938 $1,073,600
LSD O& M Data and Costs Case1 Case 2 Case 3 Case 4 Case 5Cost Basis (Year) 2009 2009 2009 2009 2009
Parameters
Reagent Required lbs/hr 90 90 90 90 47
lbs/MMBtu 0.380 0.380 0.380 0.380 0.198
Percent SO2 Removal % 30% 30% 30% 30% 25%
FGD Solids - dry lbs/hr 2,072 2,072 2,072 2,072 2,019
- wetted lbs/hr 2,590 2,590 2,590 2,590 2,524
Fresh Water to FGD gpm 1 1 1 1 0
Blowdown Water to FGD gpm 33 33 33 33 33
Total FGD Power Consumption kW 158 158 158 158 158
Fixed O&M Costs
Number of Operators 3 3 3 3 3
(40 hrs/week)
Operating Labor Cost ** $/yr $182,758 $182,758 $182,758 $182,758 $182,758
Maint. Labor & Matls. Cost $/yr $1,294,938 $1,294,938 $1,294,938 $1,294,938 $1,073,600
Admin. & Support Labor $/yr $210,220.07 $210,220 $210,220 $210,220 $183,660
TOTAL $/yr $1,687,916 $1,687,916 $1,687,916 $1,687,916 $1,440,018
Variable Operating Costs **
Reagent Costs $/yr $0 $0 $0 $0 $0
Disposal Costs $/yr $0 $0 $0 $0 $0 Credit for Byproduct $/yr $0 $0 $0 $0 $0
Steam Costs $/yr $0 $0 $0 $0 $0
Fresh Water Costs $/yr $177 $177 $177 $177 $92
Power Costs $/yr $69,861 $69,861 $70,123 $69,861 $69,861
TOTAL $/yr $70,038 $70,038 $70,301 $70,038 $69,953
** These costs assume inputs are in current dollars (no escalation included).
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CUECost - Air Pollution Control Systems Economics Spreadsheet
Fabri c F il ter - Preliminary Case1 Case 2 Case 3 Case 4 Case 5
Fl ue Gas, Upstream of Fabri c Fi lter
Temperature F 300 300 147 147 147
Pressure in. H2O -12 -12 -17 -17 -13
Flow Rate SCFM 58,015 58,015 63,810 63,810 63,627
Flow Rate ACFM 88,958 88,958 79,166 79,166 78,124
CO2 lb/hr 50,489 50,489 50,489 50,489 50,535 N2 lb/hr 184,042 184,042 184,042 184,042 183,960
SO2 lb/hr 301 301 229 229 151
O2 lb/hr 14,693 14,693 14,689 14,689 14,685
HCl lb/hr 28 28 0 0 0
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 17,793 17,793 34,317 34,317 33,854
Fly Ash lb/hr 1,808 1,808 3,356 3,356 3,006
Total (gas only) lb/hr 267,412 267,412 283,831 283,831 283,250
Total Fabric Requir ed Ft2
25,416 25,416 22,619 22,619 22,321
Surf ace Ar ea per Bag Ft2
31.4 31.4 31.4 31.4 31.4
Requir ed No. of Bags (no spare compartments) 809 809 720 720 710
Fi nal No. of Bags 890 890 792 792 782
No. of Casings 1 1 1 1 1
Fabric Fi lter Dimensions (per Casing) Ft2
874 874 778 778 767
Length Ft 42 42 39 39 39
Width Ft 21 21 20 20 20
Capital Cost Case1 Case 2 Case 3 Case 4 Case 5
Cost Basis (Year) 2009 2009 2009 2009 2009
Fabric Filter $ $1,098,464 $1,098,464 $1,011,319 $1,011,319 $1,001,864
Bags $ $67,784 $67,784 $60,323 $60,323 $59,529 Ash Handling System $ $346,222 $346,222 $372,812 $372,812 $366,805
ID Fan(s) $ $176,894 $176,894 $164,575 $164,575 $163,230
Equipment Cost Subtotal $ $1,689,364 $1,689,364 $1,609,030 $1,609,030 $1,591,428
Instruments & Controls $ $33,787 $33,787 $32,181 $32,181 $31,829
Taxes $ $109,809 $109,809 $104,587 $104,587 $103,443
Freight $ $84,468 $84,468 $80,451 $80,451 $79,571
Purchased Equipment Cost Subtotal $ $1,917,429 $1,917,429 $1,826,249 $1,826,249 $1,806,271
Installation $ $1,284,677 $1,284,677 $1,223,587 $1,223,587 $1,210,202
Total Di rect Cost $ $3,202,106 $3,202,106 $3,049,835 $3,049,835 $3,016,473
Total Direct Cost with Retrofit Factor $ $5,123,369 $5,123,369 $4,879,736 $4,879,736 $4,826,356
General Facilities $ $512,337 $512,337 $487,974 $487,974 $482,636
Engineering Fees $ $512,337 $512,337 $487,974 $487,974 $482,636
Contingency $ $1,024,674 $1,024,674 $975,947 $975,947 $965,271
Total Plan t Cost (TPC) $ $7,172,717 $7,172,717 $6,831,631 $6,831,631 $6,756,899Total Plan t Cost (TPC) w/ Prime Contractor' s M $ $7,387,898 $7,387,898 $7,036,579 $7,036,579 $6,959,606
Total Cash Expended (TCE ) $ $7,280,307 $7,280,307 $6,934,105 $6,934,105 $6,858,252
All ow. for F unds Dur ing Constr. (AFDC) $ $387,327 $387,327 $368,908 $368,908 $364,873
Total Plant I nvestment (TPI) $ $7,667,634 $7,667,634 $7,303,013 $7,303,013 $7,223,125
Preproduction Costs $ $153,353 $153,353 $146,060 $146,060 $144,462
Inventory Capital $ $0 $0 $0 $0 $0
Total Capital Requirement (TCR) $ $7,820,987 $7,820,987 $7,449,073 $7,449,073 $7,367,587
$/kW $347.6 $347.6 $331.1 $331.1 $327.4
O&M Data and Costs Case1 Case 2 Case 3 Case 4 Case 5
Cost Basis (Year) 2009 2009 2009 2009 2009
Power Required Excluding ID Fan(s) kW 42 42 38 38 37
ID Fan Power for FF Delta P kW 90 90 80 80 79
Total Power kW 132 132 118 118 116
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Power Cost ** $/yr $58,563 $81,065 $72,526 $72,255 $71,317
Maintenance Costs $/yr $224,147 $224,147 $213,488 $213,488 $211,153
Periodic Replacement Items $/yr $67,784 $67,784 $60,323 $60,323 $59,529
First Year Cost. Bags Replaced Every 5 Years 5 Years 5 Years 5 Years 5 Years
** These costs assume inputs are in current dollars (no escalation included).
ESP Case1 Case 2 Case 3 Case 4 Case 5
Fl ue Gas, Upstream of ESP
Temperature F 300 300 147 147 147
Pressure in. H2O -12 -12 -17 -17 -13
Flow Rate SCFM 58,015 58,015 63,810 63,810 63,627
Flow Rate ACFM 88,958 88,958 79,166 79,166 78,124
CO2 lb/hr 50,489 50,489 50,489 50,489 50,535
N2 lb/hr 184,042 184,042 184,042 184,042 183,960
SO2 lb/hr 301 301 229 229 151
O2 lb/hr 14,693 14,693 14,689 14,689 14,685
HCl lb/hr 28 28 0 0 0
Other Gases lb/hr 66 66 66 66 66
H2O lb/hr 17,793 17,793 34,317 34,317 33,854
Fly Ash lb/hr 1,808 1,808 3,356 3,356 3,006
Total (gas only) lb/hr 267,412 267,412 283,831 283,831 283,250
I nlet Particul ate Loading lb/hr 1,808 1,808 3,356 3,356 3,006
gr/ft3 2.37 2.37 4.95 4.95 4.49
Overall PM Collection Ef fi ciency % h 100.0% 100.0% 100.0% 100.0% 100.0%
ESP Requi rements
k dimensionless 0.451 0.451 0.451 0.451 0.451
E kV/cm 10.0 10.0 10.0 10.0 10.0
Ash Compositi on
Na2O wt% in Ash 2.80 2.80 2.80 2.80 2.80
Fe wt% in Ash 9 9 9.00 9.00 9.00
MgO wt% in Ash 20.90 20.90 20.90 20.90 20.90
CaO wt% in Ash 0.00 0.00 0.00 0.00 0.00
Fl ue Gas Composition
H2O Vol% 10.77 10.77 19.57 19.57 19.34
SO2 ppm 512 512 367 367 242
SO3 ppm 3.8 3.8 2.7 2.7 1.8
Fl ue Gas Temperature
TF F 300 300 147 147 147
TC C 149 149 64 64 64
TK Kelvin 422 422 337 337 337
Resistivity Calculati ons
Volume Resistivity
rv1 Log10(ohm-cm) 8.31 8.31 8.31 8.31 8.31rv2 Log10(ohm-cm) 8.07 8.07 8.07 8.07 8.07
iv Log10(ohm-cm) 1.14 1.14 1.14 1.14 1.14
rv Log10(ohm-cm) 11.41 11.41 14.00 14.00 14.00
rv(TK=1000/2.4) Log10(ohm-cm) 11.54 11.54 11.54 11.54 11.54
Volume Resistivity ohm-cm 2.5602E+11 2.5602E+11 9.9638E+13 9.9638E+13 9.9638E+13
Surface Resistivity
rs1 Log10(ohm-cm) 9.78 9.78 9.78 9.78 9.78
rs2 Log10(ohm-cm) 9.55 9.55 8.42 8.42 8.45
rs3 Log10(ohm-cm) 8.94 8.94 7.81 7.81 7.84
rs4 Log10(ohm-cm) 8.70 8.70 7.57 7.57 7.60
rs4(with E=12) Log10(ohm-cm) 8.64 8.64 7.51 7.51 7.54
rs0 Log10(ohm-cm) 10.01 10.01 10.00 10.00 10.00
rs Log10(ohm-cm) 9.20 9.20 4.17 4.17 4.24
Surface Resistivity ohm-cm 1.5767E+09 1.5767E+09 1.4717E+04 1.4717E+04 1.7216E+04
rvs1 ohm-cm 1.5670E+09 1.5670E+09 1.4717E+04 1.4717E+04 1.7216E+04
rs2(with H2O=10) Log10(ohm-cm) 9.65E+00 9.65E+00 9.65E+00 9.65E+00 9.65E+00
rs3(with H2O=10) Log10(ohm-cm) 9.04 9.04 9.04 9.04 9.04
rs4(with H2O = 10) Log10(ohm-cm) 8.80 8.80 8.80 8.80 8.80
rs4(with H2O = 10, E = 12) Log10(ohm-cm) 8.74 8.74 8.74 8.74 8.74
rs0(with H2O = 10) Log10(ohm-cm) 10.01 10.01 10.01 10.01 10.01
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rs(with H2O = 10, TK = 1000/2.4) Log10(ohm-cm) 9.20 9.20 9.20 9.20 9.20
rvs1(with H2O=10, TK = 1000/2.4) ohm-cm 1.5830E+09 1.5830E+09 1.5830E+09 1.5830E+09 1.5830E+09
rvs2 Log10(ohm-cm) 9.44 9.44 9.44 9.44 9.44
Acid Resistivity
ia1 Log10(ohm-cm) 0.29 0.29 0.29 0.29 0.29
ra1 Log10(ohm-cm) 7.53 7.53 7.53 7.53 7.53
sa -2.05 -2.05 -2.05 -2.05 -2.05
ia2 Log10(ohm-cm) 8.76 8.76 8.76 8.76 8.76
ra2 Log10(ohm-cm) 7.58 7.58 7.88 7.88 8.25
acid_v index value 2 2 1 1 1
atom_v index value 1 1 1 1 1
sa1 -28.39 -28.39 -4.74 -4.74 -4.74
ia3 Log10(ohm-cm) 75.72 75.72 19.25 19.25 19.62
ra3 Log10(ohm-cm) 8.45 8.45 5.19 5.19 5.56
ra Log10(ohm-cm) 8.37 8.37 5.89 5.89 6.17
Acid Resistivity ohm-cm 2.3400E+08 2.3400E+08 7.8246E+05 7.8246E+05 1.4960E+06
Total Resistivity
rvsa ohm-cm 2.0359E+08 2.0359E+08 1.4445E+04 1.4445E+04 1.7020E+04
Migration Velocity
w k 1000ft/minute 0.060 0.060 0.091 0.091 0.091
Specifi c Collection Area
SCA ft2/1000acfm 2155 2155 1633 1633 1601
Total Collector Plate Area ft2
191,669 191,669 129,297 129,297 125,105
ESP Footprint Area ft2
5,324 5,324 3,592 3,592 3,475
Capital Cost Case1 Case 2 Case 3 Case 4 Case 5
Cost Basis (Year) 2009 2009 2009 2009 2009
ESP $ $763,689 $763,689 $687,816 $687,816 $679,686
Ash Handling System $ $346,222 $346,222 $372,812 $372,812 $366,805
ID Fan(s) $ $176,894 $176,894 $164,575 $164,575 $163,230 Equipment Cost Subtotal $ $1,286,805 $1,286,805 $1,225,203 $1,225,203 $1,209,721
Instruments & Controls $ $25,736 $25,736 $24,504 $24,504 $24,194
Taxes $ $83,642 $83,642 $79,638 $79,638 $78,632
Freight $ $64,340 $64,340 $61,260 $61,260 $60,486
Purchased Equipment Cost Subtotal $ $1,460,524 $1,460,524 $1,390,606 $1,390,606 $1,373,033
Installation $ $1,183,024 $1,183,024 $1,126,391 $1,126,391 $1,112,157
Total Di rect Cost $ $2,643,548 $2,643,548 $2,516,996 $2,516,996 $2,485,190
Total Direct Cost with Retrofit Factor $ $4,229,677 $4,229,677 $4,027,194 $4,027,194 $3,976,303
General Facilities $ $422,968 $422,968 $402,719 $402,719 $397,630
Engineering Fees $ $422,968 $422,968 $402,719 $402,719 $397,630
Contingency $ $845,935 $845,935 $805,439 $805,439 $795,261
Total Plant Cost (TPC) $ $5,921,548 $5,921,548 $5,638,072 $5,638,072 $5,566,825
Total Plan t Cost (TPC) w/ Prime Contractor ' s M $ $6,099,194 $6,099,194 $5,807,214 $5,807,214 $5,733,829
Total Cash Expended (TCE) $ $6,010,371 $6,010,371 $5,722,643 $5,722,643 $5,650,327
All ow. for Funds Dur ing Constr. (AFDC) $ $319,764 $319,764 $304,456 $304,456 $300,609
Total Plant I nvestment (TPI) $ $6,330,135 $6,330,135 $6,027,099 $6,027,099 $5,950,936
Preproduction Costs $ $126,603 $126,603 $120,542 $120,542 $119,019
Inventory Capital $ $0 $0 $0 $0 $0
Total Capital Requirement (TCR) $ $6,456,737 $6,456,737 $6,147,641 $6,147,641 $6,069,954
$/kW $287.0 $287.0 $273.2 $273.2 $269.8
O&M Data and Costs Case1 Case 2 Case 3 Case 4 Case 5
Cost Basis (Year) 2009 2009 2009 2009 2009
Power Required Excluding ID Fan(s) kW -103 -103 -21 -21 -17 ID Fan Power for FF Delta P kW 45 45 40 40 39
Total Power kW -58 -58 19 19 22
Power Cost ** $/yr ($25,649) ($35,505) $11,709 $11,665 $13,515
Maintenance Costs $/yr $185,048 $185,048 $176,190 $176,190 $173,963
** These costs assume inputs are in current dollars (no escalation included).
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CUECost - Air Pollution Control Systems Economics Spreadsheet
FUEL AND COMBUSTION CALCULATIONS Case1 Case 2 Case 3 Case 4 Case 5
FUEL ANALYSIS FOR SPECIFI ED COALS
PROXIMATE ANALYSIS (wt. %)
Moisture wt% 25.2 25.2 25.2 25.2 25.2
Volatile Matter wt% 36.4 36.4 36.4 36.4 36.4
Fixed Carbon wt% 30.3 30.3 30.3 30.3 30.3
Ash wt% 8.15 8.15 8.15 8.15 8.36 TOTAL 100.05 100.05 100.05 100.05 100.26
COAL ULTIMATE ANALYSIS (wt. %)
Moisture wt% 25.2 25.2 25.2 25.2 25.2
Carbon wt% 51.52 51.52 51.52 51.52 51.52
Hydrogen wt% 3.29 3.29 3.29 3.29 3.29
Nitrogen wt% 0.69 0.69 0.69 0.69 0.69
Chlorine wt% 0.1 0.1 0.1 0.1 0.1
Sulfur wt% 0.56 0.56 0.56 0.56 0.35
Ash wt% 8.15 8.15 8.15 8.15 8.36
Oxygen wt% 10.49 10.49 10.49 10.49 10.49
TOTAL 100 100 100 100 100
HIGHER HEATING VALUE (HHV)
Modified Mott Spooner - calc Btu/lb 8789 8789 8789 8789 8781
COAL COST $/MMBtu 1.50 1.50 1.50 1.50 1.50COAL ASH ANALYSIS (ASTM, as rec'd)
SiO2 wt% 27.00 27.00 27.00 27.00 27.00
Al2O3 wt% 19.00 19.00 19.00 19.00 19.00
TiO2 wt% 1.08 1.08 1.08 1.08 1.08
Fe2O3 wt% 9.00 9.00 9.00 9.00 9.00
CaO wt% 18.50 18.50 18.50 18.50 18.50
MgO wt% 2.40 2.40 2.40 2.40 2.40
Na2O wt% 2.80 2.80 2.80 2.80 2.80
K2O wt% 0.45 0.45 0.45 0.45 0.45
P2O5 wt% 0.42 0.42 0.42 0.42 0.42
SO3 wt% 18.85 18.85 18.85 18.85 18.85
Other Unaccounted for wt% 0.50 0.50 0.50 0.50 0.50
TOTAL wt% 100.00 100.00 100.00 100.00 100.00
PROXIMATE ANALYSIS (lbs/MMBtu) Moisture lbs/MMBtu 28.67 28.67 28.67 28.67 28.70
Volatile Matter lbs/MMBtu 41.42 41.42 41.42 41.42 41.45
Fixed Carbon lbs/MMBtu 34.47 34.47 34.47 34.47 34.51
Ash lbs/MMBtu 9.27 9.27 9.27 9.27 9.52
TOTAL lbs/MMBtu 113.84 113.84 113.84 113.84 114.18
COAL ULTIMATE ANALYSIS (lbs/MMBtu)
Moisture lbs/MMBtu 28.67 28.67 28.67 28.67 28.70
Carbon lbs/MMBtu 58.62 58.62 58.62 58.62 58.67
Hydrogen lbs/MMBtu 3.74 3.74 3.74 3.74 3.75
Nitrogen lbs/MMBtu 0.79 0.79 0.79 0.79 0.79
Chlorine lbs/MMBtu 0.11 0.11 0.11 0.11 0.11
Sulfur lbs/MMBtu 0.64 0.64 0.64 0.64 0.40
Ash lbs/MMBtu 9.27 9.27 9.27 9.27 9.52
Oxygen lbs/MMBtu 11.94 11.94 11.94 11.94 11.95
TOTAL lbs/MMBtu 113.78 113.78 113.78 113.78 113.88
COAL ULTIMATE ANALYSIS (lbmoles/MMBtu)
Moisture lbmoles/MMBtu 1.5915 1.5915 1.5915 1.5915 1.5930
Carbon lbmoles/MMBtu 4.8804 4.8804 4.8804 4.8804 4.8848
Hydrogen lbmoles/MMBtu 1.8569 1.8569 1.8569 1.8569 1.8586
Nitrogen lbmoles/MMBtu 0.0280 0.0280 0.0280 0.0280 0.0280
Chlorine lbmoles/MMBtu 0.0016 0.0016 0.0016 0.0016 0.0016
Sulfur lbmoles/MMBtu 0.0199 0.0199 0.0199 0.0199 0.0124
Ash lbmoles/MMBtu 9.2730 9.2730 9.2730 9.2730 9.5206
Oxygen lbmoles/MMBtu 0.3730 0.3730 0.3730 0.3730 0.3733
F lue Gas, Downstream Of Economizer
Flue Gas (lb-moles/MMBtu)
CO2 lbmoles/MMBtu 4.856 4.856 4.856 4.856 4.860
NOx lbmoles/MMBtu 0.009 0.009 0.009 0.009 0.009 HCl lbmoles/MMBtu 0.003 0.003 0.003 0.003 0.003
SO2 lbmoles/MMBtu 0.020 0.020 0.020 0.020 0.012
Total O2 Req'd - * lbmoles/MMBtu 6.529 6.529 6.529 6.529 6.526
N2 lbmoles/MMBtu 24.584 24.584 24.584 24.584 24.572
O2 lbmoles/MMBtu 1.088 1.088 1.088 1.088 1.088
H20 lbmoles/MMBtu 4.096 4.096 4.096 4.096 4.099
Total Dry lbmoles/MMBtu 30.560 30.560 30.560 30.560 30.545
Total Wet lbmoles/MMBtu 34.656 34.656 34.656 34.656 34.644
Wet Flue Gas PPMV & % Vol
% O2 % Vol 3.140 3.140 3.140 3.140 3.139
% CO2 % Vol 14.012 14.012 14.012 14.012 14.030
% N2 % Vol 70.936 70.936 70.936 70.936 70.928
NOx ppmv 268.765 268.765 268.765 268.765 268.903
HCL ppmv 92.604 92.604 92.604 92.604 92.721 SO2 ppmv 573.395 573.395 573.395 573.395 358.822
% H2O % Vol 11.818 11.818 11.818 11.818 11.831
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CUECost - Air Pollution Control Systems Economics Spreadsheet
Dry Flue Gas PPMV & % Vol
% O2 % Vol 3.561 3.561 3.561 3.561 3.561
% CO2 % Vol 15.890 15.890 15.890 15.890 15.912
% N2 % Vol 80.444 80.444 80.444 80.444 80.446
NOx ppmv 304.786 304.786 304.786 304.786 304.985
HCL ppmv 105.015 105.015 105.015 105.015 105.162
SO2 ppmv 650.243 650.243 650.243 650.243 406.969
% H2O % Vol 0 0 0 0 0
F lue Gas, Air & Ash Downstream Of Economizer
Flue Gas (lbs/MMBtu) O2 lbs/MMBtu 34.818 34.818 34.818 34.818 34.802
CO2 lbs/MMBtu 213.711 213.711 213.711 213.711 213.905
N2 lbs/MMBtu 688.834 688.834 688.834 688.834 688.517
NOx lbs/MMBtu 0.280 0.280 0.280 0.280 0.280
HCl lbs/MMBtu 0.117 0.117 0.117 0.117 0.117
SO2 lbs/MMBtu 1.273 1.273 1.273 1.273 0.796
H2O lbs/MMBtu 73.786 73.786 73.786 73.786 73.838
Gas Dry lbs/MMBtu 939.033 939.033 939.033 939.033 938.418
Gas Wet lbs/MMBtu 1012.819 1012.819 1012.819 1012.819 1012.256
% H2O wt% 7.285 7.285 7.285 7.285 7.294
Theoretical Wet Air lbs/MMBtu 757.293 757.293 757.293 757.293 756.944
Actual Total Wet Air lbs/MMBtu 908.752 908.752 908.752 908.752 908.333
Mol Wt Wet, Lb/Lb-Mol lbs/lb-mole 29.225 29.225 29.225 29.225 29.219
Total Ash lbs/MMBtu 9.566 9.566 9.566 9.566 9.814 Fly Ash lbs/MMBtu 7.653 7.653 7.653 7.653 7.851
Bottom Ash lbs/MMBtu 1.913 1.913 1.913 1.913 1.963
NOx - Flue Gas lbs/MMBtu 0.280 0.280 0.280 0.280 0.280
Carbon Loss lbmoles/MMBtu 0.024 0.024 0.024 0.024 0.024
* - Theoretical + Excess O2 Required for Combustion, Not O2 in Flue Gas
Gases, Downstream Of Ai r H eater
Flue Gas (lb-moles/MMBtu)
CO2 lbmoles/MMBtu 4.856 4.856 4.856 4.856 4.860
NOx lbmoles/MMBtu 0.009 0.009 0.009 0.009 0.009
HCl lbmoles/MMBtu 0.003 0.003 0.003 0.003 0.003
SO2 lbmoles/MMBtu 0.020 0.020 0.020 0.020 0.012
N2 lbmoles/MMBtu 27.802 27.802 27.802 27.802 27.790
O2 lbmoles/MMBtu 1.944 1.944 1.944 1.944 1.943
H2O lbmoles/MMBtu 4.181 4.181 4.181 4.181 4.183
Total Dry Flue Gas lbmoles/MMBtu 34.634 34.634 34.634 34.634 34.618
Total Wet Flue Gas lbmoles/MMBtu 38.815 38.815 38.815 38.815 38.801
Dry Air Addition lbmoles/MMBtu 4.074 4.074 4.074 4.074 4.072
Wet Air Addition lbmoles/MMBtu 4.159 4.159 4.159 4.159 4.157
Wet Flue Gas PPMV & % Vol
% O2 % Vol 5.01 5.01 5.01 5.01 5.01
% CO2 % Vol 12.51 12.51 12.51 12.51 12.53
% N2 % Vol 71.63 71.63 71.63 71.63 71.62
PPMV NOx ppmv 239.97 239.97 239.97 239.97 240.09
PPMV HCL ppmv 82.68 82.68 82.68 82.68 82.79
PPMV SO2 ppmv 511.96 511.96 511.96 511.96 320.38
% H2O % Vol 10.77 10.77 10.77 10.77 10.78
TOTAL 100.00 100.00 100.00 100.00 100.00
Dry Flue Gas PPMV & % Vol
% O2 % Vol 5.61 5.61 5.61 5.61 5.61
% CO2 % Vol 14.02 14.02 14.02 14.02 14.04
% N2 % Vol 80.27 80.27 80.27 80.27 80.28
NOx ppmv 268.93 268.93 268.93 268.93 269.11
HCL ppmv 92.66 92.66 92.66 92.66 92.79
SO2 ppmv 573.76 573.76 573.76 573.76 359.09
% H2O % Vol 0 0 0 0 0
TOTAL 100.00 100.00 100.00 100.00 100.00
F lue Gas & Air Downstream Of Ai r H eater
Flue Gas (lbs/MMBtu)
O2 lbs/MMBtu 62.194 62.194 62.194 62.194 62.168
CO2 lbs/MMBtu 213.711 213.711 213.711 213.711 213.905 N2 lbs/MMBtu 779.013 779.013 779.013 779.013 778.665
NOx lbs/MMBtu 0.280 0.280 0.280 0.280 0.280
HCl lbs/MMBtu 0.117 0.117 0.117 0.117 0.117
SO2 lbs/MMBtu 1.273 1.273 1.273 1.273 0.796
H2O lbs/MMBtu 75.314 75.314 75.314 75.314 75.365
Gas Dry lbs/MMBtu 1056.587 1056.587 1056.587 1056.587 1055.931
Gas Wet lbs/MMBtu 1131.901 1131.901 1131.901 1131.901 1131.297
Wt % H2O wt% 6.654 6.654 6.654 6.654 6.662
Total Wet Air lbs/MMBtu 1027.834 1027.834 1027.834 1027.834 1027.374
Mol Wt Wet, Lb/Lb-Mol lbs/lb-mole 29.162 29.162 29.162 29.162 29.156
Boi ler Losses & Ef fi ciencies
Dry Gas % 6.295 6.295 6.295 6.295 6.292
Moisture % 7.172 7.172 7.172 7.172 7.178
Carbon % 0.413 0.413 0.413 0.413 0.414 Radiation % 0.352 0.352 0.352 0.352 0.352
Manufacturers Margin % 1.5 1.5 1.5 1.5 1.5
Ash Losses % 0 0 0 0 0
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Total Losses % 15.732 15.732 15.732 15.732 15.736
Boiler Efficiency % 84.268 84.268 84.268 84.268 84.264
Coal F low Rates
Btu Input Rate to Boiler MMBtu/hr 236.25 236.25 236.25 236.25 236.25
Coal Input Rate to Boiler tons/hr 13.4 13.4 13.4 13.4 13.5
Coal Input Rate to Boiler lbs/MMBtu 113.8 113.8 113.8 113.8 113.9
Economizer Outlet
Flue Gas SCFM/MMBtu 13,156 13,156 13,156 13,156 13,152 Flue Gas SCFM 51,803 51,803 51,803 51,803 51,785
Wet Flue Gas lb/hr 239,278 239,278 239,278 239,278 239,145
Wet Air SCFM 47,076 47,076 47,076 47,076 47,054
Wet Air lb/hr 214,693 214,693 214,693 214,693 214,594
Total Air % 120% 120% 120% 120% 120%
Excess Air % 20% 20% 20% 20% 20%
Air Heater Outlet
Flue Gas SCFM/MMBtu 14,735 14,735 14,735 14,735 14,730
Flue Gas SCFM 58,020 58,020 58,020 58,020 58,000
Wet Flue Gas lb/hr 267,412 267,412 267,412 267,412 267,269
Wet Air SCFM 53,245 53,245 53,245 53,245 53,221
Wet Air lb/hr 242,826 242,826 242,826 242,826 242,717
Wet Air Leakage SCFM 6,169 6,169 6,169 6,169 6,167
Wet Air Leakage lb/hr 28,133 28,133 28,133 28,133 28,123 Equivalent Total Air % 135.7% 135.7% 135.7% 135.7% 135.7%
Equivalent Excess Air % 35.7% 35.7% 35.7% 35.7% 35.7%
Flue Gas Temperature F 300 300 300 300 300
Pressure in. H2O -12 -12 -12 -12 -12
Flue Gas ACFM 88,965 88,965 88,965 88,965 88,934
Ash Parameters
Fly Ash tons/hr 0.90 0.90 0.90 0.90 0.93
Bottom Ash tons/hr 0.23 0.23 0.23 0.23 0.23
Total Ash tons/hr 1.13 1.13 1.13 1.13 1.16