EPA
TVA
United States
Environmental Protection
Agency
Industrial Environmental Research EPA-600/8-81-00£
Laboratory            MARCH 1981
Research Triangle Park, NC 27711
Tennessee Valley
Authority
Office of Power
Division of Energy
Demonstrations
and Technology
TVA/OP/EDT-81/15
         Computerized  Shawnee

         Lime/Limestone  Scrubbing

         Model Users Manual


         Interagency
         Energy/Environment

         R&D Program Report

-------
                 RESEARCH REPORTING SERIES


Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories  were established to facilitate  further  development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:

     1.  Environmental Health Effects Research

     2.  Environmental Protection Technology

     3.  Ecological Research

     4.  Environmental Monitoring

     5.  Socioeconomic  Environmental Studies

     6.  Scientific and Technical Assessment Reports (STAR)

     7.  Interagency Energy-Environment Research and Development

     8.  "Special" Reports

     9.  Miscellaneous Reports

This report has been assigned to the SPECIAL  REPORTS series. This series is
reserved for reports which are intended to meet  the technical  information needs
of specifically targeted user groups. Reports in this series include Problem Orient-
ed Reports, Research Application Reports, and Executive Summary Documents.
Typical of these reports include state-of-the-art analyses, technology assess-
ments, reports on the results of major research and development efforts, design
manuals, and user manuals.



                        EPA REVIEW NOTICE

This report has been reviewed by the U.S. Environmental Protection Agency, and
approved for publication. Approval does not signify that the contents necessarily
reflect the views and policy of the Agency, nor does mention of trade names or
commercial products constitute endorsement or  recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.

-------
                         EPA-600/8-81-008
                         TVA/OP/EDT-81/15
                               MARCH 1981
  Computerized  Shawnee
Lime/Limestone Scrubbing
    Model Users Manual
                  by

         W. L. Anders and R. L. Torstrick

             TVA, Office of Power
         Division of Energy Demonstrations
              and Technology
         Muscle Shoals, Alabama 35660
            EPA-IAG-79-D-X05 1 1

       EPA Project Officer: Michael A. Maxwell
     Industrial Environmental Research Laboratory
   Office of Environmental Engineering and Technology
        Research Triangle Park, NC 27711
               Prepared for

      U.S. ENVIRONMENTAL PROTECTION AGENCY
        Office of Research and Development
            Washington, DC 20460

-------
                                DISCLAIMER
     The Tennessee Valley Authority makes no representation or warranty of
any kind, including, but not limited to,  representation or warranties,
expressed or implied, or merchantability, fitness for use or purpose,
accuracy or completeness of processes,  procedures,  designs, definitions,
instructions, information, or functioning of this model and related
material; nor does TVA assume any liability, responsibility, or obliga-
tion arising from the use of the model  or related materials.
                                     11

-------
                                 ABSTRACT
     This manual provides a general description of the Shawnee lime-
limestone scrubbing computerized design - cost-estimate model and the
detailed procedures for using it.  It is a revision of an earlier manual
(1979).  All inputs and outputs are described along with the options
available.  Design and economic premises are included.  The model is
based on Shawnee Test Facility scrubbing data and includes a combination
of material balance subsystems provided to the Tennessee Valley Authority
(TVA) by Bechtel National, Inc., and capital investment - revenue require-
ment subsystems developed by TVA.  As key features, the model provides
estimates of capital investment and operating revenue requirements for a
lime or limestone scrubbing facility.  Also provided are a material
balance, equipment list, and a breakdown of costs by processing areas.
The primary uses of the model should be for projecting comparative
economics of lime or limestone flue gas desulfurization processes (on
the same basis as the model) or in the evaluation of system alternatives
prior to the development of a detailed design.
                                     iii

-------
                                  CONTENTS
Abstract	iii
Figures	vii
Tables	viii

Introduction 	    1

General Information  	    3
  Current Scope  	    3
  Future Development 	    3
  Availability 	    4

Model Description  	    5
  Input	    5
  Output 	    5
  Options  	    7
    Print Options	    8
    Particulate Collection Device Option 	    8
    Reheat Option  	   12
    Emergency Bypass Option  	   12
    Partial Scrubbing/Bypass Option  	   14
    Coal-Cleaning Option 	   14
    Input Composition Option 	   17
    Particulate Removal Option 	   19
    S02 Removal Option	   21
    Operating Parameter Calculation Option 	   23
    Scrubbing Absorbent Option (Lime or Limestone) 	   25
    Chemical Additive Option 	   25
    Forced-Oxidation Option  	   31
    Fan Option	   31
    Scrubbing Option 	   34
    Redundancy Options 	   34
    Waste Disposal Option	   36
    Pond Design Option	   43
    Pond Liner Option	   45
    Economic Premises Option 	   45
    Sales Tax and Freight Option	   48
    Overtime Option  	   54
    Separate Pond Construction Indirect Investment Factors Option  . .   54
    Pond Capacity Option	   55
    Operating Profile Option 	   55
                                      v

-------
Usage of the Model	   62




References	   66




Appendix A:  Process Flowsheets and Layouts  	  A-l




Appendix B:  Design and Economic Premises  	  B-1




Appendix C:  Detailed Descriptions of Model Input Variables  	  C-l




Appendix D:  Base Case Input and Printout	D-l
                                      VI

-------
                                   FIGURES


Number                                                                  Page

   1    Controlled SC>2 emission requirements for 1979 NSPS.  Premise
        coals, shown underlined, are based on premise boiler
        conditions	    22
   2    Pond construction configuration  	    44
   3    Operating profile assumed for IOPSCH = 1 based on old TVA
        premises	    58
   4    Operating profile assumed for IOPSCH = 2 based on historical
        Federal Energy Regulatory Commission data  	    58
A- 1    Limestone scrubbing process utilizing TCA absorber 	  A- 2
A- 2    Limestone scrubbing process utilizing a spray tower  	  A- 3
A- 3    Limestone scrubbing process utilizing a venturi - spray
        tower	A- 4
A- 4    Lime handling and preparation area for lime scrubbing option  .  A- 5
A- 5    Plan and elevation for TCA	A- 6
A- 6    Plan and elevation for spray tower	A- 7
A- 7    Plan and elevation for venturi - spray tower	A- 8
A- 8    Waste disposal options 1 and 2	A- 9
A- 9    Waste disposal options 3 and 4	A-10
A-10    Single tank oxidation loop	A-ll
A-ll    Double tank oxidation loop	A-12
A-12    Plan and elevation for TCA utilizing forced-draft fans ....  A-13
A-13    Plan and elevation for partial scrubbing with bypass duct  .  .  A-14
B- 1    Rosin-Rammler plots of premise coal sizes  	  B- 8
B- 2    Boiler flow diagram	B-28
B- 3    Controlled S02 emission requirements for 1979 NSPS.  Premise
        coals, shown underlined, are based on premise boiler
        conditions	B-26
B- 4    Pond plan and dike construction details	B-35
B- 5    Landfill plan and construction details	B-36
B- 6    Construction schedule	B-37
B- 7    Process area cost summary sheet	B-42
B- 8    Area summary sheet	B-42
                                     Vll

-------
                                  TABLES

Number                                                                 Page

   1    Variable Ranges 	     6
   2    Example Short Form Printout 	     9
   3    Mechanical Collector Cost Illustration  	    13
   4    Example Results Showing Partial Scrubbing/Bypass  	    15
   5    Example Results Showing Coal Cleaning 	    18
   6    Example Results Showing User Input Flue Gas Composition ...    20
   7    Lime Scrubbing Output Listing 	    26
   8    Lime Option Inputs and Raw Material Preparation Area  ....    27
   9    Example Results Showing the Addition of Adipic Acid 	    29
  10    Example Results Showing Forced Oxidation, Two Effluent Tanks     32
  11    Example Results Showing Forced Oxidation, One Effluent Tank      33
  12    Venturi - Spray Tower Absorber Cost Illustration  	    35
  13    Example Results Showing No Redundancy 	    37
  14    Example Equipment List for Sludge Option 2	    38
  15    Example Equipment List for Sludge Option 3	    39
  16    Example Equipment List for Sludge Option 4	    40
  17    Example Revenue Requirements for Sludge Fixation
        Alternative (Sludge Option 3) 	    42
  18    Example of Optimum Pond Subject to Area Limits	    46
  19    Synthetic Pond Liner Example  	    47
  20    Example Revenue Requirements Using the New Economic
        Premises With No Levelizing	    49
  21    Example Revenue Requirements Using the Old Economic Premises     51
  22    Example Investment Summary Sheet With Sales Tax and
        Freight Excluded  	    53
  23    Example Investment Summary Sheet With Common Indirect
        Investment Factors for Process and Pond	    56
  24    Example Lifetime Revenue Requirements Using the Old TVA
        Premises Operating Profile  	    59
  25    Example Lifetime Revenue Requirements Using the Historical
        FERC/FPC Operating Profile  	    60
  26    Example Lifetime Revenue Requirements Using A User-
        Supplied Operating Profile  	    61
  27    Example Procedure for Executing the Model in Batch Mode ...    64
  28    Example Batch Run to Execute the Model Using a Procedure
        File	    64
  29    Sample Procedure for Executing the Model Interactively  ...    65
B- 1    Composition of Premise Coals	B- 7
B- 2    Fly Ash Compositions	B- 6
B- 3    Power Unit Remaining Life, Operating Time, and Heat Rate  .  .  B-10
B- 4    Boiler Material Balance - Eastern Bituminous Coal, 5% Sulfur   B-ll
B- 5    Flue Gas Composition for 5% Sulfur Eastern Bituminous Coal   .  B-12

                                    viii

-------
                             TABLES  (continued)
Number
B- 6    Boiler Material Balance - Eastern Bituminous Coal,
        3.5% Sulfur	B-13
B- 7    Flue Gas Composition for 3.5% Sulfur Eastern Bituminous Coal    B-14
B- 8    Boiler Material Balance - Eastern Bituminous Coal,
        2.0% Sulfur	B-15
B- 9    Flue Gas Composition for 2% Sulfur Eastern Bituminous Coal   .   B-16
B-10    Boiler Material Balance - Eastern Bituminous Coal,
        0.7% Sulfur	B-17
B-ll    Flue Gas Composition for 0.7% Sulfur Eastern Bituminous Coal    B-18
B-12    Boiler Material Balance - Western Bituminous Coal,
        0.7% Sulfur	B-19
B-13    Flue Gas Composition for 0.7% Sulfur Western Bituminous Coal    B-20
B-14    Boiler Material Balance - Western Subbituminous Coal,
        0.7% Sulfur	B-21
B-15    Flue Gas Composition for 0.7% Sulfur Western Subbituminous
        Coal	B-22
B-16    Boiler Material Balance - North Dakota Lignite, 0.9% Sulfur     B-23
B-17    Flue Gas Composition for 0.9% Sulfur North Dakota Lignite .  .   B-24
B-18    1979 Revised NSPS Emission Standards	B-25
B-19    Premise Coal Emission Standards 	   B-27
B-20    Reheater Data	B-32
B-21    Sample Reheater Calculations  	   B-31
B-22    Raw Material Characteristics  	   B-33
B-23    Cost Indexes and Projections	B-37
B-24    Cost Factors	B-38
B-25    Capital Cost Estimate Classification  	   B-40
B-26    Capital Investment Sheet  	   B-41
B-27    Range of Indirect Investments 	   B-44
B-28    Contingency	B-45
B-29    Allowance for Startup and Modifications 	   B-45
B-30    Interest During Construction Illustration 	   B-46
B-31    Annual Revenue Requirements Sheet 	   B-50
B-32    Sample Electrical Requirement Calculation 	   B-52
B-33    Maintenance Factors 	   B-53
B-34    Maintenance Factors for Specific FGD Processes  	   B-53
B-35    Levelized Annual Capital Charges  	   B-54
B-36    Levelizing Factors  	   B-58
C- 1    Model Inputs - Fortran Variable Names 	   C- 2
C- 2    Model Input Variable Definitions  	   C- 3
C- 3    Limestone Fineness of Grind Index Factor  .  	   C-17
D- 1    Base Case Printout	D- 2
                                      ix

-------
            COMPUTERIZED SHAWNEE LIME/LIMESTONE SCRUBBING MODEL

                               USERS MANUAL



                               INTRODUCTION
     Since 1968 the U.S. Environmental Protection Agency (EPA) has
sponsored a flue gas desulfurization (FGD) test facility at the Tennessee
Valley Authority (TVA) coal-fired Shawnee Steam Plant near Paducah, Kentucky.
TVA is the constructor and operator and Bechtel National, Inc., is the
major contractor.  The test facility originally consisted of three
prototype-size scrubber units, each capable of processing about 30,000
aft-Vmin (10 MW equivalent) of flue gas.  One unit, a marble-bed absorber,
was shut down in 1973 and converted to a cocurrent absorber in 1978.
The other two units, a mobile-bed absorber (Turbulent Contact Absorber,
or TCA) and a venturi - spray tower, have been operated under a variety
of conditions since 1972.

     A computer model capable of projecting comparative capital investment,
and annual and lifetime revenue requirements for lime and limestone FGD
scrubbing systems based on the Shawnee results has been under development
since the mid-1970's.  Only informal documentation for the model was
available until 1979 when a formal  users  manual was published (Stephenson
and Torstrick, 1979).  Since that time the model has been expanded to
include spray tower and venturi - spray tower absorbers; forced-oxidation
systems; systems with absorber loop additives (MgO and adipic acid) ;
revised design and economic premises; and many other miscellaneous
changes reflecting process improvements and variations.

     The primary purpose of the model is not to calculate the economics
of an individual system to a high degree of accuracy, but to provide
sufficient detail to allow projections of preliminary conceptual design
and costs for various lime or limestone scrubbing case variations.  The
model permits the estimation of the relative economics of these systems
for variations in process design alternatives such as limestone versus
lime scrubbing, TCA versus spray tower, use of chemical additives such
as MgO or adipic acid, or alternative waste disposal methods such as
onsite ponding versus forced oxidation-landfill.  The effect of variations
in the values of independent design criteria such as absorber gas velocity,
liquid-to-gas (L/G) ratio, alkali stoichiometry, slurry residence time,
and reheat temperature, may also be assessed.

-------
     Initial development of the Shawnee computer economics model began
in 1974, with the responsibility shared by Bachtel and TVA.   Bechtel's
major responsibility has been to develop models for calculating the
overall material balance flow rates and stream compositions.   TVA has
been responsible for determining the sizes of the required equipment,
accumulating cost data for the major equipment items, and developing
both a subsystem for calculating equipment costs and a subsystem for
projecting capital investment costs.  TVA has also developed procedures
to use the output of these models in a separate TVA subsystem that
projects annual and lifetime revenue requirements.

     The combined models should be useful to utility companies as well
as architectural and engineering contractors who are involved in the
selection and design of FGD facilities.  It is intended to assist in the
evaluation of system alternatives leading to the development of a detailed
design rather than to project a final detailed design.  It should also
be useful for evaluating the potential effects of various process variables
on economics as a guide for planning research and development activities.
Although the model has not been validated as a method for comparing
projected lime or limestone scrubbing economics with the economics of
alternate processes, these comparisons should be valid if the assumptions
for the alternate systems are equivalent to the model assumptions for
lime or limestone systems.

     The model has already been used for several applications other than
those for which it was specifically developed.  These include simulated
industrial boiler applications, smelter off-gas desulfurization applica-
tions, and plant fuel optimization studies.

     This revision of the users manual provides the updated information
and procedures necessary to use the Shawnee lime and limestone computer
model.  It does not provide the concepts and background information
basic to the model development.  Presentations related to the model have
been given at EPA industry briefings (Torstrick, 1976; and Stephenson
and Torstrick, 1978, 1979) and FGD symposiums  (Torstrick et al., 1978;
and McGlamery et al., 1980).  The publications associated with these
presentations discuss the model in general, describe the process and
program options, and show sample results.  Copies of these publications
should be used in conjunction with the manual.  Process flowsheets and
diagrams are included in Appendix A to provide the user with the equip-
ment layouts.  Design and economic premises in effect since December 1979
(and expanded and amplified in March 1980), which serve as guidelines for
computer input, are described in Appendix B.  These premises are used
for TVA economic studies and contain specifications beyond the scope of
the model.

-------
                           GENERAL INFORMATION
CURRENT SCOPE

     The present model projects a complete conceptual design package for
either a lime or limestone scrubbing system.   It is designed for a wide
range of options that are applicable to new coal-fired power units.
Currently six scrubbing options (each with either lime or limestone) and
four separate waste disposal options are provided.   Several other options
are provided to allow different combinations  of process variations and
improvements such as MgO or adipic acid addition or forced oxidation-
ponding.  Equipment size and layout configurations  are based on units
that range in size from 100 to 1300 MW and for coal sulfur contents that
range from 2% to 5%.  Because extreme variations in equipment sizes and
layout configurations can result from factors other than unit size and
coal sulfur content, ranges for some of these variables have been defined
as follows:

            Absorber gas velocity (TCA)          8-12.5 ft/sec
            Liquor recirculation rate            25-100 gal/kft^
            Slurry residence time in hold tank   2-25 minutes
            Number of scrubbing trains           1-10
            S02 concentration                    1500-4000 ppm

     The validity of results for operating conditions outside the ranges
shown above has not been determined.  However, results for intermediate-
sized plants operating outside these boundaries may still be valid.

     Several model runs may be required to fully analyze the combined
effects of individual input factors, especially if  the specified ranges
are exceeded.  The effect of variations in inputs (such as absorber gas
velocity, degree of S02 removal, reheat temperature, alkali stoichiometry,
or L/G ratio) can be assessed individually by varying one factor per
model run, or the cumulative effect can be determined by varying several
factors simultaneously.
FUTURE DEVELOPMENT

     Further modifications to the model are expected to be made as test
data from Shawnee become available.  Options which are currently being
considered are:  (1) landfill of treated waste, including gypsum; (2) an
expanded pond model to allow input options and variables for dike width,
dike roads, diverter dikes, and pond layout; (3) multiple boiler

-------
applications with common feed preparation and waste disposal facilities;
(4) cocurrent scrubbing; (5) dry particulate removal costs included with
FGD capital investment and revenue requirements; (6) alternate reheating
methods such as hot air injection, flue gas recycling, and regenerative
reheat systems; (7) retrofit difficulty factors for projecting costs for
existing units; and (8) expansion of the model to validate projections for
S02 concentrations less than 1500 ppm.  If future additions are made,
revisions will be made to the users manual to reflect the changes.
AVAILABILITY

     The model is available to the public through TVA under an information
exchange agreement between EPA and TVA.  Upon receipt of a written
request, TVA provides a copy of the model suitable for loading onto an
IBM 370 compatible computer system, along with FORTRAN program listings
and the documentation required to execute the model.   Under the same
information exchange agreement, capabilities are provided for TVA to
make model runs based on user-supplied input data.  This allows users to
analyze model capabilities with a minimum amount of investigation and
investment.

     TVA has also loaded the Shawnee Computer Model on the Control Data
Corporation (CDC) CYBERNET system which is a nationwide, commercial data
processing network.  The program can be made available on this system
after the appropriate authorization for use is cleared by TVA and billing
arrangements have been made between the user and CDC.  Updated versions
of the program will be maintained on this system and made available
based on user interest.

     Model options and input variables are added and modified on a
regular basis as the scrubbing facility test results become available.
The latest version is usually supplied to users and is typically the
basis for user runs made by TVA.  Model and documentation availability
are subject to limitations based on available funding and the costs that
must be incurred in connection with a user request.  Requests for copies
of the computer model, model runs to be made by TVA,  or additional
information should be made to the authors at the following address:
Energy Design and Operations, Tennessee Valley Authority, Muscle Shoals,
Alabama  35660, telephone number (205) 386-2814 or (205) 386-2514.

-------
                            MODEL DESCRIPTION
INPUT

     The overall model requires a minimum of 15 lines of input.  Addi-
tional input is required when a user-specified operating profile is
chosen instead of the built-in profiles.  A detailed FORTRAN variable
list of the model input is shown in Table C-l of Appendix C.  The variables
are defined in Table C-2 of Appendix C.  Ranges for key variables to aid
in establishing input data to the model are shown in Table 1.

     As new options are incorporated, the required inputs are subject to
change.  When this occurs, the list of variables and the associated
definitions will be updated and made available as necessary.
OUTPUT

     The outputs of the Shawnee lime-limestone computer model provide a
complete conceptual design package for lime or limestone scrubbing,
consisting of:  (1) a detailed material balance including properties of
the major streams; (2) a detailed water balance itemizing water availa-
bility and water required; (3) specifications of the scrubbing system
design; (4) a display of overall pond design and costs; (5) specifications
and costs of the process equipment by major processing area; (6) a
detailed breakdown of the projected capital investment; (7) an itemized
breakdown of the projected levelized revenue requirements by component;
(8) an optional itemized breakdown of the revenue requirements for the
first year of operation of the system; (9) an optional lifetime revenue
requirement analysis showing projected costs for each year of operation
of the plant as well as lifetime cumulative and discounted costs and
equivalent unit revenue requirements; and (10) a particulate removal
cost table which lists operating conditions and itemizes capital invest-
ment and revenue requirements costs for a cold-side electrostatic
precipitator (ESP), a hot-side ESP, a baghouse, and a wet scrubber.
However, upstream particulate removal is independent of the FGD process
and costs are not included in the FGD economic projections.  These
outputs are illustrated in the base case printout shown in Appendix D
(p. D-17).

     In addition to the outputs listed above, a diagnostic message file
is generated each time the model is executed.  This file contains informa-
tive messages related to processing such as data case number and title,
possible conflicts between options, variable values that may be out of

-------
                 TABLE 1.  VARIABLE RANGES
              Item
       Description
Power plant
Fuel sulfur content
Absorber gas velocity
Liquor recirculation rate
Effluent hold tank residence
 time
Number of scrubbing trains
Number of spare scrubbing
 trains
Sulfur to overhead as SC>2 gas
Ash to overhead as fly ash
System pressure drop (TCA
 only)
Investment year

Revenue requirement year
New, 100-1300 MW
2-5%
8-12.5 ft/sec
25-100 gal/kft3
2-25 minutes

1-10
0-10

0-100%
0-100%
Should not exceed 3 inches
 per stage
Midpoint of project
 expenditure schedule
First year of operation of
 plant
Note:  The variable ranges were established for model
development purposes.  Values beyond these ranges are not
necessarily invalid but the potential for error is greater
when these ranges are exceeded.

-------
range, and fatal conditions that terminate model execution.   In typical
model runs made by TVA the message file is listed between the printed
output from the investment program and the printed output from the
revenue programs, but this depends on the control language procedures
used for execution.  An example message file is shown in the base case
printout in Appendix D (p. D-23).
OPTIONS

     A detailed list of all of the model inputs is included in Tables C-l
and C-2 of Appendix C.   These tables include a number of options for
selecting process design and controlling model output.   Types of options
are listed below:

  •  Print

  •  Particulate collection device Reheat

  •  Reheat

  •  Bypass and partial scrubbing

  •  Coal-cleaning and input composition

  •  Particulate removal

  •  S02 removal

  •  Operating parameter calculation

  •  Scrubbing absorbent (lime or limestone)

  •  Chemical additive and forced-oxidation

  •  Fan and absorber

  •  Redundancy

  •  Waste disposal

  •  Pond design

  •  Pond liner

  •  Economics

  •  Pond capacity

  •  Operating profile

-------
Some examples of the various options are shown on the pages  that follow.
For illustration purposes the appropriate input data line is shown and
the particular option code is indicated.  An explanation of  each option
and sample output resulting from its usage is provided where necessary.
Values for all variables must be entered for each case even  though a
variable value is being calculated by the model as a result  of a user-
specified option.  When this condition occurs, the calculated value will
override the input value.  A value of zero will be appropriate for many
variables but the value cannot be omitted.  Spaces cannot be used to
take the place of variables which have a value equal to zero.

     Some user-specified input values result in the use of default
values of other variables for consistency in the calculations.  For the
options that allow defaults, the option code that must be input and the
default values that are assumed are described.  All model output listings
used to illustrate individual options are derived from the base case
data shown in Appendix D.  Only the variables related to options being
illustrated are changed from the base case unless otherwise  noted.
Print Options
Line No
1
2
3
Input data
1
1
1
111
111
1 1
1
11111111

     The options on the first three lines of the input data control
printed output from the model.   These options are described in the input
definition list in Appendix C,  Table C-2.  The only print option requiring
further explanation is the first option on line 3.   This option controls
the printout of the capital investment and revenue requirement sections.
The short form printout is shown in Table 2 and may be compared with the
long printout of the base case  example in Appendix D.

Particulate Collection Device Option

   Line No .  	Input data	

      5      2 500 9500 11700 39 300 2 1 0 0 0 0 0 0 175 470 751
             *
            XESP

     The particulate collection device option is controlled by the XESP
variable.  The value of XESP may be 0, 1, or 2.  A zero value is used if
no particular removal device is to be considered.  A value of 1 is used
if a mechanical collector (33%  efficient) is selected, and the code for
upstream removal (line 6, ASHUPS, see Table C-2) should have an input
value of 33 (% removal).   If an XESP value of 2 is selected, a separate
particulate removal cost model  (Argonne, 1979) projects the capital

                                      8

-------
                             TABLE 2.    EXAMPLE  SHORT FORM PRINTOUT
   RAW MATERIAL  I-ANCLING AREA

   NUMBER OF REDUNDANT ALKALI PREPARATION UNITS
   ECONOMIC CHARACTERISTICS
   1979  TVA-EPA  ECONOMIC PREMISES
   PROJECTED REVENUE REQUIREMENTS  INCLUDE LEVELIZEO OPERATING AND MAINTENANCE  COSTS
   RATE =  1.886  TIMES FIRST YEAR  OPERATING AND MAINTENANCE COSTS
   FREIGHT INCLUDED IN TOTAL INVESTMENT
   FREIGHT RATE =  3.5 *
   SALES TAX INCLUDED IN TOTAL  INVESTMENT
   SALES TAX HATE =  4.0 S
   LABOR OVERTIME INCLUDED IN TOTAL  INVESTMENT
   OVERTIME RATE  =  1.5
   INFLATION RATE =  6.0 *
   PROCESS MAINTENANCE =  8.0 4
   POND MAINTENANCE =  3.0 It
                     POND DESIGN
    OPTIMIZED  TO MINIMIZE TOTAL COST PLUS OVERHEAD
POND COSTS  (THOUSANDS OF DOLLARS)
                                 LABOR    MATERIAL    TOTAL
SUBTOTAL DIRECT
TAX AND FREIGHT
POND CONSTRUCTION
LAND COST
14920.

14980.

30Z.
23.
325.

15222.
23.
15245.
2104.
POND SITC                                            17349.
                                                (continued)

-------
                                          TABLE  2  (continued)
LIMESTONF SLURRY PROCESS  — BASIS:  500  MW UNIT. 1*84  STARTUP
                         USER SHORT  FORM PRINT                                                CASE 012
PROJECTED CAPITAL INVESTMENT REQUIREMENTS
                                                 INVESTMENT, THOUSANDS OF 1982 DOLLARS
                                            RAH MATERIAL
                                            HANDLING AND                    HASTE
                                             PREPARATION    SCRUBBING       DISPOSAL        TOTAL
    SUBTOTAL DIRECT INVESTMENT                   780S.         35764.         17569.        61141.
    TOTAL CAPITAL INVESTMENT                    14229.         65133.         29652.        109014.
                                                 (continued)

-------
                                            TABLE 2   (continued)
PROJECTED  FIRST YEAR REVENUE  REQUIREMENTS - USER SHORT  FORM  PRINT

    ANNUAL  OPERATION Kn-hK/rfW =   5500
                                         HEVENUE
                                      REQUIHtNEM, t
    SUBTOTAL KAM MATERIAL                 1304000

    SUPTOTAL CONVERSION COSTS              7854400
SUBTOTAL  IMOIRFCT COSTS                   2816500
LtVELIZEO  CAPITAL COSTS                  IbOiSOOO
FIHST YEAR  ANNUAL REVENUE REQUIREMENTS    27999900

-------
investment and revenue requirements for particulate removal.   The results
are listed in the output but are not included in the projected FGD
costs.  The percentage of particulate removal required for this option
is specified by the ASHUPS variable.  Example output showing  the results
of specifying mechanical collectors (XESP = 1) is shown in Table 3.
Example output showing the results of using the built-in particulate
removal cost model is shown in the base case printout in Appendix D
(p. D-17).

Reheat Option

   Line No .  	Input data	

      5      2 500 9500 11700 39 300 2 1 0 0 0 0 0 0 175 470  751
                                     i                   i    J
                                    XRH               TSTEAM  HVS

     The reheat option (XRH) allows for either an inline steam reheater
for the scrubbed gas or for no reheating of the scrubbed gas.  The inline
steam reheater is the only type of reheater available in the  current
version of the model.  When a reheater is specified (XRH = 2), the TSTEAM
variable is used to specify the temperature of the reheater steam and
the HVS variable is used to specify the heat of vaporization  of the
reheater steam.  Example output showing the results of specifying an
inline steam reheater is shown in the base case in Appendix D  (p. D-10).
When no reheating is specified (XRH = 0) the reheater section as shown
in the base case printout is omitted.

Emergency Bypass Option

   Line No.  	Input data	

      5      2 500 9500 11700 39 300 2 1 0 0 0 0 0 0 175 470  751
                                       \
                                     KEPASS

     The emergency bypass option (KEPASS) allows an emergency bypass
around the FGD system for one-half of the gas normally scrubbed as
specified in the premises used by TVA for comparative economic evalua-
tions for EPA  (Appendix B).  An emergency bypass is allowed by the
revised NSPS promulgated in 1979 (Federal Register, 1979) when spare FGD
modules (trains) are provided.  If only one operating scrubbing train is
specified  (line 9, NOTRAN) then the emergency bypass is sized  for all of
the gas normally scrubbed instead of only one-half.  When both emergency
bypass and partial scrubbing/bypass  (line 5, KPAS02 and PSS02X) are
specified, the bypass duct is sized for 50% of the gas normally scrubbed
(100% of the gas normally scrubbed if only one operating train) plus the
partial bypass normally used for the unscrubbed gas (total cannot
exceed 100%).  The following values are used for the KEPASS option:

                         0 - No emergency bypass

                         1 - Emergency bypass

                                    12

-------
                      TABLE  3.    MECHANICAL  COLLECTOR COST ILLUSTRATION





                                 SCRUBBING


         INCLUDING  4 OPERATING  AND   1 SPARE SCRUBBING  TRAINS


        ITEM                      DESCRIPTION         NO.  MATERIAL    LABOR
MECHANICAL  ASH COLLECTOR

1.0. FANS


SHELL
RUBBER LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES

   TOTAL  SPRAY SCRUBBER COSTS

HEHEATERS

SOOTBLOWERS


EFFLUFNT  HOLD TANK



EKFLUFNT  HOLD TANK AGITATOR

COOLING SPRAY PUMPS



ARSOHREP  RECYCLE PUMPS



MAKEUP WATER PUMPS
                             33» PARTICULATE REMOVAL
  7.SIN H20.  WITH  631.
HP MOTOR AND  DRIVE
 40 AIM-FIXED
 20 AIR-RtTRACTASLE

343449.GAL.  38.8FT OIA.
 38.8FT  HT, FLAKEGLASS-
LINEO CS

  82.HP

13P6.GPM 100FT HEAD'
  64.HP, 4 OPERATING
AND  6 SPARE

16611.6PM. 100FT HEAD.
 723.HP, 8 OPERATING
AND  7 SPARE

 3469.GPM,  200.FT HEAD.
 292.HP, 1 OPERATING
AND  1 SPARE
1
5

5
5
60
654166.
3J41982.
1769029.
1766858.
393850.
853235.
4782970.
2647704.
294910.
112232
58581

449605
166446
162512
     373173.
 5   505849.

10   104732.
15  1581896.
                                                           33169.
              301519.
207512.

 32268.
               139397.
TOTAL  EQUIPMENT COST
                                                        14320518.  1655810.

-------
Example output showing an emergency bypass specified is shown in the
base case printout in Appendix D (p. D-7).

Partial Scrubbing/Bypass Option

   Line No.	Input data	
      5      2 500 9500 11700 39 300 2 1 1 90 0 0 0 0 175 470 751
                                       /   \
                                    KPAS02 PSS02X

     The partial scrubbing/bypass option (KPAS02) allows FGD systems to
be projected for conditions where all of the flue gas does not have to
be scrubbed to meet specified emission levels.   The percent removal in
the absorber is specified with the PSS02X variable and the model will
calculate the percentage of flue gas that can be bypassed (if any)  and
still meet the emission limit or overall removal percentage specified
(line 7, IS02 and XS02).  The appropriate ductwork and reheater adjustments
are made as required depending on the amount of bypassed gas.  When both
partial scrubbing/bypass and emergency bypass (line 5, KEPASS) are
specified the bypass duct is sized for the gas  normally bypassed plus
50% of the gas normally scrubbed (100% if only one operating train;
total cannot exceed 100%).   Partial scrubbing/bypass is not allowed when
S02 removal is calculated from scrubber operating parameters (line  7,
XSR = 3).  The following values are used for the KPAS02 option:

                     0 - No partial scrubbing/bypass

                     1 - Partial scrubbing/bypass

Example output showing partial scrubbing/bypass specified is shown  in
Table 4 and is based on an emission limit of 1.2 Ib S02/MBtu.

Coal-Cleaning Option

   Line No.
       5     2 500 9500 11700 39 300 2 1 0 0 1 84.16 12.16 2.21 175 470 751
                                         /I       \    ^
                                      KCLEAN  WPRCVR  WPPSAC  WPPSRC

     The coal-cleaning option (KCLEAN) allows the model to be used in
conjunction with physical coal cleaning.  The model calculates the
composition and firing rate of cleaned coal to the boiler based on the
raw coal characteristics, the coal cleaning parameters, and boiler heat
rate and megawatts.  The corresponding composition of the flue gas to
the scrubbing system is used for determining the degree of S02 removal
required.  The variables WPRCVR, WPPSAC, and WPPSRC are used to specify
the required coal-cleaning parameters.  The WPRCVR variable specifies
the percent weight recovery (Ib clean coal per Ib of raw coal); the
WPPSAC variable specifies the weight percent of pyritic sulfur plus ash
in the cleaned coal; and the WPPSRC variable specifies the weight percent

                                    14

-------
                     EXAMPLE RESULTS  SHOWING  PARTIAL SCRUBBING/BYPASS
EMERGENCY 8Y-FOSS
EMERGENCY BY-PASS DESIGNED FOR  57.1 *
HOT GAS FROM BOILER

C02
HCL
502
02
N?
H20
MOLE PERCENT LB-MOLE/HR
H.-'ie 0 2255E*Ob
O.OOt 0
0.214 o
5.560 0
75.227 0
6.654 0
1 145E+02
3914E*03
1016E»05
1375F«06
1216E-05
LB/HR
0.9923E-06
0.4175E*03
0 • 2b08t *0b
0.3251E»06
0.3H52E*07
0.2 19 1E*06
HOT GAS  FLO* KATE =   ,1154E*07 SCFM  ( 60. DEG F.  14.7  PSIA)
                 =   .1687E'07 ACFM  (3UO. DEG f,  14.7  PSIA)

CORRESPONDING COAL FIRING RATE =  .4060E»06 LB/HR

HOT GAS  HUMIDITY =  0.04? L3 H20/LS  DRY GAS

WET BULfl TEMPERATURE  =  124. DFG F


HOT GAS  TO BY-PASS
        MOLE FFWCENT     LH-MOLE/HR     LB/HR

C02        12.338       0.3189E.04     0.1404E*06
HCL        0.006       0.1(S20E»01     0.5S06E»02
S02        0.214       0.5537E«02     0.3547E«04
02         5.560       0.1437E«04     0.4599E*05
N2         75.227       0.194bE+Ob     0.5449E+06
H?0        6.6?4       0.1720E»04     0.3099E*Ob

HOT GAS  BY-PASSED 14.1 *

HOT GAS  FLO» RATE =   .1633E«06 SCFM  (  60. DEG F. 14.7  PSIA)
                 =   .2386E«06 ACFM  (300. OEG F. 14.7  PSIA)

CORRESPONDING COAL FIRING RATE =   .5743E«05 LB/HR
                                         (continued)

-------
                                       TABLE  4  (continued)
 HOT  GAS  TO  SCRUBBER

         MOLE  PERCENT     LB-MOLE/HR     LB/HR
C02
HCL
502
02
N2
H20
12.33fc
0.006
0.214
5. 56C
75.227
6.654
0.1936E-05
0.9832E*01
0.3361E«03
0.8723E»04
0.1180E»06
0.1044E«05
0.8519F«06
0.3585E«OJ
0.2153E»Ob
0.2791E*06
0.3307E»07
0.1S91E«06
 S02  CONCENTRATION IN SCRUBBER INLET GAS = 2142.  PPM
                                        = 5.28 LBS / MILLION BTU

 FLYASH  EMISSION =  0.060 LBS/MILLION HTU
                =  0.029 tHAINb/SCF (WET)   OH     28b.  L8/HH

        SOLUBLE CAO IN FLY ASH =      0.  LB/HR
        SOLUBLE MGO IN FLY ASH =      0.

 HOT  GAS FLOW RATE =  .9910E'06 SCFM (  60.  DEG  F.  14.7  PSIA)
                  =  .144fE«07 ACFM (300.  DEG  F.  14.7  PSIA)

 CORRESPONDING COAL FIRING RATE =  .3486E«06 LH/HR

 HOT  GAS HUMIDITY =  0.042 La H20/LB DRY GAS

 WET  HULB TEMPERATURE = 124.  UEli  F


 WET  GAS FROM SCPL8BER


        MOLE PERCENT     LB-MOLE/HH     LB/HR
C02
HCL
S02
02
N2
H20
11.716
0.000
0.020
5.169
70.300
12.795
0.1967E.OS
0.491bE*00
0.3361t«02
0.8677E»04
0.1180E«06
0.2148E»05
0.8657E«06
0.1792E«02
0.2153E*04
0.2777E->06
0.3307E»07
0.3870E»06
S02 CONCENTRATION IN SCRUBBER  OUTLET GAS =  200. PPM

FLYASH EMISSION =  0.030 LBS/MRLION BTU
                =  0.016 C-HAINS/SCF  (WET)  OR    143. LB/hR

TOTAL WATER PICKLP =  40B.   GP«
           INCLUDING    9.7  GPM ENTRAINMENT

WFT GAS FLOW RATE =   .1060E*07 SCFM  ( 60. DEG F. 14.7 PSIA)
                  =   ,1191E«07 ACFM  (124. DEG F, 14.7 PSIA)

WET GAS SATURATION HUMIDITY  =  0.087 Lfi H20/LB DRY GAS

-------
of pyritic sulfur in the raw coal.  When the revised NSPS (Federal
Register, 1979) emission limit is automatically calculated by the model
(line 7, IS02 = 4), the appropriate credit for coal cleaning will also
be automatically calculated by the model, on a raw coal basis.  In all
other cases, the emission limit or removal percentage (line 7, IS02 and
XS02) must be specified on a cleaned coal basis or must be calculated by
the model from scrubber operating parameters (line 7, XSR = 3).  Coal
cleaning is not allowed when the gas composition is specified directly
(line 6, INPOPT = 2).  The following values are used for the KCLEAN
option.

                          0 - No coal cleaning

                          1 - Coal cleaning

Example output showing the results of specifying coal cleaning is shown
in Table 5, and is based on 84.16% weight recovery, 12.16% pyritic
sulfur plus ash in the cleaned coal, and 2.21% pyritic sulfur in the raw
coal.

Input Composition Option

  Line
   No.	                  Input data                  	

        INPOPT
         /
   6A   1 66.7 3.8 5.6 1.3 3.36 .1 15.1 4.0 92 80 2 .06 .03

   or

   6B   2 12.338 .006 .214 5.560 75.227 6.654 1154000 47500 100 100 2 .06 .03
         \
        INPOPT

     The input composition option (INPOPT) allows the flue gas composition
to be specified directly instead of being calculated by the model from a
coal composition.  This allows the model to be used to project FGD
systems for other than coal-fired boilers, such as smelter off-gas.   The
variables described for line 6A (C, H,  0, N,  S, Cl, ash, H20,  etc. ;  see
Table C-2)  should be used when the coal composition is specified; the
variables described for line 6B (C02> HC1, S02, 02, N2,  H20,  etc.;  see
Table C-2)  should be used when the flue gas is specified directly.   Coal
cleaning (line 5, KCLEAN = 1) and the automatic calculation of revised
NSPS emission levels (line 7, IS02 = 4) are not allowed when the flue
gas composition is specified directly.   The following values are used
for the INPOPT option:

               1 - Coal composition is specified (line 6A)

               2 - Flue gas composition is specified (line 6B)


                                    17

-------
                                           TABLE  5.   EXAMPLE  RESULTS  SHOWING COAL  CLEANING
                    PHYSICAL COAL CLEANING
                                                   STREAM LunPOSlTIONS
                    COMPONENT
                                           RAW COAL
                                                                 CLEAN COAL
                                                                                         REFUSE
00
HEIGHT
PERCENT
18 PER LB
RAW COAL
WEIGHT
PERCENT
LB PER LB
RAW COAL
WEIGHT
PERCENT
LB PER LB
RAW CCAL
                    CARBON
                    HYDROGEN
                    OXYGEN
                    NITROGEN
                    SULEUR.lOi.
                    PURE COAL
 66.7000
  3.8000
  3.6000
  1.3000
— 1.15.00—
 7B.5500
   0.7013
   0.0400
   0.0589
   0.0117
—0.0121.
   0.9259
                    SULFUR (P>        2.2100      0.0221
                    ASb	1J.1000	0.15.10.
                    ASH £ 5         17.3100      0.1731

                    CHLOiltJE	0.1000	Q.OQ1Q-
                    TOTAL           100.0000      1.0000
 74.9248
  4.2498
  6.2570
  1.4525
-.1.28.4.9—
 87.7630

  1.5525
.10.6023...
 12.1600
   0.6272
   0.0357
   0.0527
   0.0122
	0.0108-
   0.73)6

   0.0131
—0.089.3-
   0.1023
 46.7B30
  2.6653
  3.9278
  0.9118
..0.8066...
 55.0945

  9.7014
.38.9.69.2—.
 44.6726
   0,0741
   0.0042
   0.0062
   0.0014
...0.0013
   0.0873

   0.0090
...0.0612
   0.0708
                      ...0.0710	Q.QQQ6.
                       100.0000      0.8416
                                   —0.212B	0.000*
                                    100.0000      0.1584
                    BTU/LB            122B2.      12292.

                    PERCENT ORTOINAL  BTU    1.0000
                         13469.      11335.

                              0.9229
                                                                                     9764.
                                                                                                 1547.
                                                                                          0.1299

-------
When a coal composition is specified, a "BOILER CHARACTERISTICS" section
is included in the output report.  Example output showing the results of
specifying a coal composition as input (INPOPT = 1) is shown in the base
case printout in Appendix D (p. D-4).  When a flue gas composition is
specified, a "HOT GAS ANALYSIS" section is provided.  Example output
showing the results of specifying a flue gas composition as input is
shown in Table 6.

Particulate Removal Option

   Line No.                     Input data	

      6A     1 66.7 3.8 5.6 1.3 3.36 .1 15.1 4.0 92 80 2 .06 .03
                                                jf^^jS     /
                                              IASH ASHUPS ASHSCR

     The particulate removal variables are IASH, ASHUPS, and ASHSCR.
The IASH option identifies the method for specifying particulate removal,
i.e., as percent removal or as outlet emission in Ib/MBtu.   IASH may
take values of 0, 1, 2, or 3.  If IASH is equal to 0, upstream particulate
removal (ASHUPS) and absorber particulate removal (ASHSCR)  take default
values of 33% and 99.2% removal respectively.  If IASH equals 1, ASHUPS
and ASHSCR are input as percent removal.  If IASH equals 2, ASHUPS and
ASHSCR are input particulate loadings in Ib/MBtu at the outlet of the
upstream particualte collector and the absorber respectively.  If IASH
equals 3, ASHUPS is input as percent removal and ASHSCR takes a default
value of 75%.  Regardless of the option chosen, the output listing
provides the equivalent particulate emission as both percent removal and
Ib/MBtu.  A summary of the options is shown below.

          IASH = 0  ASHUPS default value = 33% removal

                    ASHSCR default value = 99.2% removal


          IASH = 1  ASHUPS input value as percent removal

                    ASHSCR input value as percent removal


          IASH = 2  ASHUPS input value as Ib/MBtu to absorber

                    ASHSCR input value as Ib/MBtu from absorber


          IASH = 3  ASHUPS input value as percent removal

                    ASHSCR default value equals 75% removal

Example output showing the results of specifying particulate removal based
on Ib/MBtu (IASH = 2) is shown in the base case printout in Appendix D
(pp. D-8, -10).

                                     19

-------
    TABLE 6.   EXAMPLE RESULTS  SHOWING USER INPUT  FLUE GAS COMPOSITION
                 «*« INPUTS «•*


HOT GAS ANALYSTS. MOLt PERCENT:

   C02       CL      SOS      02      N2       H20
 12.3380   0.0006   0.2140    5.b600   75.2270   6.6540

SULFW OVERHEAD = 100.0 PE^CtNT

ASH OVERHEAD =  100.0 PERCENT

-------
SO? Removal Option

   Line No.
Input data
      7      90 0 0 10 25 4 0.0 10 1 0.0 1 0 .15 0 0 0 4.85 500
                          I   \
                        IS02  XS02

     The model has five methods for specifying SC>2 outlet concentrations
or removal.  The controlling variables are the IS02 option and the
actual value to be removed, XS02.  If IS02 = 1, XS02 is input as the
percentage of S02 to be removed.  (The percentage of S02 to be removed
is used as the percent removal by the absorber except when partial
scrubbing is specified with the KPAS02 option on line 5.)  If IS02 = 2,
XS02 is input as the absorber outlet emission expressed as pounds S02/MBtu.
If IS02 = 3, XS02 is input as ppm S02 in the absorber outlet stream.  If
IS02 = 4, XS02 is automatically calculated by the model from the input
coal composition based on the revised NSPS (Federal Register, 1979).
Figure 1 illustrates the relationship between the SC>2 content of the raw
coal and the controlled outlet emission levels used in the model for the
revised NSPS.  A fifth method for specifying S02 removal, S02 removal
calculated, is described in the operating parameter options section
(line 7, XSR = 3).  Regardless of the option chosen, the equivalent S02
removal in all three units is displayed in the model output.  The input
value is indicated as having been specified and the other values are
indicated as having been calculated.  A summary of the input options is
shown below.

  IS02 = 1  XS02 is input as percent removal

  IS02 = 2  XS02 is input as pounds S02/MBtu at the absorber outlet

  IS02 = 3  XS02 is input as ppm S02 in the absorber outlet stream

  IS02 = 4  XS02 will be automatically calculated by the model based
            on the revised NSPS (Federal Register, 1979)

Example output showing the results of specifying emission limits based
on the revised NSPS is shown in the base case printout in Appendix D.

     An important concept related to S02 removal calculations in the
model should be emphasized here.  The S02 removal options are based on
long-term average removals and are not to be construed as 3-hour or 24-
hour averages.  When sizing an FGD facility the raw material handling,
feed preparation, and scrubbing areas should be based on the maximum
sulfur content of the coal rather than the long-term average.  The waste
disposal pond, however, should be sized on the long-term average sulfur
content.  This can be done by entering the weight percent sulfur as the
maximum expected and then entering the pond capacity factor (line 14,
PNDCAP) to adjust the total amount of waste generated back to the
equivalent long-term average amount.
                                    21

-------
NJ
ro
            1.2
            1 .0
            0.8
            0.6
           0. 2
                                removal  required
                            70
80
 I
85
 I
                                      5.0% S, 11,700 Btu/lb bit, coal
                                                        3.5% S, 11,700 Btu/lb bit, coal
                                       2.0% S, 11,700 Btu/lb bit. coal
                            0.9% S, 6,600  Btu/lb lignite
                         0.7/: S, 8,200 Btu/lb subbit.  coal
                                                _L
                    _L
                           _L
_L
J_
                                          A             6             8            10

                                        EOUlVALKiMT S02  CONTEND OF RAW COAL,  Ib S02/MBtu
                                                             12
         Figure  1.   Controlled S02 emission requirements for  1979 NSPS.   Premise  coals,  shown
                     underlined, are based  on premise boiler conditions.

-------
Operating Parameter Calculation Option

   Line No.	      Input data	

             XLG           XS02   XSR  SRIN
              f              \     \   /
       1     90 0 0 10 25 4 0.0 10 1 0.0 1 0 .15 0 0 0 4.85 500

       8     15 40 .2 40 0 30 0.0 80 1.2 0.0 0 9 0 14.7 1
                                          i
                                       PHLIME

     Four options are available in the model to allow either user input
or model calculation of the major operating parameters which include L/G
(expressed as absorber liquor recirculation rate in gallons of liquor
recirculated per 1000 actual cubic feet of gas at the absorber outlet),
stoichiometry (expressed as mols CaCC>3 or CaO added per mol of S02
absorbed), and SC>2 removal.  The options differ slightly for the lime-
stone scrubbing system and the lime scrubbing system so the description
is divided into two sections.

     First, for limestone scrubbing (line 7, XIALK = 1) the variables
used are XSR, XLG, SRIN, and XS02.  XSR is the controlling option and
takes values from 0 to 3.  If XSR has an input value of 0, the L/G
(XLG), stoichiometry (SRIN), and S02 removal (XS02, units depend on
IS02) are all user input values.  Specifying XSR = 0 is referred to as
"force-through" because no program checks are made for validity or
consistency among the three input variables to ensure that specified L/G
and stoichiometry can result in the input degree of removal.  If XSR is
equal to 1, XLG and XS02 are input and the model calculates stoichiometry.
If XSR is equal to 2, SRIN and XS02 are input and the model calculates
XLG.  When XSR is equal to 3, XLG and SRIN are input and the model
calculates XS02.  Values of 1.01 or greater should be used for SRIN when
it is specified as input.  A summary of the various options for a limestone
scrubbing system is shown below.

                       XSR = 0  XLG is input

                                XS02 is input

                                SRIN is input
                       XSR = 1  XLG is input

                                XS02 is input

                                SRIN is calculated
                                    23

-------
                       XSR = 2  XLG is calculated

                                XS02 is input

                                SRIN is input


                       XSR = 3  XLG is input

                                XS02 is calculated

                                SRIN is input

Example output showing the results of specifying XSR = 1 is shown in the
base case printout in Appendix D (pp. D-5, -12).

     Similar options are available in the lime scrubbing option (line 7,
XIALK = 2).  Except when XSR = 0, the variable PHLIME replaces SRIN
because for lime scrubbing the model calculates the pH of the recirculation
liquor instead of the lime stoichiometry.  (When limestone is specified
the value of PHLIME is ignored.  When lime is specified SRIN is ignored
except when XSR = 0 in which case PHLIME is ignored.)  A summary of the
options for a lime scrubbing system is shown below.

                      XSR = 0  XLG is input

                               XS02 is input

                               SRIN is input


                      XSR = 1  XLG is input

                               XS02 is input

                               PHLIME is calculated


                      XSR = 2  XLG is calculated

                               XS02 is input

                               PHLIME is input


                      XSR = 3  XLG is input

                               XS02 is calculated

                               PHLIME is input
                                     24

-------
     The output listing for the lime scrubbing option is similar to that
for the limestone option shown in Appendix D except that the stoichiometry
is printed out for CaO instead of CaC03, as shown in Table 7.   (An input
value of 7.85 is used for PHLIME in this example.)  For both the lime
and limestone options, if input values are specified for the variables
that are to be calculated by the model, the input values are ignored.

Scrubbing Absorbent Option (Lime or Limestone)

   Line No.                     Input data	i	

       7     90 0 0 10 25 4 0.0 10 1 0.0 1 0 .15 0 0 0 4.85 500
                                         *
                                       XIALK

     The alkali scrubbing absorbent option (XIALK) allows a choice of
either lime or limestone.  If XIALK = 1, limestone slurry is selected as
the scrubbing medium.  If XIALK = 2, lime slurry is selected.   Example
output showing the results of specifying limestone scrubbing (XIALK = 1)
is shown in the base case printout in Appendix D.  Table 8 shows how the
lime option output differs from limestone in both the input display and
the raw material preparation area equipment list.

Chemical Additive Option

   Line No.                       Input data	
       7     90 0 0 10 25 4 0.0 10 1 0.0 1 0 .15 0 0 0 4.85 500
                                           \i
                                          IADD

     The chemical additive option (IADD) provides for the addition of
either magnesium oxide (MgO) or adipic acid to the slurry stream to
improve scrubber efficiency and S02 removal rates.  The following values
are used for the IADD option:

  0 - No chemical additive

  1 - MgO added

  2 - Adipic acid added ("force-through" mode must be used for the
      adipic acid option; see the operating parameter calculation
      option, XSR, on line 7)

Example output showing the results of adding adipic acid is shown in
Table 9.
                                    25

-------
                         TABLE 7.   LIME  SCRUBBING  OUTPUT  LISTING
SCRUBBER SYSTEM


TOTAL NUMBER OF SCRUBBING  TWAINS  e.6 PERCENT

PARTICULATE REMOVAL IN  SCNUrtbER SYSTEM =  50.0 PERCENT

SPRAY TOWER PRESSURE DROP  =   2.?  IN. H<;0

TOTAL SYSTEM PRESSURE CROP =   7.5 IN. "20

SPECIFIED   SPRAY TOkER L/G RATIO  =    APSORtED

SOLUHLE CAO FRC" FLY ASH =  0.0  WOLt HER MOLE (SOa»2HCL)  ABSORBED

TOTAL SOLUBLE Mf=C       =  0.00 MOLE PER MOLE (S02*«!MCLI  ABSORBED
TOTAL STOIChlCVETSY
                            1.10 MOLE SOLOdLF (CA'MG)
                                PER MOLE 1S02»2HCL) ABSORBED
SCRUBBER INLET LIQUOR  PH  =   7.P5

MAKt UP wATtR =  720.  GPM

CROSS-SECTIONAL AHtA  PEH  SCRUHdES =   577. SQ FT


SYSTEM SLUDSE DISCHARGE

SPECIES
CAS03 .1/2 h?C
CAS04 .2H20
CAC03
INSOLURLE s
H?0
CA+ +
MG**
S03--
S04--
CL-

LB-fOLE/f-H
0.242BE.03
0.1029E-03
0.3523£«0a
0.4440E«04
0.5i7?F«01
0.1515E-01
0.1426E»00
0.119«E»01
O.lOfSE-02

Ld/HK
0.3135E-05
0.1771E«Oi
0.3527E«04
0.79S9E«OS
0.2113E-OJ
0.36B^E»0^
0.11*lE«l)i
0.1147E»03
0.3«57E«03
3UL 1 U
COMP,
«T 1
58.23
32.90
6.55
2.32





C 1 udu 1 u
COMP,
IVM




2617.
45ft.
141.
1421.
4776.
TOTAL DISCHARGE FLOW  RATE  =  0.1346E»06 LB/HR
                          =   <:03.     GPM
TOTAL DISSOLVED SOLIDS  IN DISCHARGE LIQUID =

DISCHARGE LIQLIH Ph  =   7.37

-------
K3
—I
                               TABLE  8.    LIME  OPTION  INPUTS AND  RAW MATERIAL PREPARATION AREA





                         LIME  SCRUBBING                                                       CASE  007


                                           •«« INPUTS *••



                         BOILER  CHARACTERISTICS
MFbAWATTS =   500.

BOILER  HEAT RATf =   5500. FJTU/MIH

EXCESS  AIR =  39. PERCFMT. INCLUDING LEAKAGE

HOT GAS TF.MPEI-ATLRE  =  300. DE(j F

COAL ANALYSIS! *T *  OS FIRED :

  C     H      C     N      S     CL    ASH    H20
66.70   3.80   5.60    1.30   3.36   0.10  IS.10   4.00

SULFUR  OVERHEAD = ^2.0 PEHCENT

ASH OVERHEAD =  60.0 PKKCENT

HEATINC VALUE OF CO«L  = 11700. BTU/L8

                      EFFICIENCY.    EMISSION,
FLYASH  REMOVAL              *        L"S/C BTU
                         UPSTREAM OF SCRUEBER        99.4          0.06

                         KITHIN SCRUBBER            50.0          O.OJ

                         COST  OF UPSTREA1"  FLYASH REMOVAL FXCLUDEO


                         ALKALI
                               CAO         =  95.00 WT  *  DRY BASIS
                               SOLUBLE VGO  =   0.15
                               INERTS      *   4.H5
                               MOISTURE CONTENT :    5.00  LH H20/100 L8S  DRY LIME
                         FLY  ASH  :
                               SOLUBLE  CAO  =   0.0  NT  *
                               SOLUbLE  MCO  =   0.0
                               INERTS      = 100.00
                                                                    (continued)

-------
                                                                TABLE  8  (continued)
                                         RA»  MATEHIAL HANDLING AND PREPARATION


                            INCLUDING   2  OPERATING  AND  1 SPARE PREPARATION UMTS


                           ITEM                       DESCRIPTION         NO. MATERIAL    LABOR
00
CONVEYOP FROM CALCINATION
PLANT

STORAGE SILO ELEVATOR

CONCRETE STORAGE SILO



STORAGE SILO HOPPER PCTTCM

RECLAIf VIBRATING FEECEN

RECLAIM PELT CONVEYOR

FtFD BIN FLEVaTOK

FEED REIT CONVEYOR

FEED CONVFYOR TRIPPFR

FEED BIN!


blN VIBRATING EEEOER

tlN KEKiH KtEI.it H

SLAKER

SLAKE" PRODUCT TANK

SLAKEP PRODUCT TANK AGITATOR

LIME SYSTEM OUST COLLECTORS
                   SLAKER PRODUCT  TANK  SLURRY
                   HUMPS
                  SLURRY  FEED  TANK
                   SLURRY  FEED  T&NK  AGITATOR

                   SLURRY  FEED  TANK  PUMPS
                   TOTAL  EQUIPMENT  COST
1SOOFT HORIZONTAL.  30HP


 l?b.FT HIGH. 50 HP

136674.FT3.t8.8FT DIA .
 73.2F1 STRAIGHT SIDF
STORAGE nT

en DEGREE, cs

3.5PP

 124.FT HORIZONTAL. 5HP

bOFT HKiM. 50HP

SOFT HORIZONTAL. bHP

30FFM, 1HP

10FT 014.  15FT STRAIGHT
SIDE Hi,  COVERED. CS

3.5PP

12FT. I^IN SCRE«. IMP

   6.TPH.    10.HP



10HP

POLYPROPYLENE HAG TYPE
2200 CM,7.SfP

 134.GP'1.  60FT HEAD.
   4.HP.   2 OPERATING
AND 1 SPARES

 14101S.GAL. 26.8FT DIA,
 2P.8FT HT. ELAKEGLASS-
LINED CS

  50.HP

   67.GPM, 60 FT HEAD.
   2.HP,   4 OPERATING AND
 4 SPARE
                                                                          1
                                                                              207327.
                                                                                         37741.
1
1
1
1
1
1
1
1
3
3
3
3
3
3
5
3
1
1
8
62607.
177002.
22252.
3S13.
2578d.
377b4.
12076.
18940.
144<,1.
30508.
15635.
175997.
15445.
22881.
38770.
11863.
35984.
57120.
22498.
4494.
375654.
15214.
391.
3392.
2216.
)f>43.
651H.
9973.
3911.
2347.
1(1433.
12515.
5475.
14340.
3480.
25727.
4686.
7300.
                                                                                        550850.

-------
              TABLE 9.   EXAMPLE RESULTS  SHOWING  THE ADDITION  OF ADIPIC  ACID




                    PA*  MATERIAL HANDLING AND PREPARATION

        INCLUDING  2 OPERATING AND  1  SPARE PREPARATION UNITS

       ITEM                     DESCRIPTION        NO. MATERIAL    LABOR
CAR SHAKER AND HOIST

CfR PULLER

UNLOADING HOPPER


UNLOADING VIBRATING FENCER

UNLOADING 9ELT CONVEYCk

l^LOAOUG INCLINE  BELT
CONVFYOP

UNLOADING PIT DUST COLLFCTOB


UNLOADING KIT SUMP PUMP

STORAGE BELT CONVEYOR

STORAGE CONVEYOR  TRIPPER

MOBILE EQUIPMENT

RECLAIM HOPPER


RECLAIM VIBRATINb  FEECEP

hl-CLAIM BFLT CONVEYOR

RECLAIM 1MCLINF BELT CO^VFYO^

RtCLAI" PIT DUST  COLLECTOR

RECLAIM PIT SUMP  PUMP

RECLAIM BUCKET ELEVATOR

EEED BELT CONVEYOR
20HP SHAKER 7.5HP HOIST
25HP PULLFR. 5HP RETURN
16FT OIA, 10FT STRAIGHT
INCLUDES h IN SU GRuTING
3.5HP
20FT HORIZONTAL. 5HP
310FT, 50HP
POLYPROPYLENE oAbTYPE.
INCLUDES OUST HOOD
fcOGPM, 70FT HEAD. 3HP
200FT. 5MR
30FPM, 1HP
SCRAPPER TRACTOR
7FT xIUEi 4.25FT HT. 2FT
WIDE BOTTOM. CS
3.5HP
JOOKT. ?HP
193FT. 40HP
POLYPROPYLENE BAG TYPE
feOGPM* 70FT HEAD* 5HP
90FT HIGH. 75HP
60. FT HORIZONTAL 7.5HP
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
71916.
63050.
15508.
5466.
11440.
95295.
11186.
2415.
73092.
27203.
141862.
?415.
10932.
40931.
60253.
7754.
2415.
57838.
20466.
13037.
19555.
5932.
521.
1434.
4824.
-215.
782.
3911.
9126.
0.
1630.
1043.
2868.
3650.
2607.
782.
6649.
1434.
                                                 (continued)

-------
                                                                 TABLE  9  (continued)
u>
o
FEED CONVEYOR T^IPPEP.

FEED RIN


BIN »FIf~,H FEEDER

GYRATORY CKUSHEKb

E-ALL MILL DUST COLLECTOPb


BALL MIIL

KILLS PRODUCT TANK


KILLS PPOPUCT TANK AGITATOR

KILLS PPODUCT TANK bLIRPY



ADIPIC ACID ADD STORAGE SILO


PNEUMATIC CONVEYOR SYSTFK

ADDITION FEED BIN

SCREW FFEDEH

AUDITIVE DUST COLLECTOR


SLURRY FEED TANK



SLURRY FEFO TANK AGITATOR

SLURRY FEFD TANK PUMPS




TOTAL EQUIPMENT COST
                                                30 FPMi  IMP
                                                13FT  DIA,  21FT  STRAIGHT
                                                SIDE  HT. COVERED.  CS
                                                14FT PULLEY  CENTERS.  2HP

                                                75HP
                                                POLYPHOPYLENE  HAG  TYPE
                                                ctOO CFM,  T.bHP
5500 GAL 10FT OIA.  10FT
HT, FLAKtGLASS LINED CS

HIHP

  S3.UPM.  60FT HEAD,
   J.HP.  2 OPERATING
AND 1 SP4HES

  6058.KT1, 17.3ET  UlA
 40.3FT MT 60 DEG CONE

 10. np

«UB6E« LINED

30 FT LONG. 6 IN 0.  SS

POLYPHOPLE.NE BAG TYPE
 4bO CFM,  1.5 HP

  Sbbil.OAL. 21.2FT  UIA,
 21.2FT hT, ELAKEGLASS-
LINEO CS

  48 .HP

   26.GPC, 60 FT HE«D.
   l.HP.  4 OPERATING AND
 4 SPAKE
1
3
3
3
J
J
3
3
j
1
1
1
1
1
1
1
8
37203.
43283.
495/5.
297071.
23262.
1699745.
13729.
228H1.
»SU7.
242J7.
HSBO.
5520.
4703.
3305.
19361.
41832.
21553.
9126.
24052.
J347.
6453.
7822.
120659.
10951.
5475.
273H.
16264.
5345.
3044.
521.
261.
15995.
3432.
7300.
                                                                             3025779.

-------
Forced-Oxidation Option

   Line No.	Input data

       8     15 40 .2 40 0 30 0.0 80 1.2 0.0 0 9 0 14.7 1
                         \
                        IFOX

     The forced-oxidation option (IFOX) provides for converting sulfite
sludge (which chemically has an oxygen demand) to gypsum (which does
not).  Gypsum, in comparison with sulfite sludges, offers better disposal
options such as easier dewatering, a higher settling rate, and a higher
density of settled sludge.  The following values are used for the IFOX
option:

  0 - No forced oxidation

  1 - Forced oxidation in a single effluent tank (within the absorber
      loop)

  2 - Forced oxidation in the first of two effluent tanks (within the
      absorber loop)

  3 - Forced oxidation in the disposal feed tank (bleedstream from the
      absorber loop); the number of effluent tanks depends on the ISCRUB
      variable (line 9)

The number of effluent tanks specified by the forced-oxidation option
must not conflict with the number of tanks indicated by the absorber
option (ISCRUB, line 9).  Example output showing the results of specifying
forced oxidation in the first of two effluent tanks (IFOX = 2) is shown
in Table 10.  An example of one tank (IFOX = 1) is shown in Table 11.

Fan Option

  Line No.	Input data	

      8     15 40 .2 40 0 30 0.0 80 1.2 0.0 0 9 0 14.7 1
                                                       \
                                                      IFAN

     The fan option (IFAN) allows either induced draft (ID) fans or
forced draft (FD) fans to be specified.  The following values are used:

                          0 - Forced draft fans

                          1 - Induced draft fans

Example output showing the results of specifying ID fans is shown in the
base case printout in Appendix D (pp. D-5, -20).  The format of the
output is similar for the FD fan option; however, the fan costs are
different.

                                     31

-------
       TABLE  10.    EXAMPLE RESULTS  SHOWING FORCED OXIDATION,  TWO EFFLUENT TANKS
                                  SCRUBBING


         INCLUDING   4 OPERATING AND  I SPARE SCRUBBING TRAINS


        ITEM                      DESCRIPTION         NO.  MATERIAL    LABOR
I.D. FANS


SMFLL
MJRBFP LINING
MIST ELIMINATOR
SLURRY HEADER AND  NOZZLES

   TOTAL SPRAY SCRUdBEfi COSTS

REHEATERS

SOOTRLOWERS


EFFLUENT HOLD TANK



EFFLUENT HOLD TANK AGITATOR

RtCIRCULATION TANK



RECIRCULATION TANK AGITATOR

COOLING SPRAY PUMPS



RtCIRCULATION PUMPS



OXIDATION BLEED PUMPS



OMDAi.JN 6IR SLOWER

OXIDATION SPARGER

MAKEUP WATER  PUMPS
  7.SIN h20.  WITH  630.
HH WOTOH AND  DRIVE
                                                      5  3340693.
                            1768270.
                            176A030.
                             393580.
 40 AlH-FIXEO
 20 AIR-RETRACTAeLE

343220.GAL,  38.8FT DIA.
 38.8FT  HI. FLAKEGLASS-
LINED CS

  82.HP

171610.GAL  27.4FT DIA,
 38.8FT  hT, FLAKEGLaSS-
LINED CS

  69.HP

13B7.GPM  100FT HtAO-
  64.HP,  4 OPERATING
AND  6 Sf-ARE

15601.GPM, 100FT HEAD,
 7J3.HP,  fl OPERATING
SNO  7 SPARE

  240.6PM, 60 FT HEAD
   7.HP,  4 OPERATING
AND  4 SPARE

 3264.SCFM,   344.HP

19.4  FT OIA RING

 3467.GPM,  200.KT HEAD,
 292.HP,  1 OPERATING
AND  1 SPARE
 5  4780547.

 5  2646582.

60   294910.


 5   37300S.



 5   505611.

 5   218513.



 5   309612.

10   104710.



15  1581315.
 6   208405.

 5    95155.

 2    33153.
                                                                    58558.
445402.

168382.

162512.


301386.



207414.

180603.



127011.

 32259.
 11999.



  4693.

 41619.

  3740.
TOTAL  EQUIPMENT COST
                                                        14526781.  1SOB930.

-------
                          TABLE  11.    EXAMPLE  RESULTS  SHOWING FORCED OXIDATION,  ONE EFFLUENT TANK
                                              SCRUBBING


                      INCLUDING  4 OPERATING AND  1 SPARE SCRUBBING  TRAINS


                     ITEM                      DESCRIPTION         ND. MATERIAL    LABOh
(.0
OJ
             I.D.  FA'-S

             SHELL
             RUBBER  LIMING
             MIST  ELIMINATOR
             SLURRY  HEADER AND NUZZLES

                TOTAL  SPRAY SCRUBBER CDSTS

             REHEATEKS
             SOnTBUOvERS
  7.JIN H20, «IITH  630.
HP MOTOR  AND DRIVE
             EFFLUSNT-OXIDATtON
             HULD TAW.
             EFFLUFNT-OXIDATION
             HOLD TANK  AGITATPR

             COOLING SPRAY PUMPS



             ARSQRREK RECYCLE PUMPS



             OXIOATIHN  BLEED PUMPS



             OXIDATI IN  AIR BLOWER

             OXIDATION  SPARGER

             MAKEUP  (.'ATER PUMPS




             TOTAL EQUIPMENT COST
                                                                   5  3340693,
                            1768Z70,
                            1766030.
                             393580.
                             852669,
                                           40 AIR-FIXED
                                           20 AIR-RETRACTABLE
                         5

                         5

                        60
343220,GAL*  J8.3FT DIA,   5
 38.3FT  HT, FLAKEG LASS-
LINED  CS

  82.HP                   5
1387,GPU  100FT HEAD,     10
  64.HP,  4  OPERATING
AND  6  SPARE

15601.GPM.  IOOFT HEAD,   15
 723,HP,  8 OPERATING
AND  7  SPARE

  240,GPM,  60 FT HEAD     8
   7,HP,  4 OPERATING
AND  4  SPARE

 3264.SCF1,   344.HP      6

19.4 FT DIA RING          5

 3467.GPM.  200,FT HEAD,  2
 292,HP,  1 OPERATING
AND  1  SPARE
4780547,

2646582,

 294910,
                             503611.


                             104710.
  34604.



 208405,

  95155.

  33153.
                                                                                 58350,
449402.

168382.

132512,
                                                                      373008,   301386.
           207414,


            32259.
1581315.    139356,
 11999.



  4693.

 41619.

  3740.
                           13998669,   1601313,

-------
Scrubbing Option

  Line No.                 Input data	

      9      1 0 0 0 35 .0000005 32 10 5.70 1 4 1 .1
             \
           ISCRUB

     The scrubbing option (ISCRUB) provides six separate scrubbing
systems that can be projected.  The ISCRUB values that can be used and
corresponding scrubber systems are as follows:

  1 - Spray tower (one effluent tank unless two tanks are specified
      by the forced-oxidation option, IFOX, on line 9)

  2 - TCA (one effluent tank unless two tanks are specified by the
      forced-oxidation option, IFOX, on line 9)

  3 - Venturi - spray tower with two effluent tanks (if forced oxida
      tion is specified by IFOX on line 9, IFOX must be equal to 2.

  4 - Venturi - spray tower with one effluent tank (if forced oxida
      tion is specified by IFOX on line 9, the number of tanks must
      agree with the number specified here)

  5 - Venturi - TCA with two effluent tanks (if forced oxidation is
      specified by IFOX on line 9, IFOX must be equal to 2.

  6 - Venturi - TCA with one effluent tank (if forced oxidation is
      specified by IFOX on line 9, the number of tanks must agree
      with the number specified here)

There are no specific material balance models for the venturi - TCA
scrubbing combination specified by options 5 and 6.  These options are
provided to allow comparative cost estimates for analysis and should
normally be used only in "force-through" mode (see the operating parameter
calculation option,  XSR, on line 7).  Example output showing the results
of specifying a spray tower is shown in the base case printout in Appendix D.
Example output showing the results of specifying a venturi - spray tower
with two effluent tanks is shown in Table 12.

Redundancy Options

  Line No.	Input data        	__

      9     1 0 0 0 35 .0000005 32 10 5.70 1 4 1 .1
                                          /   V
                                       NSPREP NOTRAN NOREDN

     Options for redundancy in the model apply to the raw material
preparation area and the scrubbing area.  The controlling input variables
are NSPREP, NOTRAN,  and NOREDN.  NSPREP specifies the number of spare

                                     34

-------
                                  TABLE  12.    VENTURI - SPRAY  TOWER  ABSORBER  COST  ILLUSTRATION
                                             SCRUBBING

                     INCLUDING  * OPERATING AND  1  SPARE  SCRUBBING TRAINS

                    ITEM                      DESCRIPTION         NO. MATERIAL     LABOR
01
I.D.  FAnS

VENTURI

SHELL
RUBBER  LINING
MIST  PLIMINATOR
SLURRY  HEADER AND NOZZLES

   TOTAL  SPRAY SCRUBBER COSTS

REHEATERS

SERS

VENTUKI  HOLD TANK


VENTURI  HOLD TihK AGITATOR

VENTURI  RECYCLE PUPPS


EFFLUFNT  HOLD TANK


EFFLUfNT  HOLD T4NK AGITATOR

ABSORBER  RFCYCLE PUMPS


MAKEUP  WATER PUMPS
                                        HP MOTOR AND  DRIVE
 it  AIR-FIXED
 20  tlR-RETWUBLE

 85768.GAL 19.4FT DIA«
 38.6FT HT/FLAKEGLASS-
LIlsEQ  CS

  58.HP

 693S.GPM 100 FT HEAD»
 321,HP 
-------
preparation units (ball mills for limestone or slakers for lime)  and may
be given any realistic value, 0,  1, 2, 3, ....  NOTRAN specifies  the
number of operating absorbers.  The model automatically overrides the
value of NOTRAN if the specified number requires an absorber larger than
the maximum available size.  NOREDN indicates the number of spare scrubbing
trains.  The base case equipment list in Appendix D (pp. D-18-20) shows
the output for a limestone scrubbing system designed with redundancy in
both ball mills and absorbers.  For comparison, Table 13 shows similar
output for a limestone system with no redundancy in the absorber  area.

Waste Disposal Option

  Line No.	Input data	

     10     10 9999 5000 0 25 5280 1 12 4.75
            /   X
         ISLUDG SDFEE

Four waste disposal options are provided in the model.  The input variables
are ISLUDG and SDFEE.  ISLUDG may take the values 1, 2, 3, or 4.   SDFEE
specifies the cost per dry ton to fix or treat the sludge.  When  ISLUDG
= 1 the model assumes an onsite ponding sludge disposal system.   If
ISLUDG = 2 a disposal system consisting of a gravity thickener and an
onsite pond is assumed.  For ISLUDG = 3 the disposal system includes
costs for a gravity thickener and fixation.  Total fixation and disposal
costs are input at $/ton of dry waste to be fixed using the SDFEE variable.
Option 4 is similar to option 3 except that a rotary vacuum filter is
added to the system downstream from the thickener and before fixation.
The fixation fee is applied in the same manner as for ISLUDG = 3; however,
in this case the material being fixed is the filter cake.  Typically,
SDFEE will be zero for options 1 and 2 but an additional fee for  fixation
of the sludge in the pond can be included by setting SDFEE equal  to the
desired fee value.  A summary of the ISLUDG options is as follows:

  1 - Onsite ponding

  2 - Gravity thickener and onsite ponding

  3 - Gravity thickener and fixation (the SDFEE variable is used  to
      specify the thickener underflow fixation fee expressed in $/ton
      of dry sludge to be fixed)

  4 - Same as option 3 plus a rotary vacuum filter  (the SDFEE variable
      is used to specify the filter cake fixation fee in $/ton of dry
      sludge to be fixed)

The base case printout in Appendix D (pp. D-16, -21) is an example of
the onsite ponding option.  Sample output for the other waste disposal
options are shown in Tables 14-16.  Annual revenue requirements correspond-
ing to waste disposal option 3 are shown in Table 17.
                                     36

-------
                          TABLE  13.    EXAMPLE RESULTS  SHOWING NO  REDUNDANCY
        ITEM
                                 SCRUBBING


                                 DESCRIPTION
                                                     NO. MATERIAL    LABOR
I.D. FANS


SHELL
RUBBER LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES

   TOTAL SPRAY SCRUBBER COSTS

REHEATERS

SOOTBLOMERS


EFFLUENT HOLD TANK



EFFLUENT HOLD TANK AGITATOR

COOLING SPRAY PUMPS



ABSORBER RECYCLE PUMPS



MAKEUP MATER PUMPS
  7.SIN  H20* WITH  631.
HP MOTOR AND DRIVE
                                                     4  2673986.
                                                                    46869.

4
4
8
1415222.
1413466.
315080.
682588.
3826376.
2118163.
239928.

359684
134797
146009
 12 AIR-FIXED
 16 AIR-RETRACTABLE
343449.GAL*  38.8FT DIA*  4   298938.   241219.
 38.8*1  HT» FLAKEGLASS-
LINED  CS

  82.HP                   4   404679.   132807.

1388.GPM 100FT HEAD/      8    83786.    29814.
  64.HP*  » OPERATING
AND 4 SPARE
19611.GPM.  100FT HEAD*
 723.HP*  8 OPERATING
AND  4  SPARE

 3469.GPM,  200.FT HEAD*
 Z4Z.HP,  1 OPERATING
AND  1  SPARE
                        12  1269917.    111918.
                                                          33169.
                                                                     3742.
TOTAL EOUIPMENT COST
                                                        10939738.  1202409.

-------
                                      TABLE  14.   EXAIIPLE  EQUIPMENT LIST  FOR  SLUDGE  OPTION  2
                                              vJASTE  DISPOSAL
                        ITEM
                                                  DESCRIPTION
                                                                     ND.  MATERIAL
                                                                                     LABOR
UJ
00
                ABSORBER BLEED  RECEIVING
                TANK
ABSORBER BLEED  TANK  AGITATOR

PDND FEED SLURRY  PU'lPS


PDNO SUPERNATE  PUMPS


THICKFNER FEED  PUMP


THICKENER


THICKENER OVERFLOW PUMPS


THICKFNER OVERFLOW TANK
 85768.GAL;  19.".FT OIA/
 38.8FT  HT,  FLA
-------
                TABLE  15.   EXAMPLE  EQUIPMENT  LIST  FOR  SLUDGE  OPTION 3
                             rfASTE DISPOSAL
        ITEM                      DESCRIPTION         NO, MATERIAL     LABOR
ABSORBER  BLEED RECEIVING       85768. GAL* I^.^FT  D:A*   i    29716.     2*56».
TANK                         3B,eFT HT* FLA. 60FT  HEAD*     Z    15815,      5195,
                              23, HP*  1 OPERATING
                            AND  1 SPARE

THICKENER                     23200. SO. FT, ,172, FT OIA* 1   <(53553.    *92801,
                              9.2TANK FT HT
                             11, RAKE HP

THlCKENfcR  OVERFLUW PUMPS        558. GPI*,  75. OFT  HEAD*  2    10337,      116ft.
                              IB, HP*  1 OPERATING
                            AND  1 SPARE

THICKENER  OVERFLOW T«NK         9213. GAL*  13.1FT DIA*  I     3261.      2230,
                              9.2FT HT

SLUDGE  FIXATION FEEU PUMP       263,GPM» SOFT  HEAD*     2     8717,      3121,
                               7, HP,  I OPERATING
                            AND  1 SP4P.E
TOTAL  EQUIPMENT CUST                                      555788,    J31904,

-------
                                      TABLE 16.   EXAMPLE  EQUIPMENT  LIST  FOR  SLUDGE  OPTION  4
                                           *ASTE DISPOSAL
                     urn
                                               DESCRIPTION
                                                                 NO. MATERIAL
                                                                                 LABDn
                      BLEED RECEIVING
             TANK
-P-
O
             ACSJRhEK BLtED  TANK  AGITATPK

             THICKINtR FEED  PUhP
             Ti-'ICKfNtR
             THICKRteR UNDERFLOW SLURRY
             PUMPS
             THICKPNtK  OVERFLOW PUMPS



             THICKENtR  CVFRHOW TANK


             FILTER FEED  TAilK
 e57fc8.GAL/ 19.4FT DIA/
 38.8FT HT» FLAKGLASS-
LINED CS
                                            848. GPM, 60FT  HEAD*
                                            2
-------
                                                TABLE  16  (continued)
FILTER FEED TANK
AGITATOR
FILTER FEED SLIPPY  PUMP
FILTER



FILTRATF PUMP  (PER  FILTER)



FILTRATE SURGE  TANK


FILTRATE SURGE  TANK PUfP



FILTEK CAKE  CONVEYOR




TOTAL EQUIPMENT COST
                                7.HP                   1     3159.      4ZJ.
  132.GPMi  SOFT HEAD/     3    Ild37.      3463.
   4.HP,   2 OPERATING
AND  1  SPARE

 350.SO FT  FILTRATION     3   367249,     07579.
AREA;    44. VACUUM HP
 2 OPERATING  AND  1 SPARE

  88.GPM/   20.OFT HEAD/   4    17193.      1940,
   l.HP/   2 OPERATING
AMD  2  SPARE
2891. GAL/ 7.9FT DIA/ 1 1573.
7.9FT HT
175. GPM. 85. OFT HEAD/ 2 9182.
6. HP/ 1 OPERATING
iC 1 SPARE
75 FT. HORIZONTAL 1 37108.
100 FT. INCLINE
1.5 HP
1075.

1036,


3453.


                                                         1009079.
                                                                    61537s.

-------
            TABLE 17.    EXAMPLE REVENUE REQUIREMENTS FOR  SLUDGE FIXATION ALTERNATIVE  (SLUDGE  OPTION  3)
            LIMESTONE  SLURRY PROCESS —  BASIS;   500

            PROJECTED  REVENUE KEJUIRfcMENTS - SLUDGE
                                                  SCRJPBING UNIT -  500 KW GENERATIuG UNlTj  1984 STARTUP
                                                                                                         CASE 004
•P-
hO
                                               DISPLAY SHEET  FDR YEAR*    1
                                             ANNUAL  OPERATION KK-HR/KW  «  5500

                                    34.89 TONS PER -4DLIR                        DRY
                                           TOTAL CAPITAL INVESTMENT     131600000
                    OIRfcCT COSTS

                     RAW MATERIAL

                       LI'lESTONE

                          SUBTOTAL RAK MATERIAL

                     C.UMVFRSICI. CI'STS
                                                         ANNUAL QUANTITY
153.4 K TONS
                                                                             UNIT COST>1
                  8.50/TON
                                SLUDGE
                                     TOTAL
                                     ANNUAL
                                     COST,*
                                    1304000

                                    1304000
OPFRATING LABOR AND
SUPERVISILN 356ZO.O MAN-HR IS.OO/MAN-HR
UTILITIFS
STEAM 546160.0 K LB 2.51/K L8
PROCFSS '/ATER 235000.0 K GAL 0.14/K GAL
FUECTRICITV 47403380.0 KWH 0.037/KWH
.1AIMTEN4NCF
LABOR AND MATERIAL
ANALYSES 4940.0 HR 21.00/HR
SUBTC1TAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
INDIRECT COSTS
OVERHEADS
PLANT AMD ADMINISTRATIVE ( 60, 3% OF CONVERSION COSTS LESS UTILITIES)
SLUDGE DISPOSAL FEE 191900.0 TONS 10.00/TON
FIRST YEAR OPERATING AND MAINTENANCE COSTS
LEVELIZEO CAPITAL CHARGES! 14.70!! DF TOTAL CAPITAL INVESTMENT)
FIRST VEAR ANNUAL REVENUE RE6U1REMENTS
EOUIVALENT FIRST YEAR UNIT REYEMUE REQUIREMENTS* MILLS/KWH (l-'W SCRUBBED)
LtVELIZEO OPERATING AND MAINTENANCE ( 1.886 TIMES FIRST YEAR OPER. (. MAIN.)
LEVELIZED CAPITAL CHARGES! 14.70* OF TOTAL CAPITAL INVESTMENT!
LEVELUED ANNUAL REVENUE REQUIREMENTS
EQUIVALENT LEVELIZED UNIT REVENUE REQUIREMENTS, MILLS/KWH (MW SCRUBBED)
HEAT RATE 9500. BTU/KWH - HEAT VALUE DF COAL 11700 BTU/LB
534300
1365400
32900
1733900
5776300
103800
9566600
10870600

3848600
1919000
16638200
19345200
35983400
13.08
31379600
19345200
50724BOO
16,45
COAL RATE 1116500 TONS/YR

-------
Pond Design Option

  Line No.             Input data

     10     10 9999 5000 0 25 5280 1 12 4.75
                 /      /   \
              PSAMAX PDEPTH PMXEXC
     The configuration for disposal ponds used in the model and shown in
Figure 2 is assumed to be square with a diverter dike that is three-
fourths the length of the sides.  Based on this configuration and the
volume of waste to be disposed of over the total life of the plant,  the
pond design option provides three different options for defining the
relationships between pond land area, excavation depth, and depth of
waste in the finished pond.  These options are as follows:

   Fixed depth pond

   Optimum pond based on minimum investment costs, subject to specified
   area limits, excavation limits, or both

   Optimum pond based on minimum investment costs

Three variables, PSAMAX, PDEPTH, and PMXEXC,  determine which pond option
is selected by the model.  The PSAMAX variable specifies the maximum
land area in acres available for the pond, the PDEPTH variable specifies
the ultimate depth of waste in the finished pond, and the PMXEXC variable
specifies the maximum depth of topsoil and subsoil (clay) that will  be
excavated and used for dike construction (excavation and dike construc-
tion calculations are based on the assumption that the excavated material
compacts to 85% of the original volume).  For a fixed depth pond, PSAMAX
should be set to zero, PDEPTH should be set to the desired depth, and
PMXEXC should be set to zero.  For an optimum pond based on minimum
investment costs but subject to area and excavation limits, PSAMAX
should be set to the maximum area in acres available for pond construc-
tion, PDEPTH should be set to zero, and PMXEXC should be set to the
maximum excavation depth allowed.  The final  option, optimum pond based
on minimum investment costs (no area and excavation limits) is essentially
the same as the second option except that the values specified for the
area and excavation limits should be set high enough that they will  not
realistically limit the optimized values, for example, PSAMAX = 9999 and
PMXEXC = 25.  The following variable values illustrate each of the pond
design options.

   PSAMAX = 0, PDEPTH = 10, PMXEXC = 0 - Fixed depth pond (pond area and
   excavation depth will be calculated by the model) .

   PSAMAX = 250, PDEPTH = 0, PMXEXC = 3 - Optimum pond based on minimum
   investment costs, but pond area cannot exceed 250 acres and excavation
   depth cannot exceed three feet (if the optimum pond does not exceed
   the specified area and excavation limits,  the values calculated by
   the model will be used, otherwise pond depth and the optimum value
   that is not exceeded will be adjusted as necessary).

                                     43

-------
-p-
-P-
f—
r
I
t
\
I
t
t
A T
t;
*
*
i
*
t
i
*-«-
^-.^, **,»«. »-..,
                                                                           GROUND LEVEL
                                                                               TOPSOIL
                                                                              EXCAVATION
                                                                               (15 FT.JN
                                                                                                                                                  '0% FREE BOARD
                                                                                                                                                        TOTAL
                                                                                                                                                    EXCAVATION DEPTH
                                                                                                                                 TOPSOIL '
                                                                                                                                EXCAVATION
                                                                                                                                 (15 FT)
                                                                                                                SECTION AA
                                                                                                            POND PERIMETER DIKE
                                                                                                                SECTION BB
                                                                                                            POND DIVERTER DIKE
 SUBSOIL
EXCAVATION
                                                                                                                                                  10% FREE BOARD
DEPTH OF SLUDGE
                                                                                                                                                  1   TOTAL
                                                                                                                                                    EXCAVATION DEPTH
      Figure  2.    Pond construction configuration.

-------
   PSAMAX = 9999, PDEPTH = 0, PMXEXC = 25 - Optimum pond based on mini-
   mum investment costs (pond area, depth, and excavation depth will all
   be calculated by the model).

When pond design option two is used and calculations indicate that the
total waste volume cannot be contained within the specified area and
excavation limits, an error message is issued and the data case is
terminated.  Example output showing the results of specifying an optimum
pond based on minimum investment costs is shown in the base case printout
in Appendix D (p. D-16).   Example output showing the results of specifying
an area limitation of 270 acres  is shown in Table 18.

Pond Liner Option

  Line No.               Input data	

     10     10 9999 5000 0 25 5280 1 12 4.75
                                 /   \   \
                              ILINER XLINA XLINB

     The pond liner option allows a choice of an unlined, clay-lined, or
synthetic-lined pond.  The input variables are ILINER, XLINA, and XLINB.
ILINER specifies the type of lining in the pond as illustrated below.

                             1 = Clay liner

                             2 = Synthetic liner

                             3 = No liner

     For a clay-lined pond (ILINER = 1), XLINA specifies the depth of
clay in inches and XLINB specifies the clay lining installation cost (or
the costs for reworking the clay subsoil into a lining) in $/yd^.  For
a synthetic-lined pond (ILINER = 2), XLINA specifies the liner material
cost in $/yd2 and XLINB specifies the installation cost in $/yd2.  For
no liner (ILINER = 3), XLINA and XLINB should be set to zero.

     Example output showing the  results of specifying a clay pond liner
is shown in the base case printout in Appendix D (p. D-16).  Example
output showing the results of specifying a synthetic pond liner is shown
in Table 19.  The input values for the synthetic liner were ILINER = 2,
XLINA = 4.00, and XLINB = 1.50.

Economic Premises Option

  Line No.  	Input data	

     11     7 2 16 5 10 8 15.6 10 8 3 6 1 60 1.886 14.7 0.0

                          IECON  PCTOVR XLEVEL CAPCHG PCTMKT

                                         or     or     or

                                       PCTADM UNDCAP PCTINS
                                    45

-------
                TABLE 18.   EXAMPLE  OF  OPTIMUM POND  SUBJECT  TO AREA LIMITS
                     POND DESIGN


    OPTIMIZED TO  MINIMIZE TOTAL  COST PLUS OVERHEAD

         WITH POND SITE ACREAGE  CONSTRAINT



POND DIMENSIONS
DEPTH OF PONO
DEPTH OF EXCAVATION
LENGTH OF DIVIDER DIKE
LENGTH OF PONO  PERIMETER DIKE
LENGTH OF POND  PERIMETER FENCE

SURFACE AREA  OF  BOTTOM
SUPFSCE AREA  OF  INSIDE WALLS
SURFACE AREA  OF  OUTSIDE WALLS
SURFACE AREA  OF  RECLAIM STORAGE
LAND AREA OF  POND
LAND AREA OF  PONC SITE
LAND AREA OF  POND SITE

VOLUME OF EXCAVATION
VOLUME OF RECLAIM STORAGE
VOLUME OF SLUDGE TO BE
DISPOSED OVER LIFE OF PLANT
45.36
10.93
3078.
11804.
13227.
756.
217.
173.
93.
954.
1307.
270.
FT
FT
FT
FT
FT
THOUSAND
THOUSAND
THOUSAND
THOUSAND
THOUSAND
THOUSAND
ACRES





YD2
Y02
YD2
Y02
Y02
YD2

 3001.   THOUSAND YDS
  571.   THOUSAND YD3
12900.   THOUSAND YD3
 7996.   ACRE FT
POND COSTS  (THOUSANDS OF  DOLLARS)
                                 LABOR
                                          MATERIAL   TOTAL
CLEARING LAND
EXCAVATION
DIKE CONSTRUCTION
LINING! 12. IN. CLAY)
SODDING DIKE WALLS
ROAD CONSTRUCTION
PERIMETER COSTS. FENCE
RECLAMATION EXPENSE
MONITOR WELLS
SUBTOTAL DIRECT
TAX AND FREIGHT
POND CONSTRUCTION
LAND COST
POND SITE
OVERHEAD
528.
8998.
6335.
1541.
214.
27.
66.
710.
4.
18422.

18422.







135.
8.
132.

4.
279.
21.
300.



528.
8998.
6335.
1541.
349.
35.
198.
710.
8.
18701.
21.
18722.
1350.
20072.
8894.
TOTAL
                                                   28966.

-------
                           TABLE  19.   SYNTHETIC  POND  LINER  EXAMPLE
    OPTIMIZED TO
                     POND  DESIGN


                    MIZE  TOTAL COST PLUS OVERHEAD
POND DIMENSIONS
OfcPTh (IF  PONU
PERTH UF  EXCAVATION
LF'"GTH OF DIVIDED DIKE
lOhTH OF PONU PERIMETER DIKE
LENGTH OF POND PERIMETER FENCE

SURF-ACE AREA Of tOTTOM
SURFACE AREA Of INSIDE HALLS
SURFACE APEA OF OUTSIDE .(ALLS
SURFACE AREA OF nECLAl" STORAGE
1 AND AREA OF PUNC
LAMP AREA OF POND SITE
L or.fj AREA Of- POND SITE

VOLU"E UF EXCAVATION
VOlU"t OF RECLAIM STORAGE
VClU^t OF SLUDGE TO HE
PISPOStD  OVER LIFE CF PLANT
33.06
6.27
2434.
13530.
14717.
lOflO.
193.
14«.
109.
1256.
1612.
333.
FT
FT
FT
FT
FT
THOUSAND
THOUSAND
THOUSAND
THOUSAND
THOUSAND
THOUSAND
ACRES





Y02
VD2
rD2
YD2
YD2
Y02

 2442.   TMOUSAND YDS
  712.   THOUSAND YD3
12900.   THOUSAND vua
 7996.   ACHE FT
     COSTS  (THOUbANCS OF DOLLARS)
                                 LAHOP.
                                          MATERIAL    TOTAL
TLE A^ ING LAND
FXCAVAT [ON
MVF CONMK'OCTION
1 IK IKfalSrNTHtTIC)
SODDING HIKE HALLS
^?OAU CCJNSTRUCT ION
DFRI^tTER COSTS. FFNCE
RECLAMATION EXPENSE
^•0^1TOR rfFLLb
SUPTOTAL DIRECT
TAX ANU FREIGHT
P0l>0 CONSTRUCTION
LAND COST
POM) SITE
OVf RHEAf)
651.
732?.
45H.
190H.
114.
31.
74.
923.
4 .
1553H.

15531.






5089.
72.
9.
147.

4.
5321.
399.
5720.



651.
7322.
»SH.
6997.
186.
40.
2?1.
9?3.
a.
20859.
399.
21258.
1665.
22923.
10099.
                                                    330P2.

-------
     The economic premises option (IECON) allows cost projections based
on either the EPA-TVA economic premises adopted December 5, 1979 (and
expanded and amplified in March 1980), or the old premises that were
used prior to December 5, 1979.  Appendix B contains a description of
the revised premises.  Four variables are used in conjunction with the
economic premises option, and the meaning of these variables depends on
which set of premises is selected (see Appendix B).  If the revised
premises are specified (IECON = 1), the PCTOVR variable specifies the
plant administrative overhead rate, applied as a percent of conversion
costs less utilities, the XLEVEL variable specifies the levelizing
factor to be applied to first-year operating and maintenance costs to
develop levelized operating and maintenance costs for the total life of
the plant, the CAPCHG variable specifies levelized annual capital charges
applied as a percent of total capital investment, and the PCTMKT variable
specifies marketing costs applied as a percent of byproduct credit
(applies only to processes with a salable byproduct).  If the levelizing
factor (XLEVEL) is set to zero then a lifetime revenue sheet is printed
showing annual revenue requirements for each year of plant operation.
If the old premises (used before December 1979) are specified (IECON = 0),
the PCTOVR variable specifies the plant overhead rate, applied as a
percent of conversion costs less utilities, the PCTADM variable specifies
the administrative research and service overhead rate, applied as a
percent of operating labor and supervision, the UNDCAP variable specifies
the annual capital charge basis for undepreciated investment, and the
PCTINS variable specifies the rate for insurance and interim replacements,
applied as a percent of total capital investment.  Example output showing
the results of specifying the new economic premises (IECON = 1) and a
nonzero levelizing factor (XLEVEL = 1.886) is shown in the base case
printout in Appendix D (pp. D-22, -24).  The results of specifying a
zero levelizing factor are shown in the example revenue requirements in
Table 20.  The results of specifying the old economic premises are shown
in the example revenue requirements in Table 21.
Sales Tax and Freight Option

  Line No.             Input data	

     12     1 4 3.5 6 0 1 1.5 1 2 1 8 5 10 0

         ITAXFR TXRATE FRRATE
     The sales tax and freight option (ITAXFR) allows sales tax and
freight to be applied as a percentage of material costs.  The sales tax
rate is specified with the variable TXRATE, and the freight rate is
specified with the FRRATE variable.  When ITAXFR is set to 1, the speci-
fied rates are applied to material costs and included in the capital
investment summary printout; when ITAXFR is set to zero sales tax and
freight are excluded.  Example output showing the results of specifying
sales tax and freight is shown on the capital investment summary sheet
in the base case printout in Appendix D (p. D-22).  An example invest-
ment summary sheet showing sales tax and freight excluded is shown in
Table 22.

                                     48

-------
TABLE 20.   EXAILPLE  REVENUE REQUIREMENTS USING  THE NEW ECONOMIC PREMISES  WITH  NO LEVELIZING
 LIMESTJNE SLURRY PROCESS — SASISI  soo  in SCRUBBING UNIT -  soo MW GENERATING UNIT* 1984 STARTUP
 PROJECTED REVENUE REQUIREMENTS - ZERO LE^AL
                                                                                    CASE ooa
DISPLAY SHEET FOR YEAR* 1
ANNUAL OPERATION KW-HR/KW « 5500
34.89 TONS fiK HOUR DRY
TOTAL CAPITAL INVESTMENT 109013000
ANNUAL QUANTITY UNIT COST,*
DIRECT COSTS
RAW ".ATERIAL
LIMESTONE
SUBTOTAL RAV> MATERIAL
CO'JVrkSIO'J COSTS
OPERATING LABOR AND
SllPERYISIlTI
UTILITIES
STEA"'
PROCESS '»ATEP
ELECTRICITY
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
INDIRECT COSTS
153.4 K TUNS 8.50/TON
30680.0 MAN-HR 15.00/MAN-HR
546160.0 K LB 2.50/K LB
E39930.0 K GAL 0.14/K GAL
47526160.0 KWH 0.037/KWH
4940,0 HR 21.00/HR
OVERHEADS
PLA.lT AND ADHrilSTRAriVE ( 60. OX OF CONVERSIuN COSTS LESS UTILITIES)
FIRST YEAK DPfcRATING AND MAINTENAMCE COSTS
LEVELIZEO CAPITAL CHARGES! 14.70X OF TOTAL CAPITAL INVESTMENT)
FIRST YEAR ANNUAL REVENUE REOUI REMENTS
EQUIVALENT FIRST YEA" UNIT REVENUE REOUIP.EMENTS/ MILLS/KWH (MW SCRUBBED)
HEAT RATE 9500. BTU/KWH
HEAT VALUE OF CUAL 11700 BTU/LB
SLUDGE
TOTAL
ANNUAL
COST/$
1304000
1304000
460200
1365400
36400
1758900
4130100
103800
7854400
9158400
2816500
1197*900
16025000
27999900
10,18
COAL HATE 1116500 TONS/YR
                                                (continued)

-------
                                                            TABLE  20  (continued)
O
             Ll'iEST.INt  SLURRY PROCESS — 8ASISI  500 "I IV SCRUBBING UNIT -  500 Mw GENERATIiG UNIT/ 198*1 STARTUP
             PROJECTED  LIFET'l'.F RtVE'liF  REQU! REI1E ill 5 " ZFAJ  LEVAL
                                                           TOTAL CAPITAL INVESTMENT!   »  109014000
CASE 008
ADJUSTED GROSS


YEARi

PLUE^
UNIT
START
1

3

5

7

9
I'/
1 1
12
13
14
11

17

19
20
21
22
23
2«
25

27
a
29
30
TD1


/. N 00
5iOO
5300
5300
5500
1()5.>00
LIFCTIME




KE>/E'«




SJLFUR
PEEVED
L P'MER ""IT PUhER UNIT BY
HfcAT FUEL PDILJTI3N
RKjUIPtME"T> CONSUMPTION, CuNTROL
MILLlni. BTu TONS COAL PKUCESSj
/YFAk /YEAR TJ'iS/Y6AR
26125000 1116500 30600
26125000 11165JO 30600
26125000 1116500 30600
26123000 1116500 30600
26125000 1116500 30600
26125000 1116500 3"600
26125000 1116500 30600
261250CO 1116500 30600
2612500? 1116500 30600
26125000 11165"0 30600
Z61Zi>000 1116500 30000
26125000 1116500 30600
26125000 11165-10 30600
26125000 11165'10 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 11165.)0 3D600
2612500" 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
,-6125000 11165"0 30600
26125000 1116500 31.600
26125000 11165CO 30600
26125000 1116300 30hOO
2617.5000 1116500 3O600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
7*3750001 33495000 91BOOO
AVERAGE INCRF.ASf IN UNIT REVENUE REQUIREMENT
DOLLARS PER TON OF C3AL BUdNEQ
NILLb PfR KILOWATT-H3UR
CENTi PFR MILLION 8TJ HEAT INPUT
DOLLARS PER TCN DF SJLFUR REMOVED
Uf , . U
i.. . 0
; ,o
0.0
0,0
I'.O
L..O
0.0
0.0
') , 0
L , 0
r.,u
0.0
{;, 0
0,0
J,0
U.O
(. ,0
o.o
0.0
u.t-
f. .0
U.O
y.o
t, ,0
0,0
i, ,0
0,0
0,0
0,0







REQUIREMENT
EXCLUDING
SLUDGE
FIXATION
COST,
J/YEAR
27999900
28718500
29479900
30Z87200
31142800
32050100
33011400
34030700
35110900
36256200
37470100
38756700
40120700
41566600
43099100
44723300
4644S100
48270500
50205300
52256300
54429800
56734200
59176800
61765BOO
64510200
67419300
70503100
73771700
77236500
60909400
1427458000

42.62
17.30
182.13
1554,97
351898600
LEVELtZEr* INCREASE Hi UNIT REVENUE RESUIRfcMENT EQUIVALENT TU DISCOUNTED REOUJREMENT OVER LIFE




UNIT




CHSTS
DOLLARS PER TON OF C3AL BURNED
HILLS PER KILOWATT-H3UR
CENTS PER MILLION BTJ HEAT INPUT
DOLLARS PER TON OF SJLFUR REMOVED
INFLATED AT 6, OCX PER YEAR










33.43
13.57
142.89
1219.75

TOTAL
ANNUAL
SLUDGE
FIXATION
COST,
*/YEAR
0
0
0
0
0
0
0
0
0
D
0
y
0
0
0
0
0
3
0
0
0
0
0
0
0
0
0
0
0
0
0

0.0
0.0
0.0
0.0
0
DF POKES
0.0
0,0
0.0
0,0

NET ANNUAL
INCREASE
IN TUTAL
REVENUE
RE3UIREMENT,
1
27999900
28718500
29479900
30Z37ZOO
31142800
320S0100
33011400
34030700
35110900
36256200
37470100
38756700
40120700
41566600
43099100
44723300
46445100
48270500
50205300
52256200
54429800
56734200
59176800
61765BOO
64510200
67419300
70503100
73771700
77236500
80909400
1427458000

42.62
17.30
182.13
1554.97
351898600
UNIT
33.43
13.57
142.89
1219.75

CUMULATIVE
NET INCREASE
IN TUTAL
REVENUE
REQUIREMENT/
t
Z7999900
56718400
36198300
116485500
147628300
179678400
212689800
246720500
281831400
318087600
355557700
394314400
434435100
476001700
519100800
563824100
610269200
658539700
708745000
761001200
815431000
B72165200
931342000
993107800
1057618000
1125037300
1195540400
1269312100
1346548600
1427458000














-------
             TABLE  21.   EXAMPLE REVENUE  REQUIREMENTS USING THE  OLD ECONOMIC PREMISES
LIMESTONE SLURRY PRHCESS — BASISl  500 1W SCRUBBING UNIT -
PROJECTED REVENUE REQUIREMENTS - OLD PREIISE
       500 MW GENERATING UNIT*  198* STARTUP
                                                                                              CASE 009
                                   DISPLAY  SHEET FDR YEARn    1
                                  ANNUAL OPERATION KW-HR/KW »  5500

                        34,89 TONS  PER HOUR                        DRY
                               TOTAL CAPITAL  INVESTMENT       99172000
        DIRECT COSTS

          PAW '-1ATERIAL

            LIMESTONE

              SUBTUTAL RAV MATERIAL

          C'lNVERSIHN COSTS
                                             ANNUAL QUANTITY
153.* K TONS
                                                                  UNIT COST»»
                  8.SO/TON
                                SLUDGE
                                     TOTAL
                                     ANNUAL
                                     COST,*
                                    1304000

                                    1304000
UPtRATIUG LABOR AND
SUPERVISION 30680.0 MAN-HR IS.CO/MAN-HR
UTILITIES
STEA" 5461&P.O K LB 2.5G/K L8
PROCESS ^.ATER 259970.0 K GAL 0.14/K GAL
ELECTRICITY 47526120.0 KWH 0.037/KKH
t'AINTENANCF
LtBOP AND MATERIAL
ANALYSES 4380.0 HR 21.00/HR
SUBTOTAL CONVERSION COSTS
SUBTUTAL DIRECT COSTS
INDIRECT COSTS
DEPPEC IATIDN
CuST JF CAPITAL AMD TAXES< 17.20* OF UNDEPRECIATED INVESTMENT
INSURANCE L INTERIM REPLACEMENTS* 1.17* OF TOTAL CAPITAL INVESTMENT
PVERHEAD
PLAUT, 50,o!i HP CONVERSION COSTS LESS UTILITIES
ADMINISTRATIVE. RESEARCH, AID SERVICE*
10. 0* OF OPERATING LABOR AND SUPERVISION
SUBTUTAL INDIRECT COSTS
TOTAL ANNUAL REVENUE REQUIREMENT
EQUIVALENT UNIT REVENUE REQUIREMENT,- MILLS/KrfH
HEAT RATE 9500. BTU/KWM - HEAT VALUE OF COAL 11700 bTU/LB
460200
1365400
36400
1758500
3299600
92000
7012100
8316100
3173700
17057700
1160300
1925900
46000
23365600
31681700
11.52
COAL RATE 1116500 TONS/YR
                                                     (continued)

-------
                                               TABLE 21  (continued)
LHESTUN6 SLURRY PROCESS —• BAStSI  500 1H SCRJBBING UNIT -   3OO MW GENERATING UNIT/ 198* STARTUP




PROJECTED LIFETIME  REVENUE REQUIREMENTS - QLO  PREMISE



                                             TOTAL CAPITAL INVESTMENTI   t   99172000
CASE  009
YEARS iNIJUAL
AFTER UPERA-
POWE* TI3N,
UNIT KW-HR
START /KW
I 5500
2 5500
3 5500
4 5500
5 5JOO
6 5500
7 5300
B 5500
9 5500
10 5500
11 5500
12 5500
13 5500
14 5500
15 5500
16 5500
17 5500
15 5500
19 5500
20 5500
21 5300
22 5500
23 5500
2* 5500
25 5500
26 5500
27 5500
2tJ 5500
29 5500
30 5500
TOT 165-100
LIFETIME




ADJUSTED GROSS
SULFUR BYPRODUCT ANNUAL REVENUE
REMOVED RATE* SLUDGE REOLIREMENT TOTAL
PHWER UNIT POWER UNIT BY EQUIVALENT FIXATION FEE EXCLUDING ANNUAL
HEAT FUEL POLLUTION TONS/YEAR I/TOM SLUDGE SLUDGE
REQUIREMENT, CONSUMPTION/ CQNTRUL FIXATION FIXATION
MILLION BTU TONS COAL PROCESS* DRY DRY COST/ COST*
/YEAR /YEAR TONS/YEAR SLU06E
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
P6125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26123000 1116510 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
26125000 1116500 30600
783750000 33495000 918000
AVERAGE INCREASE IN UNIT REVENUE REQUIREMENT
DOLLARS PER TON OF C3AL BURNED
MILLS PER KILQWATT-H3UR
CENTS PER MILLION BTJ HEAT INPUT
DOLLARS PER TON OF SJLFUR REMOVED
REVENUE KEOUIREMENT DISCOUNTED AT 10. OX TO INITIAL YEAR*
LEVELUED




191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
191900
5757000





DOLLARS
INCREASE IN UNIT REVENUE REQUIREMENT EQUIVALENT TO DISCOUNTED
DOLLARS PER TON OF C3AL BURNED
HILLS PER KILOWATT-H3UR
CENTS PER MILLION BTJ HEAT INPUT
DOLLARS PER TON OF SJLFUR REMOVED




SLUDGE
0.0
U.O
0,0
L.O
U.O
(J.U
nO
r ,o
0 .0
O.P
0,0
u.O
0.0
0,0
o.o
0,0
0,0
0,0
1..0
u.o
o.o
0,0
t'.O
u.O
0.0
0,0
0,0
o.o
0.0
0.0







REQUIREMENT




I/YEAR
31681700
'1133400
30989200
30043000
29496600
26950600
23404300
27858100
27311900
26763700
26219500
25673200
25127000
2*580600
24034600
23486400
22942100
22395900
21849700
21303500
20757300
20211000
19664800
19118600
18572400
16026200
17479900
16933700
16387500
15841300
712844100

21.28
8.64
90.95
776.52
256559500
OVER LIFE
24.38
9.90
104.17
889.29
t/YEAR
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
o
9
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0.0
0.0
0.0
0.0
0
OF POWER
0.0
0.0
0.0
0.0
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
IN TOTAL IN TOTAL
REVENUE REVENUE
REQUIREMENT, REQUIREMENT*
i
31681700
31135400
305H9200
300*3000
29496600
28950600
28404300
27858100
27311900
267*5700
26219500
25673200
25127000
249HC800
24034600
234X8400
22942100
22395900
21849700
21303500
20757300
20211000
19664600
19118600
18572400
18026200
17479900
16933700
16387300
13841300
712644100

21.26
8.64
90,95
776.32
256339500
UNIT
24.38
9.90
104,17
889.29
1
31681700
62817100
93406300
123449300
152946100
181896700
210301000
238159100
263471000
292236700
318436200
344129400
369256400
393837200
417871800
441360200
464302300
486698200
308547900
529851400
550608700
570819700
390484300
609603100
628175300
646201700
663681600
680615300
697002800
712844100













-------
                TABLE 22.   EXAMPLE INVESTMENT SUMMARY SHEET WITH  SALES  TAX AND FREIGHT EXCLUDED
                                                                               STARTUP
Ul
PROJECTED CAPITAL INVESTMENT REQUIREMENTS - NO



EOUIPMENT
MATERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTWORK
MATERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
BUILDINGS
MATERIAL
LABOR
TOTAL PROCESS CAPITAL
SERVICES AND MISCELLANEOUS ( 6.0 X)
TOTAL DIRECT PROCESS INVESTMENT
POND CONSTRUCTION MATERIAL
POND CONSTRUCTION LABOR
TOTAL DIRECT ?OND INVESTMENT
TOTAL DIRECT INVESTMENT
ENGINEERING DESIGN AND SUPERVISION ( 7.0 X)
ARCHITECT AND ENGINEERING CONTRACTOR ( 2.0 X)
CONSTRUCTION EXPENSES (16.0 X)
CONTRACTOR FEES I 5.0 X)
CONTINGENCY (10.0 X)
POND INDIRECTS ! 2.0/ 1.0* 8.0* 3iO* 10.0 X)
SUBTOTAL FIXED INVESTMENT
STARTUP t MODIFICATION ALLOWANCE c t.o* o.o x>
INTEREST DURING CONSTRUCTION 113.6 X)
ROYALTIES ( 0.0 X)
LAND
WORKING CAPITAL
TAX OR FREIGHT
INVESTMENT*
RAW MATERIAL
PREPARATION

3049.
307.

416.
192.

0.
0.

341.
883.

196.
142.

262.
737.

148.
22.

147.
163.
7024.
421.
7443.
0.
0.
0.
7449.
321.
149.
1191.
372.
968.
0.
10647.
832.
1661.
0.
10.
401.

THOUSANDS OF

SCRUBBING

13666.
1544.

3132.
918.

3042.
2723.

172.
374.

372.
648.

813.
1567.

814.
131.

0.
0.
319J7.
1916.
33854.
0.
0.
0.
33834.
2370.
677.
3417.
1693.
4401.
0.
48411.
3873.
7532.
0.
4.
1825.

1912 DOLLARS
WASTE
DISPOSAL

93.
34.

1056.
352.

0.
0.

20.
42.

2.
3.

146.
318.

13.
9.

0.
0.
2092.
126.
2218.
303.
14917.
13219.
17437.
153.
44.
353.
111.
288.
4201.
22591.
254.
3924.
0.
2120.
940.



TOTAL

16810.
1884.

6627.
1461.

3042.
2723.

534.
1299.

570.
794.

1221.
2641.

975.
162.

147.
163.
41053.
2463.
43517.
303.
14917.
13219.
58736.
3046.
870.
6963.
2176.
9637.
4201.
81649.
4978.
12737.
0.
2134.
3166.
CASE 002
DISTRIBUTION
DOLLARS
PER KW

33.62
3.77

13.25
2.92

6.06
5.45

1.07
2.60

1.14
1.39

2.44
5.28

1.95
0.32

0.29
0.33
82.11
4.93
87.03
0.61
29.83
30.44
117.47
6.09
1.74
13.93
4.35
11.31
8.40
163.30
9.96
23.47
0.0
4.27
6.33
         TOTAL CAPITAL INVESTMENT
                                              13371.
                                                          61665.
                                                                     29429.
                                                                                104665.
                                                                                             209.33

-------
Overtime Option
  Line No .   _    Input data

     12     1 4 3.5 6 0 1 1.5 1 2 1 8 5 10 0
                       /    \
                   IOTIME OTRATE
     The overtime option (IOTIME) allows an overtime labor rate (OTRATE)
to be applied to 7% of total labor as defined in the new TVA-EPA premises
(Appendix B) .   When IOTIME is set to 1, the specified overtime rate is
applied to 7% of all applicable labor costs; when IOTIME is set to zero
no overtime labor adjustments are made.  The added costs for overtime
labor are not shown separately in the model output, but a message is
printed in the listing of the model inputs to indicate if overtime is
specified as shown in the base case printout in Appendix D (p. D-6) .

Separate Pond Construction Indirect Investment Factors Option

  Line No.  __ _ Input data _
     12     143.56011.512185 10^

             INDPND PENGIN PARCH PFLDEX PFEES PCONT PSTART

     The separate pond construction indirect investment factors option
(INDPND) allows pond construction indirect investment to be calculated
separately from process indirect investment.  Pond construction is in
general less complex than the scrubbing process and therefore indirect
investment factors are usually lower.  Six variables are used in conjunc-
tion with the separate pond indirect investment option.  They correspond
one-for-one with the process indirect investment factors (line 11:
ENGIN, ARCTEC, FLDEXP, FEES, CONT, and START).  The PENGIN variable
specifies pond engineering design and supervision costs, applied as a
percentage of total direct pond investment.   The PARCH variable specifies
pond architectural and engineering contractor costs, applied as a percentage
of total direct pond investment.  The PFLDEX variable specifies pond con-
struction field expenses, applied as a percentage of total direct pond
investment.  The PFEES variable specifies pond contractor fees, applied
as a percentage of total direct pond investment.  The PCONT variable
specifies pond contingencies, but the way it is applied depends on the
economic premises option (line 11, IECON).  If the new economic premises
are specified (IECON = 1) then pond contingency is applied as a percentage
of total direct pond investment plus each of the preceding four pond
indirect investment costs.  If the old economic premises are specified
(IECON = 0) then pond contingency is applied as a percentage of total
direct pond investment only.  The PSTART variable specifies the allowance
for pond startup and modification, applied as a percentage of total
fixed pond investment.  Example output showing the results of specifying
separate indirect investment factors for pond construction (INDPND = 1)
is shown on the investment summary sheet in the base case printout in
Appendix D (p. D-22).  Example output showing the results of using

                                     54

-------
common indirect investment factors for both the FGD process and pond
construction (INDPND = 0) is shown in Table 23.

Pond Capacity Option

  Line No.	     Input data	

     14     4 1 5 .8 1.0 3 .65 1 1 1.10 1982 297.9

              \
            PNDCAP

     The pond capacity option provides the capability to design the raw
material and scrubbing areas based on maximum sulfur content of coal
(high sulfur content fluctuation) but, at the same time, to design the
pond based on an average sulfur content.  For example, on a long-term
basis, the coal being used may be expected to average 2.0% sulfur.
However, at times the sulfur content may be as high as 3%.  The raw
material preparation area and the scrubbing area should be sized for the
maximum coal sulfur content that is expected to be encountered.  In this
case a value of 3% must be considered for design of the feed preparation
and absorber units, but the model also calculates the sludge production
rate based on the input sulfur content and sizes the pond based on that
amount.  The PNDCAP option is included in the model to allow the projected
waste disposal pond size to be modified to account for the difference
between average and maximum sulfur content (ordinarily PNDCAP will be in
the range of 0.5-1.0).  In the preceding example, by specifying PNDCAP
equal to 0.67, the waste disposal pond would be sized based on a 2%
sulfur coal, whereas the other facilities would be designed for fluctu-
ations in coal sulfur content of up to 3%.

     If the user wishes to specify an oversized pond to cover contingencies
in sulfur content, or to specify an undersized pond for applications in
which the initial pond is not designed for the full life of the plant, an
appropriate PNDCAP factor, i.e., greater than or less than 1.0, can be
specified.

Operating Profile Option

  Line No.	Input data	

     14     3 1 5 .8 1.0 3 .65 1 1 1.10 1982 297.9
            \
          IOPSCH

     15     30
          IYRC
     One of the most important variables affecting the economics  of a
power plant and an associated FGD system is the operating profile (number
of years of operation and the hours of operation per year)  over the life
of the unit.  The effects of the year-by-year profile on investment and

                                     55

-------
TABLE 23.   EXAMPLE INVESTMENT  SUMMARY  SHEET WITH COMMON INDIRECT  INVESTMENT FACTORS FOR PROCESS AND POND
                                                          500 MH GENERATING UNIT.. 1984 STARTUP
PROJECTED CAPITAL INVESTMENT REQUIREMENTS - COMMON INDIRECTS



EOUIPMSNT
MATERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTWORK
MATERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
BUILDINGS
MATERIAL
LABOR
SALES TAX ( 4.0 X) AND FREIGHT ( 3.3 X)
TOTAL PROCESS CAPITAL
SERVICES AND MISCELLANEOUS ( 6,0 X)
TOTAL DIRECT PROCESS INVESTMENT
POND CONSTRUCTION MATERIAL
POND CONSTRUCTION LABOR
POND SALBS TAX ( 4.0 X) AND FREIGHT < 3.5 X)
TOTAL DIRECT POND INVESTMENT
TOTAL DIRECT INVESTMENT
ENGINEIRING DESIGN AND SUPERVISION ( 7,0 X)
ARCHITECT AND ENGINEERING CONTRACTOR ( 2,0 X)
CONSTRUCTION EXPENSES (16.0 X)
CONTRACTOR FEES I 5.0 X)
CONTINGENCY (10.0 X>
SUBTOTAL FIXED INVESTMENT
STARTUP £ MODIFICATION ALLOWANCE ( 8.0 X)
INTEREST DURING CONSTRUCTION (15.6 X)
ROYALTIES < o.o x>
LAND
WORKING CAPITAL
INVESTMENT;
RAW MATERIAL
PREPARATION

3049.
307.

416.
192.

0.
0.

341.
883.

196.
1*2.

262.
757.

148.
22.

147.
163.
342.
7366.
442.
7808.
0.
0.
0.
0.
7808.
347.
136.
1249.
390.
1015.
U165.
893.
1742.
0.
10.
418.
THOUSANDS OF

SCRUBBING

13666.
1544.

5152.
918.

3042.
2723.

m.
374.

372.
648.

813.
1566.

814.
131.

0.
0.
1802.
33740.
2024.
35764.
0.
0.
0.
0.
35764.
2504.
715.
57Z2.
1788.
4649.
51U3.
4091.
7978.
0.
4.
1917.
1982 DOLLARS
WASTE
DISPOSAL

93.
34.

1058.
352.

0.
0.

20.
42.

2.
3.

146.
318.

13.
9.

0.
0.
loo.
2192.
132.
2324.
303.
14903.
23.
15231.
1755S.
1229.
46.
2809.
878.
2252.
Z4T6B.
1981.
3864.
0.
2137.
941.


TOTAL

16810.
1884,

6626.
1461.

3042.
2723.

534.
1299.

57o.
794.

1221.
2641.

975.
162.

1*7.
163.
2244.
43298.
2598.
43896.
303.
14905.
23.
15231.
61127.
4279.
918.
9780.
3056.
7916.
87076,
6966.
13584.
0.
2132.
1276.
CASE 003
DISTRIBUTION
DOLLARS
PER KW

33.62
3.77

13.25
2.92

6.08
5.45

1.07
2.60

1.14
1.39

2.44
5.28

1.95
0.32

0.29
0.33
4.49
86.60
5.2D
91.79
0.61
29.81
0.05
30.46
122.25
8.56
1.8*
19.36
6.11
15.83
174.13
13.93
27.17
0.0
4.30
6.35
          TOTAL CAPITAL INVESTMENT
                                               1*229.
                                                           63133.
                                                                      1369Z.
                                                                                 11105*.
                                                                                             226.11

-------
revenue requirements are determined by the economic premises option
(line 11, IECON),  the operating and maintenance cost levelizing factor
(line 11, XLEVEL)  used with the new economic premises,  and the waste
disposal option (line 10, ISLUDG).   The model provides  four options for
specifying this profile.  The input variable for these  options is IOPSCH.
If IOPSCH = 1 the  program uses the  TVA-developed operating schedule
shown in Figure 3  which is based on the profile assumed in Detailed Cost
Estimates for Advanced Effluent Desulfurization Processes (G.  G.  McGlamery
et al., 1975).  If IOPSCH = 2 the operating schedule is based on historical
Federal Energy Regulatory Commission (FERC, previously  FPC) data as
shown in Figure 4.  If IOPSCH = 3 the user must input the operating
profile as shown below.  If IOPSCH = 4 a levelized operating profile of
5500 hours per year is used (see Appendix D).  A 30-year operating life
is assumed unless  a year-by-year operating profile is provided by the
user.  When the operating profile is specified by the user (IOPSCH = 3),
the IYROP variable on line 15 specifies the projected operating life in
years and cannot exceed 50.  Beginning on line 16, the  total number of
hours-per-year entries must be equal to the value of IYROP.  The number
of entries per line must not exceed 10.  Less than 10 entries are allowed
on the last line only, depending on the number of years required.  An
example of using 25 years is shown below.

  Line No.	    Input data	
     14     3 1 5 .8 1.0 3 .65 1 1 1.10 1982 297.9

     15     25

     16     5000 5000 6000 6000 7000 7000 7000 7000 7000 7000

     17     7000 7000 7000 7000 7000 7000 7000 7000 6000 6000

     18     6000 5000 5000 5000 4000

     19     END

If levelized operating and maintenance costs under the new premises are
being used, a levelizing factor (line 11, XLEVEL) that corresponds to
the operating profile should be used.

     Example output resulting from the Figure 3 operating profile
(IOPSCH = 1) is shown in Table 24.  Table 25 illustrates the results of
the Figure 4 FERC data operating profile (IOPSCH = 2).  Example output
resulting from a user-supplied operating profile (IOPSCH =3) is shown in
Table 26.  The base case printout in Appendix D (p. D-24) shows the
results of specifying a levelized operating profile of 5,500 hours per
year.
                                     57

-------
    30
O   60
H
U
PM
<
U
w
o
w
    40
                    I
                               I
                                     I
        0     10
                   20     30     40    50


                    BOILER AGE, YEARS
1 I

60
                                                 70
 Figure 3.  Operating profile assumed for
            IOPSCH = 1 based on old TVA premises.
;,o 50+ ISA 65
\fe^
& f,a 1=H N\\\v s^\ x
S 40 \\\\ sv\v>
U v\\\v v\\v
< v\\s ^ ^\SJ"
5! v::;:Ss|
PJ Qn k\S SsS "s\^
^ :^:v:^S
W s\S v\Ss\\^
5 v:::;^:;:':
o &;:;v£:;;;;
0 10
92-1 8A
m
S^^\'1J\^
xSs \xs"i r\^.^

;: >:yx;S^
"; v \v " ^
v v \s^~ " \Ss\x
;\<\>; \\;> v v
i iiii|ii.
20 30







1^'
y;
1 '
40
A = AGE




I r.
:|:nq
;>vSi R 0
\^;:^y H H
. i r | . i i i | i i i i
50 60 70
                   BOILER AGE, YEARS



 Figure A.  Operating profile assumed  for
            IOPSCH = 2 based on historical  Federal
            Energy Regulatory Commission data.
                       58

-------
TABLE 24.   EXAMPLE LIFETIME REVENUE REQUIREMENTS USING THE  OLD  TVA  PREMISES OPERATING PROFILE
LIMESTONE SLURRY PROCESS -- BASISl  500




PROJECTED LIFETIME  REVENUE REQUIREMENTS
                                      SCRUBBING UNIT -  500  MW GENERATING UNIT/ 198* STARTUP



                                      FIVE  PROCESS PROFILE



                                          TOTAL CAPITAL INVESTMENT!  *  10*679000
                                                                                              CASE 010
ADJUSTED GROSS
SULFUR
REMOVED
YEARS AN'iUAL PTWER UNIT PD/iER UNIT 8Y
AFTER UPCRA- HEAT FUEL POLLUTION
POWER TIHN, REQUIREMENT, CONSUMPTION, CONTROL
UNIT KW-HR MILLION BTU TONS COAL PROCESS,
START /KW /YEAK /YEAR TONS/YEAR
1 7000 33250000 1420900 38900
2 7'>00 3325UOOO 1*20900 38900
3 7000 33250000 1*20900 38900
4 7uOO 33250000 1*20900 3H900
5 7'iOO 33250000 1*20900 33900
f> 7COO 33250000 1*20900 38900
7 7POO 33250000 1*20900 38900
d 7000 33250000 1*20900 38900
9 7UOO 33250000 1*20900 3B900
lu 7.JOO 33250000 1*20900 3H900
11 5000 23750000 1015000 27800
12 5000 23750000 1015000 27800
13 S-'OO 23750000 1015000 27800
14 5000 23750000 1015000 27800
15 5000 2375UOOO 1115000 27600
16 3500 16625000 710500 19*00
17 3500 16625000 710500 19*00
18 3500 16625000 710500 10*00
19 3500 16625000 710500 19*00
20 3500 16625000 710500 1.9*00
21 1500 7125000 30*500 8300
22 1500 7125000 30*500 8300
23 1500 7125000 30*500 8300
2* 1500 7125000 30*500 «300
25 IbOO 7125000 30*500 8300
26 1500 7125000 30*500 8300
27 1500 7125000 30*500 8300
28 1500 7125000 30*500 8300
29 1500 7125000 30*500 S300
30 1500 7125000 304500 «300
TOT 127500 6T5625000 25881500 708000
LIFETIME AVERAGE INCREASE IN UNIT REVENUE REQUIREMENT
DOLLARS PER TON OF C3AL BURNED
MILLS PER KILOWATT-H3UR
CENTS PER MILLION STJ HEAT INPUT
DOLLARS PER TON OF SJLFUR REMOVED
KEVE-IUF REQUIREMENT DISCOUNTED AT 10.0X TO INITIAL YEAR
BYPRODUCT
RATE,
EQUIVALENT
TONS/VEAR

DRY
SLUDGE
2*4200
24*200
24*200
24*200
24*200
24*200
24*200
24*200
24*200
24*200
174*00
17*400
174*00
174*00
17**00
122100
122100
122100
122100
122100
52300
52300
52300
52300
52300
52300
52300
52300
52300
52300
4*47500





, DOLLARS
ANNUAL REVENUE
SLUDGE
FIXATION FEE
i/TUN

DRY
SLUDGE
0.0
0,0
o.o
0,0
0,0
0,0
u , 0
o.o
0.0
0.0
0,0
0,0
0,0
u.O
0,0
0,0
0,0
0.0
0,0
0,0
0,0
0,0
0.0
0,0
0.0
0,0
0.0
0.0
0,0
0,0







RETIREMENT
EXCLUDING
SLUDGE
FIXATION
COST,
I/YEAR
28564600
29355300
30193*00
31081700
32023300
33021400
34079700
35201100
36389800
37649900
33631600
3*726*00
35886900
37116700
38420500
3*069700
35190600
36378600
37638300
38973100
28898000
29708*00
3C567900
31*78600
32*43900
33*67500
3*552200
35702100
36921000
38212800
10215*5000

39,47
16.02
168.68
1442.86
311206100
LEVFLIZED INCREASE IN UNIT REVENUE REQUIREMENT EQUIVALENT TO DISCOUNTED REQUIREMENT OVER LIFE
DOLLARS PER TON OF CDAL BURNED
MILLS PER KILOWATT-HDUR
CENTS PER MILLION BTJ HEAT INPUT
DOLLARS PER TON OF SJLFUR REMOVED
UNIT CJSTS INFLATED AT 6,00* PER YEAR










27.9*
11.34
119.41
1021.02

TOTAL
ANNUAL
SLUDGE
FIXATION
COST.
»/YEAR
0
0
0
0
0
0
Q
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0.0
o.o
0.0
0,0
0
Of POWER
0.0
0.0
0.0
0.0

NET ANNUAL
INCREASE
IN TOTAL
REVENUE
REQUIREMENT,
>
2856*600
29355300
30193*00
31081700
32023300
33021*00
3*079700
35201100
36389800
37649900
33631600
34726*00
35866900
37116700
38*20500
3*069700
35190600
36378600
37638300
38973100
28898000
29708*00
30567900
31*78600
32443900
33467500
3*552200
35702100
36921000
38212800
10215*5000

39.47
16.02
168,68
1442.86
311206100
UNIT
27.9*
11.34
119.41
1021.02

CUMULATIVE
NET INCREASE
IN TOTAL
REVENUE
REQUIREMENT,
$
28564600
57919900
88113300
119195000
15121(300
184239700
218319400
253520500
289910300
327560200
361191800
395918200
431805100
468921600
507342300
5*1412000
576602600
612981200
650619500
689592600
718490600
748199000
778766900
610245500
842689400
876156900
910709100
946411200
983332200
1021543000














-------
TABLE 25.   EXA11PLE  LIFETIME REVENUE REQUIREMENTS USING  THE  HISTORICAL FERC/FPC  OPERATING PROFILE
        LIMESTONE SLURRY  PROCESS — BASIS:  500 MM  SCRUBBING UNIT -  500 MW GENERATING UNIT. 198* STARTUP




        PROJECTED LIFETIME REVENUE REQUIREMENTS - FPC/FERC PROFILE




                                                TOTAL CAPITAL INVESTMENT:  J  106672000
CASE 010
ADJUSTED GROSS
SULFUR
REMOVED
YEARS ANNUAL PO«ER UNIT POWER UNIT BY
AFTER OPERA- HtAT FUEL POLLUTION
POfF.R TION. REQUIREMENT. CONSUMPTION. CONTROL
UNIT KV.-HR MILLION ETU TONS COAL PROCESS.
START /Kh /YEAH /YEAH TONS/YEAH
1 451? 21433000 915500 35100
2 4643 22054300 942500 25800
3 4775 22681300 569300 26500
4 4906 23303500 995500 27300
5 5037 2392580(1 1022500 28000
t. 5169 24552800 1049300 2«700
7 5300 25175000 1075900 29400
« 5432 25802000 1102600 30200
9 5563 26424300 1129200 30900
10 5694 27046500 1155800 31600
11 5695 27051300 1156000 31600
12 5695 27051300 1156000 31600
13 5695 27051300 1156000 31600
14 5695 27051300 1156000 31600
15 5695 27051300 1156000 31600
16 5537 26300800 1124000 30800
17 5379 25550300 1091900 29900
IB 5??1 24799POO 1059600 29000
19 5064 24054000 1027500 28100
cO 4906 23303500 995900 27300
21 4748 22553000 963800 26400
22 4591 21807300 931900 25500
23 4433 21056800 899900 24600
24 4275 20306300 P67800 23800
25 411« 15560500 <335500 22900
2b 3960 18810000 803800 22000
27 3P02 18059500 771800 21100
2W 3645 17313800 739900 20300
29 3487 16563300 707800 19400
30 3329 15812POO 675800 18500
TOT 146001 693505700 29636800 811100
LIFETIME AVERAGE INCREASE IN UNIT REVENUE REQUIREMENT
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOKATT-hOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
REVENUE REQUIREMENT DISCOUNTED AT 10. OS TO INITIAL YEAR
BYPRODUCT
RATE.
ANNUAL REVENUE
SLUDGE
EQUIVALENT FIXATION FEE
TONS/YEAR

DRY
SLUDGE
157400
162000
166600
171200
175700
180300
184900
189500
194100
198700
198700
198700
198700
198700
198700
193200
187700
182100
176700
171200
165600
160200
134700
149100
143700
138200
132600
127200
121 700
116100
5093900





. DOLLARS
LEVELIZEO INCREASE IN LNIT REVENUE REQUIREMENT EQUIVALENT TO DISCOUNTED
DOLLARS PER TON OF COAL RURNED
MILLS PER KILOnATT-HOUR
CENTS PER MILLION aiu HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
UNIT COSTS INFLATED AT e.OOS PER YEAR





S/TON

DRY
SLUDGE
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0







REQUIREMENT
EXCLUDING
SLUDGE
FIXATION
COST,
S/YEAR
26703200
27612300
28590900
29640600
30767900
31981300
33281200
34679500
36177800
37785500
39114800
40520900
42011500
43591100
45265600
46394100
47547000
48723200
49926200
51143500
52377900
53631900
54890400
56155100
57428000
58690100
59941700
61184600
62393200
63566400
1351717400

45.61
18.52
194.91
1666.52
346396900
REQUIREMENT OVER LIFE





35.83
14.55
153.14
1309.63

TOTAL
ANNUAL
SLUDGE
FIXATION
COST,
i/YEAR
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0.0
0.0
0.0
0.0
0
OF POWER
0.0
0.0
0.0
0.0

NET ANNUAL
INCREASE
IN TOTAL
REVENUE
REQUIREMENT,
t
26703200
27612300
28590900
29640600
30767900
31981300
33281200
34679500
36177800
37785500
39114800
40520900
42011500
43591100
45265600
46394100
47547000
48723200
49926200
51143500
52377900
53631900
54690400
56155100
57428000
58690100
59941700
61184600
62393200
63566400
1351717400

45.61
18.52
194.91
1666.52
346396900
UNIT
35.83
14.55
153.14
1309.63

CUMULATIVE
NET INCREASE
IN TOTAL
REVENUE
REQUIREMENT,
$
26703200
54315500
82906400
112547000
143314900
175296200
208577400
243256900
279434700
317220200
356335000
396855900
438867400
482458500
527724100
574118200
621665200
6703«8400
720314600
771458100
823836000
877467900
932358300
988513400
1045941400
1104631500
1164573200
1225757800
1288151000
1351717400














-------
TABLE  26.   EXAMPLE  LIFETIME  REVENUE  REQUIREMENTS  USING A  USER-SUPPLIED OPERATING  PROFILE
   LIMESTONE SLURRY PROCESS -- HASIS:  500 MW SCRUBBING UNIT -  500 Ml* GENERATING UNIT. 198* STARTUP
   PROJECTED LIFETIME REVENUE REQUIREMENTS - USER INPUT SCHEDULE
                                                                                                 CASE 013
                                          TOTAL CAPITAL INVESTMENT:
                                                                   108027000
SULFUR
REMOVED
YEARS ANNUAL POWER UM T POKER UNIT BY
AFTER OPFRA- HEAT FUEL POLLUTION
POWER TION. REQUIREMENT, CONSUMPTION, CONTROL
UNIT KW-HR MILLION fcTu TONS CCAL PROCESS,
START /Kh /YEAR /YEAH TONS/YEAH
1 5000 23750000 1015000 27800
1 5000 33750000 1015000 27800
3 6000 28500000 1217500 33300
4 6000 28500000 1217500 33300
5 7000 33250000 1420500 3U90U
6 7000 33250000 1420500 38900
7 7000 33250000 1420500 3890U
b 7000 33250000 1420500 38900
9 7000 33250000 1420500 38900
10 7000 33250000 1420500 3B900
11 7000 33350000 1420900 38900
12 7000 33250000 14^:0500 38900
U 7000 33250000 1420900 38900
14 7000 33250000 1420900 38900
15 7000 33250000 1420900 38900
16 7000 33250000 1420900 3890U
17 7000 33250001 1420900 38900
18 7000 33250000 1420500 38900
19 6000 28500000 1217500 33300
20 6000 285000CO 1217500 33300
21 6000 28500000 1217500 33300
22 5000 23750000 1015000 27800
23 5000 23750000 1015000 27800
24 5000 23750000 1015000 27800
25 4000 19000000 812000 22200
TUT 157000 745750000 31809100 872300
LIFETIME AVFHAfaE INCREASE IN UNIT REVENUE REQUIREMENT
DOLLARS PER TON OE COAL HURNED
MILLS PER KILOKATT-hOUH
CENTS PER BILLION BTU HEAT INPUT
OOLL'RS PER TON OF SULFUR REMOVED
REVENUF REQUIREMENT DISCOUNTED AT 10.0* TO INITIAL YEAR
ADJUSTED GROSS
BYPRODUCT ANNUAL REVENUE
RATE, SLUDGE REQUIREMENT TOTAL
EQUIVALENT FIXATION FEE
TONS/YEAR

DRY
SLUDGE
174400
174400
209300
209300
244200
244200
244200
244200
244200
244200
244300
244200
244200
244200
244200
244200
244200
244200
209300
209300
209300
1 /4400
1 /4400
174400
139600
5476900





, DOLLARS
LEVELIZED INCREASE IN LNIT REVENUE REQUIREMENT EQUIVALENT TO DISCOUNTED
DOLLARS PER TON OF COAL BURNED
MILLS PER KILO»ATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PFR TON OF SULFUR REMOVED
UNIT COSTS INFLATED AT 6.00J PER YEAR





I/TON

DRY
SLUDGE
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
EXCLUDING
SLUDGE
F IXATION
COST,
S/YEAR
27379300
28069400
30678500
31566400
34548200
35668300
36855700
38114100
39448200
40862300
42361300
43950000
45634400
47419600
49312200
51318100
53444200
55697900
53473400
55729000
58120000
54973500
57319100
59S05400
55387400
1127135900






REQUIREMENT






35.37
14.36
151.14
1292.14
350801100
OVFR LIFE
30.19
12.26
129.03
1103.15

ANNUAL
SLUDGE
FIXATION
COST,
5/YEAR
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0.0
0.0
0.0
0.0
0
OF POWER
0.0
0.0
0.0
0.0

NET ANNUAL
CUMULATIVE
INCREASE NET INCREASE
IN TOTAL
REVENUE
REQUIREMENT,
t
27379300
28069400
30678500
31566400
34548200
35668300
36855700
38114100
39448200
40862300
42361300
43950000
45634400
47419600
49312200
51318100
53444200
55697900
53473400
55729000
58120000
54973500
57319100
59805400
55387400
1127135900

35.37
14.36
151.14
1292.14
350801100
UNIT
30.19
12.26
129.03
1103.15

IN TOTAL
REVENUE
REQUIREMENT,
t
27379300
55448700
86127200
117693600
152241800
187910100
224765800
262879900
302328100
343190400
385551700
429501700
475136100
522555700
571867900
623186000
676630200
732328100
785801500
841530500
899650500
954624000
1011943100
1071748500
1127135900














-------
                           USAGE OF THE MODEL
     As previously discussed, a copy of the model can be made available
for independent user execution; or TVA, under an information-exchange
agreement with EPA, can make specific runs of the model based on user-
supplied input data.  This section is provided for potential users who
wish to obtain the model for independent use.

     The model was developed for, and is executed on, the TVA in-house
IBM 370 compatible computer system.  The current model consists of two
FORTRAN programs that are compiled using either the IBM Gl or H extended
compiler.  The first program, which calculates investment costs, is
relatively large; it contains over 10,000 lines of source code.  The
second program, which calculates revenue requirements, contains about
2,000 lines.

     Core storage requirements for the first program are about 300,000
bytes; the use of overlays can reduce this requirement to about 150,000
bytes.  The second program executes within 150,000 bytes of core storage
with no overlays.  In addition to the core storage required for program
execution, temporary online storage (disk) is also required for inter-
mediate files and the transfer of data between the two programs.  The
only input data required for model execution are the user input data;
all other data for default assumptions and option-related calculations
are assigned the necessary values internally within the program.  Temporary
online storage requirements depend on the number of cases run but typically
do not exceed 200,000 bytes.

     The model is executed in both interactive and batch modes.  The
input data can be provided in three different ways depending on the mode
of execution.  For batch execution (typically remote batch) the input
data variables are punched on cards and inserted in a model execution
run deck.  The second method of providing data applies to interactive
model execution.  Input is solicited at the terminal during actual model
execution and the user must respond with the appropriate values.  The
third method is used for both interactive and batch execution.  A data
file is created interactively (typically using a text editor); all
variable values (including the options selected) are examined and
corrected if necessary; then the model is executed (either interactively
or a batch run is submitted from the interactive terminal) and the input
is processed as a standard data file.

     The third method of providing input data has been found to be
preferable in most cases.  When separate but similar model runs are
required, the data file containing the input is copied to a second file,
                                    62

-------
variables and options are modified as necessary,  and a second model run
is submitted.  This reduces both input preparation time and the number
of input data errors because only the variables and options that differ
from a previous run must be modified.

     The job control language (JCL) required to execute the model in
batch mode is stored in a catalogued procedure file.  An example procedure
file is shown in Table 27.  The catalogued procedure uses a system
utility program, IEBGENER, which can be replaced if necessary by a user
program to copy from input card data to disk storage and from disk
storage to an output print file.  The overall procedure consists of four
steps to (1) copy the input data to a temporary online storage file
(disk), (2) copy the input data to an output print file, (3) execute the
first program of the model, and (4) execute the second program.  The
programs are executed from load modules to avoid recompiling each time
they are executed.

     The remaining JCL required to execute the model in batch mode is
shown in Table 28.  If the input data have been prepared on cards, a
card deck similar to example one in Table 28 would be submitted with the
data cards following the //LOAD.DATA DD * ... card.  In example two, the
catalogued procedure (Table 27) is executed and the required input is
read from a previously created data file.  The JCL examples shown in
Tables 27 and 28 generally apply whether the job is submitted inter-
actively or with a card deck.

     Table 29 shows two example interactive procedures for model execution.
Example 1 in Table 29 shows an example procedure for directly entering
the data during model execution.  Example 2 shows a procedure for inter-
active execution using a previously created data file.

     The amount of computer time required for model execution is a
function of the number of cases of input data and the particular computer
system.  On the TVA system (Amdahl V8 with JES3)  the average CPU time
required per case is about .5 second but some cases have exceeded 2 seconds.

     The model is usually distributed on magnetic tape for independent
usage.  A fairly wide range of tape format options is available but
typically the tape is unlabeled, the density is 1600, the block size is
4,000 characters (50 records, 80 characters per record), and the tape
contains two files, one for each program.
                                     63

-------
      TABLE 27.   EXAMPLE PROCEDURE FOR EXECUTING THE MODEL IN BATCH MODE
//SHAWNEE
//LOAD
//SYSPRINT
//SYSIN
//SYSUT1
//SYSUT2
//
//LIST
//SYSPRINT
//SYSIN
//SYSUT1
//SYSUT2
//INVEST
//STEPLIB
//FT02F001
//
//FT03F001
//FT05F001
//FT06F001
//REVENUE
//STEPLIB
//FT02F001
//FT06F001
PROC
EXEC
DD
DD
DD
DD

EXEC
DD
DD
DD
DD
EXEC
DD
DD

DD
DD
DD
EXEC
DD
DD
DD
PRTFMS=A
PGM=IEBGENER
SYSOUT=A
DUMMY
DDNAME=DATA
UNIT=SYSCR, SPACE=(TRK, (1,1) ,RLSE) ,DISP= (NEW, PASS) ,
DCB=(RECFM=FB,LRECL=80,BLKSIZE=400)
PGM=IEBGENER
SYSOUT=A
DUMMY
DSN=* . LOAD . SYSUT2 ,DISP= (OLD , PASS)
SYSOUT=&PRTFMS , DCB= (RECFM=F , LRECL=80 , BLKSIZE=80 )
PGM=INV,REGION=400
DSN=CHM. SHAWNEE . LOAD , DISP=SHR
UNIT=SYSCR,SPACE=(TRK, (1,1) ,RLSE) ,DISP= (NEW, PASS) ,
DCB=(LRECL=404,BLKSIZE=408,RECFM=VBS)
SYSOUT=A
DSN=*. LOAD. SYSUT2,DISP= (OLD, DELETE, DELETE)
SYSOUT=&PRTFMS
PGM=REV,REGION=150K,COND=(COND=(0,LT, INVEST)
DSN=CHM. SHAWNEE . LOAD , DISP=SHR
DSN=*. INVEST. FT02F001,DISP=(OLD, DELETE, DELETE)
SYSOUT=&PRTFMS
00000010
00000020
00000030
00000040
00000050
00000060
00000070
00000080
00000090
00000100
00000110
00000120
00000130
00000140
00000150
00000160
00000170
00000180
00000190
00000200
00000210
00000220
00000230

  TABLE 28.   EXAMPLE BATCH RUN TO EXECUTE THE MODEL USING A PROCEDURE FILE
                                 (Example 1)

//TXSHAWNE   JOB 123456,PRGMER.R501CEBM.2513,MSGLEVEL=1,CLASS=K,      00000010
//               NOTIFY=CHM                                           00000020
/*MAIN ORG=RGROUP03                                                   00000030
//PROCLIB  DD  DSN=CHM.PROCLIB,DISP=SHR                               00000040
//SHAWNEE  EXEC SHAWNEE,PRTFMS=A                                      00000050
//LOAD.DATA   DD *       (INPUT DATA CARDS FOLLOW THIS CARD)           00000060
//                                                                    00000070

                                 (Example 2)

//TXSHAWNE    JOB 123456,PRGMER.R501CEBM.2513,MSGLEVEL=1,CLASS=K,      00000010
//                NOTIFY=CHM                                          00000020
/*MAIN ORG=RGROUP03                                                   00000030
//PROCLIB  DD  DSN=CHM.PROCLIB,DISP=SHR                               00000040
//SHAWNEE  EXEC SHAWNEE,PRTFMS=A                                      00000050
//LOAD.DATA   DD DISP=SHR,DSN=CHM.PART2.DATA                          00000060
//                                                                    00000070
                                     64

-------
TABLE 29.  SAMPLE PROCEDURE FOR EXECUTING THE MODEL INTERACTIVELY
                           (Example 1)

00010  FREEALL
00020  TERM LINESIZE(132)
00030  FREE FILE (FT02F001,FT03F001,FT05F001,FT06F001)
00040  ALLOC FI(FT02F001)  NEW BLOCK(13030)  SPACE(10,5)
00050  ALLOC FI(FT03F001)  DA(*)
00060  ALLOC FI(FT05F001)  DA(*)
00070  ALLOC FI(FT06F001)  DA(*)
00080  CALL  'CHM.SHAWNEE.LOAD(INV)'
00090  CALL  'CHM.SHAWNEE.LOAD(REV)1
00100  FREEALL

                           (Example 2)

00010  FREEALL
00020  TERM LINESIZE(132)
00030  FREE DA('CHM.PART2.DATA')
00040  FREE FILE(FT02F001,FT03F001,FT05F001,FT06F001)
00050  ALLOC FI(FT02F001)  NEW BLOCK(13030)  SPACE(10,5)
00060  ALLOC FI(FT03F001)  DA(*)
00070  ALLOC FI(FT05F001)  DA('CHM.PART2.DATA')
00080  ALLOC FI(FT06F001)  DA(*)
00090  CALL  'CHM.SHAWNEE.LOAD(INV)'
00100  CALL  'CHM.SHAWNEE.LOAD(REV)'
00110  FREEALL
                                65

-------
                                REFERENCES
Argonne, 1979.  The model that sizes and costs particulate removal
devices was provided by Paul S. Farber of Argonne National Laboratory,
Argonne, Illinois.

Federal Register, 1979.  New Stationary Sources Performance Standards;
Electric Utility Steam Generating Units.  Federal Register, Vol. 44,
No. 113, pp. 33580-33624.

McGlamery, G. G., R. L. Torstrick, W. J. Broadfoot, J. P. Simpson,
L. J. Henson, S. V. Tomlinson, and J. F. Young, 1975.  Detailed Cost
Estimates for Advanced Effluent Desulfurization Processes, Bulletin Y-90,
Tennessee Valley Authority, Muscle Shoals, Alabama; EPA-600/2-75-006,
U.S. Environmental Protection Agency, Research Triangle Park, North
Carolina, 1975.

McGlamery, G. G., W. E. O'Brien, C. D. Stephenson, and J. D. Veitch,
1980.  FGD Economics in 1980.  Preprint, paper presented at the EPA
Symposium on Flue Gas Desulfurization, Houston, Texas, October 27-31, 1980.

Torstrick, R. L., 1976.  Shawnee Limestone-Lime Scrubbing Process Compu-
terized Design Cost Estimates Program:  Summary Description Report.
Prepared for presentation at Industry Briefing Conference, Raleigh,
North Carolina, October 19-21, 1976.

Torstrick, R. L., L. J. Henson, and  S. V. Tomlinson, 1978.  Economic
Evaluation Techniques, Results, and  Computer Modeling for Flue Gas
Desulfurization.  In:  Proceedings,  Symposium on Flue Gas Desulfurization,
Hollywood, Florida, November 1977  (Vol. 1), F. A. Ayer, ed., EPA-
600/7-78-058B, U.S. Environmental Protection Agency, Washington, D.C.,
1978, pp. 118-168.

Stephenson,  C. D., and R. L. Torstrick, 1978.  Current Status of Develop-
ment of the  Shawnee Lime-Limestone Computer Program.  Prepared for
presentation  at Industry Briefing Conference, Raleigh, North Carolina,
August 29, 1978.

Stephenson,  C. D., and R. L. Torstrick, 1979.  The  Shawnee Lime-Limestone
Computer Program.  Prepared  for presentation at Industry Briefing
Conference,  Raleigh, North Carolina, December 5, 1979.

Stephenson,  C. D., and R. L. Torstrick, 1979.  Shawnee Lime/Limestone
Scrubbing Computerized Design/Cost-estimate Model Users Manual.


                                     66

-------
Tomlinson, S. V., F. M. Kennedy, F. A. Sudhoff, and R. L. Torstrick,
1979.  Definitive SOX Control Process Evaluations:  Limestone, Double
Alkali, and Citrate FGD Processes.  TVA ECDP B-4, Tennessee Valley
Authority, Muscle Shoals, Alabama; EPA-600/7-79-177, U.S. Environmental
Protection Agency, Washington, D.C.
                                   67

-------
          APPENDIX A




PROCESS FLOWSHEETS AND LAYOUTS
            A-l

-------
                                                           TCA SCRUBBER AREA
>

N>
                                                                                     STEAM FROM
                                                                                     STEAM PLANT
                                                                  m"
//////////////////.
w
0 0 0 0 0
0°0 0 0°0
O ° O O
O O O o O O
D°0 °°0°
000 0°0
ABSORBER
,






13
                                                                            MAKEUP
                                                                            WATER
                                                                                     CONDENSATE
                                                                                    TO STEAM PLANT
                                                 \ /
     Dl
WEIGH   i
BELTS [  |  ^
 GYRATO
 CRUSHERS
KEUP
TER
'1 n
1 9



16
i'
EFHbULDNT
TANK

-£












                                                                                                                       LIQUOR RETURN
                                                                                                                      .TO WASTE DISPOSAL
                    Figure A-l.   Limestone scrubbing  process  utilizing  TCA  absorber.

-------
                       BOILER
>
                           (ECONOMIZER1
                                	' ELECTROSTATIC
                                      PRECIPITATOR
                                     (OR BAGHOUSE) (PLENUM
                          COMBUSTION
                             AIR
                                       ASH TO
                                       DISPOSAL
                                                           SCRUBBER AREA
                                                            SPRAY TOWER
                                                                                      STEAM FROM
                                                                                      STEAM PLANT
                                                                                                                          - LIQUOR RETURN
                                                                                                                          - TO WASTE DISPOSAL
                                                                WEIGH   i
                                                                BELTS  II   *

                                                                 GYRATORY^*/
                                                                 CRUSHERS
                                                                                      MILLS
                                                                                     PRODUCT
                                                                                      TANK ,
SLURRY
 FEED
 TANK
               Figure  A-2.   Limestone  scrubbing process  utilizing  a spray  tower.

-------

\^
BOILER
|- E
[ECONOMIZER) p
-^ i'
AIR HEATER
1- ^
COMBUSTION
_ECTROSTAT
RECIPITATO
vw
              AIR
                         ASH TO
                        DISPOSAL
                                                                                       POND SUPERNATE
                                                                                          RETURN
                                                                                        TO WASTE
                                                                                       DISPOSAL POND
Figure A-3.   Limestone scrubbing process utilizing a venturi -  spray  tower.

-------
  T
  Ul
ENCLOSED CONVEYOR
                                                                                                 SLURRY FEED

                                                                                                 TO ABSORBER
                  ELEVATOR NO. I
   Figure A-4.   Lime  handling  and preparation  area for  lime scrubbing  option.

-------
                                                                                              STACK PLENUM
                                                               PRESATURATOR
                                                                 PUMPS
                                                         TO SPARE               FROM SPARE
                                                        SCRUBBING TRAIN          SCRUBBING TRAI
                                                 PLAN
                                                (SEE NOTES)
                           NOTES
                            I EMERGENCY BYPASS ON EACH SIDE
                           2 SPARE SCRUBBING TRAIN ON ONE SIDE ONLY
Figure  A-5.    Plan  and  elevation for  TCA.

                                             A-6

-------
                     ELECTROSTATIC
                      PRECIPITATORS
                                                                             WASTE DISPOSAL AREA
                                                                                 FEED TANK
                                                                                 EFFLUENT
                                                                                 HOLD TANK
                                                                    PRESATURATOR A        '
                                                                   r PUMPS  -
                                                                                                  ABSORBER
                                                                                              , ,    SYSTEM

                                                                                          WASTE    ' ° FAN
                                                                  -  PRESATURATOR
                                                                  ' '"PUMPS   '
                                                                                                  ABSORBER
                                                                                                   SYSTEM
                                                                                                   I D  FAN
                                         POWER PLANT
                                           I D FAN
                                                                                           FROM
                                                                                T0     SPARE SCRUBBING

                                                                           SPARE SCRUBBING    TRAIN
                                                                               TRAIN
                                                               EXPANSION JOINT
                                                             (TYP WHERE SHOWN)
                                                               INDIRECT STEAM
                                                                 REHEATER
                                                                ENTRAINMENT
                                                                 SEPARATOR
                                                                 ABSORBER
                                                               (SPRAY TOWER)
                                                               PRESATURATOR

                                                           DAMPER
                                                     (TYP WHERE SHOWN
ELECTROSTATIC
PRECIPITATOR ~l
                                             POWER PLANT
                                               I D FAN
                                              EFFLUENTJ     ABSORBER
                                              HOLD TANK       SYSTEM
                                 PRESATURATOR^ \     SLURRY     l D FAN
                                    PUMP       ^RECIRCULATION
                                                   PUMP
                                                ELEVATION
      I  EMERGENCY BYPASS ON EACH SIDE

      2  SPARE SCRUBBING TRAIN ON ONE SIDE ONLY
Figure  A-6.    Plan  and  elevation  for  spray  tower.
                                                        A-7

-------
                            V
                             >
^
 S*
   <&
    e
      V'
       A'

-------
                                                                                      SETTLING POND
                                      Onsite ponding  (Option 1)
                                 Thickener ponding  (Option 2)
Figure A-8.  Waste  disposal options 1 and 2.

-------
      ABSORBED
       SLURRY
       BLEED
             ABSORBER
             BLEED
             RECEIVING
>
I
     ABSORBER
     SLURRY
     BLEED
            ABSORBE
            BLEED
            RECEIVING
                                          Thickener  -  Fixation  (Option  3)
                                     Thickener  - Filter  - Fixation (Option 4)
      Figure  A-9.  Waste disposal  options  3  and 4.

-------
   COAL _J
SCRUBBER AREA STEAM FROM
SPRAY TOWER STEAM PLANT
FORCED OXIDATION i'°
— , 	 e JREHEATER[ S) — *\
BOILER T ~ 	 J S4 !
i— - [ T 1 D FAN
1" "~ ~1 j CONDENSATE 9
ECONOMIZER i / 	 k MAKEUP T0 STEAM PI-ANT
	 ELECTROSTATIC
L 3 5 PRECIPITATOR
-•) ,-i -1 	 , (OR BAGHOUSE) 1PLENUM 	 »i
|_AIR HEATER ' | ' 	 1 	 '
COMBUSTION \/Wl» «N '?
1
ASH TO ^
DISPOSAL LJ^^-
L
i//m//mnm//n/!>.
* * A A 	
S02
ABSORBER
ii WATER
• i
1
* 	 »
• — i

[PLENUM
                                                  S.
_i^J

  OXIDATION
   AND
RECIRCULATION
   TANK
                                                                                                       — LIQUOR RETURN
                                                                                                        « TO WASTE DISPOSAL
LIMESTONE\ * ' WEISH i
PILE \ , _ BELTS 1" " ¥ 	 „
*-« ^^ \ GYRATORY "^' BALL r'8 - n t
O' CRUSHERS \ MILLS/ , U '
ly \ / - ~|
MILLS
PRODUCT
TANK


; "i n

SLURRY
FEED
TANK
Figure  A-10.   Single  tank oxidation  loop.

-------
                                                                                                    LIQUOR RETURN
                                                                                                    TO WASTE DISPOSAL
Figure A--11.   Double  tank oxidation  loop.

-------
                                                                      D OQwASTE DISPOSAL
                                                                          	FEED PUMPS
                                          ELEVATION
             NOTES
              I EMERGENCY BYPASS ON EACH SIDE
              2. SPARE SCRUBBING TRAIN ON ONE SIDE ONLY
Figure A-12.   Plan and elevation for TCA utilizing  forced-draft  fans.
                                           A-13

-------
              ELECTROSTATIC
               PRECIPITATORS
                                                                WASTE DISPOSAL AREA
                                                                   FEED TANK     "7
                                                                   EFFLUENT
                                                                   HOLD TANK
                                                       PRESATURATOR "
                                                       PUMPS , 7
,                                                                                  ABSORBER
                                                                                   SYSTEM
                                                                                   I D FAN T~~**-~.

                                                                            FROM        J
                                                                   T0     SPARE SCRUBBING —» \
                                                              SPARE SCRUBBING   TRAIN       [	^^
                                                                                         ^_
                                                            COMBINED PARTIAL
                                                                AND
                                                            EMERGENCY BYPASS
                                           PLAN
                                                    (SPRAY TOWER)
                                                    PRESATURATOR

                                                DAMPER
                                          (TYP WHERE SHOWN
                                       ELEVATION
  I EMERGENCY BYPASS ON EACH SIDE
  2 SPARE SCRUBBING TRAIN ON ONE SIDE ONLY
Figure A-13.    Plan  and  elevation  for partial  scrubbing  with bypass  duct,
                                                 A-14

-------
         APPENDIX B




DESIGN AND ECONOMIC PREMISES
            B-l

-------
                              INTRODUCTION
     In December 1979, new design and economic premises for comparative
economic evaluations of emission control processes were adopted for
emission control studies done by TVA for EPA.   These premises were
expanded and amplified in March 1980 and applicable portions have been
incorporated into the Shawnee model.  The economic premises can be
selected by the economic premises option, IECON,  on line 11 of the model
input data.  Separate options were established for the design premises
to allow them to be selected independently.   The old premises used for
earlier versions of the model (Tomlinson et  al.,  1979, and Stephenson
and Torstrick, 1979) can still be selected if required.  The referenced
publications provide complete details on the old economic premises so
only a brief overview is presented here.

     Separate input options are used to provide for differences between
the old and new premises in the calculation  of total capital investment
except for working capital and contingency.   Under the old premises,
working capital is calculated as three weeks of raw material costs,
seven weeks of direct costs, and seven weeks of overhead costs.  Con-
tingency is calculated as a percentage of direct investment.  Under the
new premises working capital is calculated as one month of raw material
costs, one and one-half months of conversion costs, one and one-half
months of plant and administrative overhead  costs, and three percent of
total direct investment to cover spare parts,  accounts receivable, and
monies on deposit for taxes and accounts payable.  Contingency under the
new premises is calculated as a percentage of the sum of direct investment,
engineering design and supervision, architectural and engineering con-
tractor costs, construction field expenses,  and contractor fees.  The
remaining differences between the old and new premises in the calculation
of capital investment are controlled by separate input options and
variables.  They include separate indirect investment factors for pond
construction, sales tax and freight on materials, overtime labor, emergency
bypass, inflation, royalties, and a constant lifetime operating profile.

     There are also differences between the  old and new premises in the
calculation of both indirect costs for annual revenue requirements and
in lifetime revenue requirements.  Under the old premises, indirect
costs are based on depreciation, cost of capital and taxes as a percentage
of undepreciated investment, insurance and interim replacements as a
percentage of total capital investment, plant overhead as a percentage
of conversion costs less utilities, and administrative, research, and
service overheads as a percentage of operating labor and supervision.
Under the new premises, indirect costs are based on plant and administrative
overheads as a percentage of conversion costs less utilities, and levelized

                                    B-3

-------
capital charges as a percentage of total capital investment.   For processes
that result in a salable byproduct, marketing costs are applied as a per-
centage of byproduct credit under the new premises.

     Lifetime revenue requirements under the old premises are based on
annual revenue requirements calculated for each individual year of the
projected plant life.  A lifetime revenue requirements report is printed
showing year-by-year projections.  Under the new premises, a levelized
operating and maintenance factor is applied to first-year operating and
maintenance instead of calculating year-by-year requirements.  However,
for comparative analysis and flexibility, if a levelizing factor of zero
is used in conjunction with the new premises, a year-by-year revenue
requirements report based on the lifetime operating profile that is
specified can still be generated.

     Example output from the model illustrating the differences between
the old and new premises are shown in the model description section and
in the base case printout in Appendix D.  Additional comparisons between
the old and new premises that illustrate the individual effects of the
changes are described in a paper presented at the 1980 EPA FGD symposium
(McGlamery et al., 1980).  The descriptions of the individual input
options in the model description section provide additional information.
However, the references cited previously for the old premises and the
remainder of this  appendix for the new premises must be used for compre-
hensive details and background information.  The same cost indexes and
projections are used for both the old and new premises.  It should be
noted that the new premises that follow contain specifications beyond
the scope of the model.
                                    5-4

-------
           DESIGN AND ECONOMIC PREMISES EFFECTIVE DECEMBER 1979
INTRODUCTION

     These premises provide criteria for comparative economic evaluations
of emission control processes for electric utility coal-fired power
plants.  The design premises define representative coal and power unit
conditions and standard design practices for emission control systems.
The economic premises are based on regulated utility economics.   They
prescribe procedures for determining capital investment and annual
revenue requirements.  The premises are directly applicable to economic
evaluations of coal cleaning, flue gas desulfurization (FGD), nitrogen
oxides (NOX) emission control, waste disposal,  and particulate matter
emission control.

     The economic evaluations are always based on a conceptual design
developed from the design premises and engineering data such as flow
diagrams, material balances, and equipment costs.  Depending on the
specified degree of accuracy of the cost estimate, some costs are either
scaled or developed from detailed design and operating data.

     Normally a base-case new 500-MW power unit burning 3.5% sulfur, 16%
ash bituminous coal, and complying with 1979 new source performance
standards (NSPS) (1) is used as the basis of comparison.  Case variations
are developed as necessary to illustrate their effects on the economics
of the processes evaluated.  For FGD evaluations a limestone scrubbing
process using a spray tower, forced oxidation,  and gypsum landfill
disposal serves as the standard of comparison.

     The current premises are based on 1982 costs for capital investment
and 1984 costs for annual revenue requirements.  These and other premise
criteria are updated as necessary.  Established criteria are not usually
revised on a piecemeal basis, however, as this would complicate their
use and reduce the comparability and applicability of evaluations made
over a period of time.  All necessary premise changes are made at one
time, usually every one to three years.
DESIGN PREMISES

Coal Premises

     The premise coals consist of four eastern bituminous coals containing
5.0%, 3.5%, 2.0%, and 0.7% sulfur; a 0.7% sulfur western bituminous
coal; a 0.7% sulfur western subbituminous coal; and a 0.9% sulfur North

                                    B-5

-------
Dakota lignite.  They are based on analyses of U.S. steam coals repre-
sentative of the types in current use (2,3).  The analysis data for each
of these coals are summarized in Table B-l and a fly ash analysis for
each coal is shown in Table B-2.


                   TABLE B-2.   FLY ASH COMPOSITIONS



Component
Si02
A1203
Ti02
Fe2°3
CaO
MgO
Na20
K20
so3
P2°5
Other
Bituminous
fly ash,
wt %
50.8
20.6
2.5
16.9
2.0
1.0
0.4
2.6
2.4
-
0.8
Subbituminous
fly ash,
wt %
39.7
21.5
1.1
7.4
20.0
4.7
1.7
0.5
2.3
1.0
0.1
Lignite
fly ash,
wt %
23.0
11.5
0.5
8.6
21.6
6.0
5.9
0.5
19.2
0.4
2.8
                 Total   100.0         100.0       100.0
     As-fired coal refers to the coal entering the coal-cleaning plant
or power plant.  This coal is supplied in a 3- inch top size after large
rocks and trash have been removed from the run-of-mine coal.   Broken
coal is assumed to have the particle size distributions represented by
the Bennett form of the Rosin and Rammler equation,
                             R=

which can be plotted on special graph paper devised by the U.S. Bureau
of Mines (4) as shown in Figure B-l.  In the equation,

   x = particle diameter or width of screen aperture in millimeters.  It
       is the abscissa in Figure B-l.

   x = a size constant, in millimeters,  that is specific to each distri-
       bution line of particle size.  In Figure B-l, it is the value of
       x when R = 36.79%; in turn R = 36.79% when x = x in the Rosin and
       Rammler equation.

   n = a size distribution constant.  In Figure B-l, it is the arith-
       metical slope of a distribution line.  Parallel distribution
       lines have the same value of n.
                                    B-6

-------
TABLE B-l.   COMPOSITION OF PREMISE COALS
(As-Fired Basis)
Sulfur

Coal
Eastern bituminous, 5.0% S
Eastern bituminous, 3.5% S
Eastern bituminous, 2.0% S
Eastern bituminous, 0.7% S
Western bituminous, 0.7% S
Western subbituminous, 0.7% S
(Powder River Basin)
North Dakota lignite, 0.9% S
Total,
%
4.80
3.36
1.92
0.67
0.59

0.48
0.57
Pyritic ,
%
3.
2.
1.
0.
0.

0.
0.

17
21
25
44
20

16
19
Sulfatic,
%
0.05
0.05
0.04
0.01
0.01

0.01
0.01
Organic ,
%
1.58
1.10
0.63
0.22
0.38

0.31
0.37
(Moisture-Free
Eastern bituminous, 5.0% S
Eastern bituminous, 3.5% S
Eastern bituminous, 2.0% S
Eastern bituminous, 0.7% S
Western bituminous, 0.7% S
Western subbituminous, 0.7% S
(Powder River Basin)
North Dakota lignite, 0.9% S
5.00
3.50
2.00
0.70
0.70

0.68
0.89
3.
2.
1.
0.
0.

0.
0.
30
30
31
46
24

23
30
0.05
0.05
0.04
0.01
0.01

0.01
0.01
1.65
1.15
0.65
0.23
0.45

0.44
0.58
Ash, Moisture,

15
15
15
15
9

6
7
% %
.10 4.0
.14 4.0
.08 4.0
.13 4.0
.71 16.0

.30 29.3
.22 36.3
Heat
content, C,
Btu/lb %
11,700 65.
11,700 66.
11,700 67.
11,700 68.
9,700 57.

8,200 49.
6,600 40.
Ultimate analysis


2
7
8
8
0

0
1
H,
%
4.0
3.8
3.7
3.6
3.9

3.5
2.8
o,
**/
5.5
5.6
6.0
6.3
11.5

10.7
12.4
N,
%
1.3
1.3
1.4
1.4
1.2

0.7
0.6
Cl,
%
0.1
0.1
0.1
0.1
0.1

0.02
0.01
Basis)
L5
15
15
15
11

8
11
.7
.7
.7
. 7
.6

.9
.3
67.
69.
70.
71.
67.

69.
63.
9
5
6
7
9

3
0
4.2
4.0
3.9
3.8
4.6

5.0
4.4
5.7
5.8
6.3
6.6
13.7

15.1
19.5
1.4
1.4
1.4
1.4
1.4

1.0
0.9
0.1
0.1
0.1
0.1
0.1

0.02
0.01

-------
                                          I.MdnMlnuLnLlJ.J.MUJJJ
                                                                          SCREEN OPENING
 I
00
*00 325 270  100  140  100 80   60 M  40   30  10 18 16 14 II 10 8  J. t>
                US STANDARD SIEVE DESIGNATION

 II!   !   '    I  :   '     !    i    i I  I  i  '  I  I   i
400 321 in  XO  150  100 BO   60 48  35   28  20 16 H 1? 10 9 £   6
                  TYLER SIEVE DESIGNATION
                                                                                             5    I   !   I   !=   I
                                                                                                   SCREEN OPENING INCHES
                                          GRAPHICAL FORM FOR REPRESENTING DISTRIBUTION OF SIZES OF BROKEN COAL
                          Figure B-l.   Rosin-Rammler  plots  of  premise coal sizes.

-------
   e = the base of the natural logarithm.

   R = the weight percentage of coal retained on a screen whose aperture
       is x.  R expresses cumulative oversize and is the ordinate in
       Figure B-l.

     For all distribution lines in Figure B-l, the value of n is 0.8840.
Values of x for selected size distributions are given below.

                            Actual aperture size
Nominal
top sizes
3 in.
2 in.
1-1/2 in.
3/4 in.
3/8 in.
3 mesh
14 mesh
28 mesh
(Tyler /
in.
2.970
2.100
1.485
0.742
0.371
0.093
0.046
0.023
2 Series)
mm
75.43
53.34
37.71
18.86
9.429
2.357
1.179
0.589
x
mm
13.40
9.478
6.702
3.351
1.676
0.4189
0.2094
0.1047
Power Plant

     The power plant site is assumed to be in the north-central region
(Illinois, Indiana, Ohio, Michigan, Kentucky, and Wisconsin).   The
location represents an area in which coal-fired power plants burning
coals of diverse type and source are situated (5,6).   The design is
based on standard design practices (7,8) and current  trends in utility
boiler construction (9,10).  The base-case power unit is a new, single
500-MW, balanced-draft, horizontally fired, dry-bottom boiler burning
pulverized coal.  The steam pressure is 2,400 psi.  The superheat and
reheat temperatures are 1,000°F.

     Power unit size case variations consist of similar 200-MW and
1,000-MW units.  For new units the systems being evaluated are assumed
to be installed during construction of the power plant.  New units are
assumed to have a 30-year life and to operate at full load for 5,500
hours a year.  For case variations, identical existing units with 20
years of remaining life at 5,500 hours/year of full-load operation are
used.  Heat rates are based on coal type,  unit size,  and unit age.
Power plant heat rates are shown in Table  B-3.  To provide for equitable
comparisons, the power units are not derated for energy consumption by
the systems evaluated.  Instead the energy requirements are charged as
independently purchased commodities.   Normally cost estimates are based
on a single power unit independent of other units at  the site.  In cases
in which a plant-wide process or system is evaluated, a plant capacity
of 2,000 MW is used.
                                   B-9

-------
    TABLE B-3.   POWER UNIT REMAINING LIFE,  OPERATING TIME,  AND HEAT RATE

New
Power unit size, MW:
Remaining life, years
Full load, hr/yr
Heat rate, Btu/kWh
Bituminous coal
Subbituminous coal
Lignite
200

5,

9,
10,
11,
30
500

700
700
200
500

5,

9,
10,
11,
30
500

500
500
000
1,

5,

9,
10,
10,
000
30
500

200
200
700
200

5,

9,
11,
11,
20
500

900
000
400
Existing
500

5,

9,
10,
11,
20
500

700
700
200
1,000
20
5,500

9,500
10,500
11,000

Flue Gas Compositions

     Flue gas compositions are based on combustion of pulverized coal
assuming a total air rate equivalent to 139% of the stoichiometric
requirement (defined as air for combustion of carbon, hydrogen, and
sulfur).  This includes 20% excess air to the boiler and 19% additional
air leakage to the flue gas in the air heater.  It is assumed that 80%
of the ash present in all coals is emitted as fly ash.  Sulfur emitted
as SOX is dependent on the coal type; 92% of the sulfur in all eastern
coals and 85% of the sulfur in all western coals and lignite is emitted
as SOX.   The remaining sulfur is removed in the bottom ash and fly ash.
No loss of sulfur in the pulverizers is assumed.  Three percent of the
sulfur emitted as SOX is 803 and the remainder is S02-

     A flow diagram around the boiler is shown in Figure B-2 and detailed
boiler material balances and flue gas composition summaries for stream 8,
for each premise coal, are shown in Tables B-4 through B-17.  The streams
shown in the material balances have excess significant digits for cases
in which higher accuracy is needed.  All streams balance to a net of +10
Ib/hr.  These numbers are not to be published without rounding to four
significant digits, no more - no less.

Environmental Regulations

     Emissions from new coal-fired utility plants are regulated by the
new source performance standards, which are issued under authority of
Section 111 of the Clean Air Act as amended in 1970 and 1977.  This
section requires the Environmental Protection Agency  (EPA) to set Federal
emission limitations which reflect the degree of control that can be
achieved by using the best available control technology (BACT).  On
December 23, 1971, EPA issued NSPS to limit emissions of S02, NOX, and
particulate matter from utility power plants  (11).  In 1979 EPA chose
to revise the NSPS (1) which are shown in Table B-18.  The controlled
outlet S02 emission and S02 removal efficiencies for premise coals are
shown in Figure B-3 and tabulated in Table B-19.
                                   B-10

-------
TABLE B-4.  BOILER MATERIAL BALANCE




EASTERN BITUMINOUS COAL,  5% SULFUR
Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sftj/min @ 6Qop
Temperature, °F
N£ (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
405,983


(264,701)
(16,239)
(22,329)
(5,278)
(406)
(19,487)


16,239
61,303
2
Total air
to air heater
5,047,807
1,115,166
80
3,829,456
1,153,571






64,799

3
Combustion
air to
boiler
4,357,819
962,733

3,306,006
995,888






55,925

Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
303 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
4
Bottom
ash
12,572











12.572
5
Gas to
economizer
4,75)^230
999,502

3,310,415
164,941
969,982
34, 748
1,343
1,766
142
418
217,184
50,291
6
Gas to air
heater
4,751,230
999,502

3,310,415
164,941
969,982
34,748
1,343
1,766
142
418
217,184
50,291
Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
503 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
7
Air
inleakage
689,988
152,433

523,451
157,682






8,855

8
Gas to
electrostatic
precipitator
5,441,218
1,151,935

3,833,866
322,623
969,982
34,748
1,343
1,766
142
418
226,039
50,291















               B-ll

-------
         TABLE B-5.   FLUE GAS COMPOSITION

       FOR 5% SULFUR EASTERN BITUMINOUS COAL

   (Stream 8; gas to electrostatic precipitator)

Component
N2
02
C02
S02
503
NO
N02
HC1
H20

Fly asha
Total
Volume, %
75.13
5.53
12.10
0.30
0.01
0.03
0.00
0.01
6.89
100.00





(2,976 ppm)
( 93 ppm)
( 324 ppm)
( 16 ppm)
( 66 ppm)




Lb-mol/hr
136,900
10,080
22,040
542
17
59
3
12
12,550
182,200


Lb/hr
3,834,000
322,600
970,000
34,750
1,343
1,766
142
418
226,000
5,391,000
50,290
5,441,000
Sft3/mln ( 60°F) = 1,152,000
Aft3/min (300°F) = 1,684,000
                  Fly Ash Loading

                                           Gr/sft3

Wet                                         5.09
Dry                                         5.47

Sulfuric acid dew point temperature:  316°F


a.  See Table B-2 for fly ash composition.
                         B-12

-------
       3-6.  BOILER MATERIAL BALANCE




EASTERN BITUMINOUS COAL, 3.5% SULFUR
Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sftj/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
405,983


(270,791)
(15,427)
(22,735)
(5,278)
(406)
(13,641)


16,239
61,466
2
Total air
to air heater
5,071,690
1,120,442
80
3,847,575
1,159,029






65,086

3
Combustion
air to
boiler
4,378,438
967,288

3,321,648
1,000,601






56,189

Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
Oa (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
4
Bottom
ash
12,511











12,511
5
Gas to
economizer
4,771,910
1,002,880

3,326,058
165,726
992,298
24,324
940
1,766
142
418
210,192
50,046
6
Gas to air
heater
4,771,910
1,002,880

3,326,058
165,726
992,298
24,324
940
1,766
142
418
210,192
50,046
Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
Total stream, Ib/hr
Flow rate, sft^/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
13| Ash Ib/hr
7
Air
inleakage
693,252
153,154

525,927
158,428






8,879

8
Gas to
electrostatic
precipitator
5.465,162
1,156,034

3,851,985
324.154
992,298
24,324
940
1.766
142
418
219,089
50.046















                B-13

-------
         TABLE B-7.   FLUE GAS COMPOSITION

      FOR 3.5% SULFUR EASTERN BITUMINOUS COAL

   (Stream 8; gas to electrostatic precipitator)

Component
N2
02
C02
S02
503
NO
N02
HC1
H20

Fly asha
Total
Volume, %
75.22
5.54
12.33
0.21
0.01
0.03
0.00
0.01
6.65
100.00





(2,079 ppm)
( 66 ppm)
( 323 ppm)
( 16 ppm)
( 66 ppm)




Lb-mol/hr
137,500
10,130
22,550
380
12
59
3
12
12,160
182,800


Lb/hr
3,852,000
324,200
992,300
24,320
940
1,766
142
418
219,100
5,415,000
50,050
5,465,000
Sft3/min ( 60°F) = 1,156,000
Aft3/min (300°F) = 1,690,000
                  Fly Ash Loading

                                           Gr/sft3

Wet                                         5.05
Dry                                         5.41

Sulfuric acid dew point temperature:  308°F


a.  See Table B-2 for fly ash composition.
                         B-14

-------
 TABLE B-8.  BOILER MATERIAL BALANCE




EASTERN BITUMINOUS COAL,  2.0% SULFUR
Stream No.
Description
1
2
3
4
S
6
7
8
9
in
11
1?
13
Total stream, Ib/hr
Flow rate, sftj/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
303 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
405,983


f275I2S6')
(15,021)
(24,359)
(5,684)
(406)
(7,795)


16.239
61.223
2
Total air
to air heater
5,081,446
1,122,597
80
3,854,977
1,161,258






65.211

3
Combustion
air to
boiler
4,386,860
969,149

3,328,038
1,002,525






56.297

Stream No.
Description
1
7
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft3/min @ 60UF
Temperature, °F
N2 (C) Ib/hr
02 (H) ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
803 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
4
Bottom
ash
12,369











12,36Q
5
Gas to
economizer
4,780,474
1.004,532
800
3,332,,854
166,047
1,008,662
13,899
537
1,766
142
418
206,672
49 ,477
6
Gas to air
heater
4,780,474
1.004,532
705
3,332^854
166,047
1,008,662
13,899
537
1 ,766
142
418
206,672
49 ,477
Stream No.
Description
1
2
3
4
5
6
7
8
9
10
1 1
12
n
Total stream, Ib/hr
Flow rate, sft-Vmin @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
503 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
7
Air
inleakage
694,586
153,449
535
526,939
158,733






8,914

8
Gas to
electrostatic
precipitator
5,475,060
1,157,981
300
3,859,793
324.780
1,008,662
13,899
537
1.766
142
418
215,586
49,477















               B-15

-------
          TABLE B-9.   FLUE GAS COMPOSITION

        FOR 2% SULFUR EASTERN BITUMINOUS COAL

    (Stream 8; gas to electrostatic precipitator)

Component
N2
02
CO 2
so2
so3
NO
NO 2
HC1
H20

Fly asha
Total
Volume
75.24
5.54
12.52
0.12 (1,
0.00 (
0.03 (
0.00 (
0.01 (
6.54
100.00


7
, /o



185 ppm)
38 ppm)
322 ppm)
16 ppm)
66 ppm)




Lb-mol/hr
137,800
10,100
22,920
217
7
59
3
12
11,970
183,100


Lb/hr
3,860,000
324,800
1,009,000
13,900
537
1,766
142
418
215,600
5,426,000
49,480
5,475,000
Sft3/min ( 60°F) = 1,158,000
Aft3/min (300°F) = 1,692,000
                   Fly Ash Loading

                                           Gr/sff"
Wet                                         4.98
Dry                                         5.33

Sulfuric acid dew point temperature:  297°F
a.  See Table B-2 for fly ash composition.
                         B-16

-------
TABLE B-10.  BOILER MATERIAL BALANCE




EASTERN BITUMINOUS COAL,  0.7% SULFUR
Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sftj/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
SOs (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
405,983


(279,316)
(14,616)
(25,577)
(5,684)
(406)
(2,720)


16,239
61,425
2
Total air
to air heater
5,091,465
1,124,811
80
3,862,577
1,163,548






65,340

3
Combustion
air to
boiler
4,395,510
971,060

3,334,599
1,004,502






56,409

Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
4
Bottom
ash
12,329











12,329
5
Gas to
economizer
4,789,164
1,006,060
800
3,339,415
166,376
1,023,540
4,850
188
1,766
142
418
203,155
49,314
6
Gas to air
heater
4,780,164
1,006,060
705
3,339,415
166,376
1,023,540
4,850
188
1,766
142
418
203,155
4Q,314
Stream No.
Description
1
2
3
4
5
6
/
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft^/min (? 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H90 Ib/hr
Ash Ib/hr
7
Air
inleakage
695,955
153,751
535
527,978
159,046






8,931

8
Gas to
electrostatic
precipitator
5,485,1 19
1,159,811
300


1,023,540
4,850
188
1.766
142
418
212.086
40,314
















-------
         TABLE B-ll.  FLUE GAS COMPOSITION

      FOR 0.7% SULFUR EASTERN BITUMINOUS COAL

   (Stream 8; gas to electrostatic precipitator)

Component
N2
02
C02
S02
S03
NO
N02
HC1
H20

Fly asha
Total
Volume, %
75.27
5.55
12.68
0.04
0.00
0.03
0.00
0.01
6.42
100.00





(414 ppm)
( 11 ppm)
(322 ppm)
( 16 ppm)
( 65 ppm)




Lb-mol/hr
138,100
10,170
23,260
76
2
59
3
12
11,770
183,400


Lb/hr
3,867,000
325,400
1,024,000
4,850
188
1,766
142
418
212,100
5,436,000
49,310
5,485,000
Sft3/min ( 60°F) = 1,160,000
Aft3/min (300°F) = 1,695,000
                  Fly Ash Loading

                                           Gr/sft3

Wet                                         4.96
Dry                                         5.30

Sulfuric acid dew point temperature:  273°F


a.  See Table B-2 for fly ash composition.
                        B-18

-------
TABLE B-12.  BOILER MATERIAL BALANCE




WESTERN BITUMINOUS COAL, 0.7% SULFUR
Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft^/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
489,691


(279,124)
(19,098)
(56,314)
(5,876)
(490)
(2,889)


(78,351)
(47,549)
2
Total air
to air heater
5,117,371
1,130,534
80
3,882,231
1,169,468






65,672

3
Combustion
air to
boiler
4,417,874
976,000

3,351,566
1,009,613






56,695

Stream No.
Description
1
2
3
4
5
6
7
8
9
1U
11
12
13
Total stream, Ib/hr
Flow rate, sft-Vmin @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
CC>2 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
4
Bottom
ash
9,596











9,596
5
Gas to
economizer
4,897,968
1,045,965

3,356,574
167,228
1,022,834
4,760
184
1,766
142
504
305,590
38,386
6
Gas to air
heater
4,897,968
1,045,965

3,356,574
167,228
1,022,834
4,760
184
1,766
142
504
305,590
38,386
Stream No.
Description
1
2
3
4
5
6
/
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft^/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
503 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
7
Air
inleakage
699,498
154,534

530,666
159,855






8,977

8
Gas to
electrostatic
precipitator
5,597,466
1,200,499

3,887,240
327,083
1,022,834
4,760
184
1,766
142
504
314,567
38,386















                B-19

-------
          TABLE B-13.  FLUE GAS COMPOSITION

       FOR 0.7% SULFUR WESTERN BITUMINOUS COAL

    (Stream 8; gas to electrostatic precipitator)

Component
N2
02
CO 2
S02
S03
NO
NO 2
HC1
H20

Fly asha
Total
Volume , %
73.10
5.38
12.24
0.04
0.00
0.03
0.00
0.01
9.20
100.00





(390 ppm)
( 10 ppm)
(311 ppm)
( 16 ppm)
( 74 ppm)




Lb-mol/hr
138,800
10,220
23,240
74
2
59
3
14
17,460
189,800


Lb/hr
3,887,000
327,100
1,023,000
4,760
184
1,766
142
504
314,600
5,559,000
38,390
5,597,000
Sft3/min ( 60°F) = 1,200,000
Aft3/min (300°F) = 1,755,000
                    Fly Ash Loading

                                           Gr/sft3

Wet                                         3.73
Dry                                         4.11

Sulfuric acid dew point temperature:  278°F


a.  See Table B-2 for fly ash composition.
                         B-20

-------
 TABLE B-14.  BOILER MATERIAL BALANCE
WESTERN SUBBITUMINOUS COAL, 0.7% SULFUR
Stream No.
Description
1
?
3
4
5
6
7
8
9
10
11
1?
n
Total stream, Ib/hr
Flow rate, sftj/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
640,244


(313,720)
(22,409)
(68,506)
(4,482)
(128)
(3,073)


187,591
40,335
2
Total air
to air heater
5,765,154
1,273,643
80
4,373,663
1,317,506






73,985

3
Combustion
air to
boiler
4,977,111
1,099,548

3,775,824
1,137,415






63,872

Stream No.
Description
1
?
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
4
Bottom
ash
8,159











8,159
5
Gas to
economizer
5,609,196
1,215,098

3,779,506
188,611
1,149,608
5,063
196
1,627
131
132
451,685
32,637
6
Gas to air
heater
5,609,196
1,215,098

3,779,506
188,611
1,^149,608
5,063
196
1,627
131
132
451,685
32,637
Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
503 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
7
Air
inleakage
788,043
174,095

597,839
180,091






10,113

8
Gas to
electrostatic
precinitator
6,397,239
1,389,193

4,377,345
368.702
1,149,608
5,063
196
1.627
131
132
461,798
32,637















                B-21

-------
         TABLE B-15.  FLUE GAS COMPOSITION

     FOR 0.7% SULFUR WESTERN SUBBITUMINOUS COAL

   (Stream 8; gas to electrostatic precipitator)

Component
N2
°2
C02
so2
so3
NO
NO 2
HC1
H20

Fly asha
Total
Volume, %
71
5
11
0
0
0
0
0
11
100


.13
.25
.89
.04
.00
.02
.00
.00
.67
.00





(360
( 9
(246
( 14
( 18







ppm)
ppm)
ppm)
ppm)
ppm)




Lb-mol/hr
156,300
11,520
26,120
79
2
54
3
4
25,630
219,700


Lb/hr
4,377
368
1,150
5

1


461
6,365
32
6,397
,000
,700
,000
,063
196
,627
131
132
,800
,000
,640
,000
Sft3/min ( 60°F)
Aft3/min (300°F)
1,389,000
2,030,000
                   Fly Ash Loading
Wet
Dry
                        Gr/sft3

                         2.74
                         3.10
Sulfuric acid dew point temperature:  280°F
a.  See Table B-2 for fly ash composition.
                        B-22

-------
TABLE B-16.   BOILER MATERIAL BALANCE




  NORTH DAKOTA LIGNITE,  0.9% SULFUR
Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sftj/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
303 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
833,333


(334,167)
(23,333)
(103,333)
(5,000)
(83)
(4,750)


302,500
60,167
2
Total air
to air heater
5,938,178
1,311,867
80
4,504,926
1,357,047






76,205

3
Combustion
air to
boiler
5,126,485
1,132,547

3,889,145
1,171,551






65,789

Stream No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
Q2 (H) Ib/hr
C02 (0) Ib/hr
SC>2 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
4
Bottom
ash
12,176











12,176
5
Gas to
economizer
5,947,642
1,296,872
800
3,893,140
194,053
1,224,537
7,825
302
2,045
165
86
576,786
48,703
6
Gas to air
heater
5,Q47,642
1,296,872

3,893,140
194,053
1,224,537
7,825
302
2,045
165
86
576,786
48,703
Stream No.
Description
1
2
3
4
5
6
7
H
9
10
11
12
13
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
303 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
7
Air
inleakage
811,693
179,320

615,780
185,496






10,417

8
Gas to
electrostatic
precipitator
6,759,335
1,476,192

4,508,920
379,549
1,224,537
7,825
302
2,045
165
86
587,203
48,703















                B-23

-------
         TABLE B-17.  FLUE GAS COMPOSITION

       FOR 0.9% SULFUR NORTH DAKOTA LIGNITE

   (Stream 8; gas to electrostatic precipitator)

Component
N2
02
C02
S02
S03
NO
N02
HC1
H20

Fly

68.
5.
11.
0.
0.
0.
0.
0.
13.
100.
asha
Total
Volume, %
95
08
92
05
00
03
00
00
97
00








(524
(
17
(291
(
(




17
9







ppm)
ppm)
ppm)
ppm)
ppm)




Lb-mol/hr
161,000
11,860
27,820
122
4
68
4
2
32,600
233,400


Lb/hr
4,509
379
1,225
7

2


587
6,711
48
6,759
,000
,500
,000
,825
302
,045
165
86
,200
,000
,700
,000
Sft3/min ( 60°F)
Aft3/min (300°F)
1,476,000
2,158,000
                  Fly Ash Loading
Wet
Dry
                        Gr/sft3

                         3.85
                         4.47
Sulfuric acid dew point temperature:  295°F
a.  See Table B-2 for fly ash composition.
                        B-24

-------
TABLE B-18.  1979 REVISED NSPS EMISSION STANDARDS
S02

70% S02 removal  (minimum)  to  a maximum SC>2
 emission of 0.6 Ib  S02/MBtu
0.6 Ib S02/MBtu maximum emission  up  to 90%  S02
 removal
90% S02 removal  (minimum)  to  a maximum SC>2
 emission of 1.2 Ib  S02/MBtu
1.2 Ib S02/MBtu maximum emission
NOX

Bituminous coal - 0.6 equivalent  Ib N02/MBtu
Subbituminous coal - 0.5 equivalent Ib NC^/MBtu
Lignite - 0.6 equivalent Ib N02/MBtu
Particulate

0.03 lb/106 Btu
Reference  1
                         B-25

-------
   1 .2
   1 .0
   0.8
                        removal reauired
                          80
                           I
85
 I
                                         I
                               5.0% S, 11,700 Btu/lb bit, coal
                                               3.5% S,  11,700 Btu/lb bit,  coal
                              2.0?  S,  11,700 Btu/lb bit,  coal
                    0.9%  S, 6,600 Btu/lb lignite
                  _7%_S,_ 9,700 Btu/lb  bit, coal

                0^. 7% S,  9_,_700 Btu/lb  subbit. coal
                0.7% S,  8,200 Btu/lb  subbit. coal
                                                                    I
                                                                           I
                                  4             6             8             10

                               EQUIVALENT S()2 COMTEN'" OF RAW  COAL, Ib S02/MBtu
                                                       12
Figure  B-3.  Controlled  S02  emission  requirements for  1979 NSPS.   Premise  coals,  shown
              underlined,  are based on premise  boiler conditions.

-------
                TABLE  B-19.  PREMISE COAL  EMISSION STANDARDS

Equivalent
Equivalent



Eastern
Eastern
Eastern
Eastern
Western
Western


Coal
bit. ,
bit.,
bit.,
bit.,
bit. ,
subbit
N.D. lignite,






so2
of
content
coal,
Ib S02/MBtu
5
3
2
0
0
.
0
.0%
.5%
.0%
.7%
.7%
, o.
.9%
S
S
S
S
S
7% S
S
8
5
3
1
1
1
1
.21
.74
.28
.15
.22
.17
.73
Overall
equivalent S02
removal
efficiency, %
90.0
89.6
81.7
70.0
70.0
70.0
70.0
SO 2 removal
required
in
FGD
system, %a
89
88
80
67
64
64
64
.1
.7
.1
.4
.7
.7
.7
Controlled
outlet
emission


Ib S02/MBtu
0.82
0.60
0.60
0.34
0.36
0.35
0.52







 a.   Based  on FGD system as the only S02 control device and the previously
     defined sulfur retention in the ash.
 Equation  to determine equivalent S02 content of coal:

    E = (S/H)(2 x 104)

    where:  S = % sulfur in coal, as fired
            H = heat content of coal, as fired
            E = equivalent S02 content of coal as fired, Ib equivalent
                S02/MBtu


 Equations to determine overall % sulfur removal required:

    E < 2.0

    70% equivalent SOj removal required

    2.0 < E < 6.0

    % equivalent S02 removal required = ((E - 0.6)/E)(100)

    6.0 < E < 12.0

    90% equivalent S02 removal required

    E > 12.0

    % equivalent S02 removal required = ((E - 1.2)/E)(100)


Equation to determine equivalent S02 removal required in FGD  system:

    % equivalent S02 removal required = ((A - B)/(1.0 -  B))(100)

    where:  A = overall removal efficiency,  decimal  fraction
            B = decimal fraction of S removed with ash:  (1.0  -  decimal
                fraction of sulfur emitted as SO)
                                                X
                                  B-27

-------
                COAL
                             BOILER
                                               IECONOMIZER]
                                               1      i
                                            TOTAL
                                              AIR
                                                         AIR HEATER
                                                             FLUE
                                                            'GAS
                          BOTTOM  ASH
               Figure B-2.  Boiler flow diagram.
Particulate Matter

     Cold-side (post-air heater)  ESP's  sized  to meet  the  0.03  Ib/MBtu
standard are normally assumed for particulate matter  control.   In  some
evaluations cyclones, fabric filter baghouses, or  hot-side  (pre-air
heater) ESP's may be required.   The costs  for ash  collection and disposal
may or may not be included in the economic evaluations, depending  on the
particular processes being evaluated.   In  some processes  ash may be an
intrinsic part of the process.   In such processes,  or in  evaluations in
which comparison with such processes may be anticipated,  provisions for
ash control costs are included.

Flue Gas Desulfurization

     The conceptual design of the FGD  system  meets  applicable  emission
standards and reflects a practical operating  approach.  FGD systems are
close-coupled to the power unit  by a plenum into which the power plant
ID fans discharge.  The plenum allows  the  scrubbing systems to be  designed
for a different number of trains than  the  number of power plant ducts
(to account for limitations in the available  size  of  individual scrubbing
                                   B-28

-------
units), and it facilitates the use of redundant scrubbing trains.  To
minimize flow control problems which can result from this design, separate
fans are provided on each side of the plenum.  Conventional power plant
ID fans operating balanced draft in respect to the boiler are used
upstream from the plenum to overcome the pressure drop of the boiler and
associated downstream flue gas ductwork.  These fans are generally
designed to overcome a static head of about 15 in. H20.  Since they are
required even if FGD units are not installed, the installation and
resulting operating costs are not included in the costs of the FGD
system.  Separate fans are provided downstream from the plenum to over-
come the pressure drop attributed to the scrubber and the ductwork which
is required solely as a result of installing FGD facilities.

     The FGD costs include FGD-related ductwork and associated equipment
between the power plant ID fans and the stack plenum.  All ductwork
between the power plant ID fan and the stack plenum is charged to the
flue gas treatment system.  This is done on the assumption that without
the flue gas treatment system the boiler ID fan would discharge directly
into the stack plenum.  Unless specific process requirements dictate
otherwise, scrubbing trains are sized for a maximum of 125 MW of flue
gas up to a maximum of 513,000 sft3/min (60°F).  Thus, the 500-MW base
case requires four operating trains and the 200-MW and 1,000-MW case
variations require two (100-MW) and eight (125-MW) operating trains
respectively.  Furthermore, any boiler generating more than 340,000
aft /min (about 100 MW) is provided with a minimum of two operating
scrubber trains.  It is assumed that the annual availability of a
scrubbing train is 85% and that no scrubbing time is lost during startup.
Spare scrubbing trains are provided as described below.

Emergency Bypass—
     Because the 1979 NSPS allow emergency bypass around the FGD system
under some conditions if spare scrubbing capacity is provided, redundancy
in the form of spare scrubbing trains and provision for bypass of 50% of
the gas that would normally be scrubbed are included in all FGD economic
evaluations.  The 1,000-MW case variation with eight operating scrubbing
trains is provided with two spare trains.   Units on smaller boilers are
provided with one spare train.  An emergency bypass of 50% of the scrubbed
gas is assumed to be an economic balance between the higher cost of
providing additional bypass and the small likelihood of multiple scrubbing
train failures making higher bypass rates necessary.  The bypass is
installed as two identical ducts from each end of the inlet plenum to
the plenum downstream from the scrubbing trains.  Particulate collection
equipment is not bypassed.

Partial Scrubbing—
     In some cases,  depending on the sulfur content of the coal and SOX
removal requirements,  scrubbing a portion of the flue gas at a high SOX
removal efficiency and combining it with the remaining flue gas may be
more economical than scrubbing all of the flue gas at a lower SOX removal
efficiency.   In such cases the bypassed gas duct requirements and the
emergency bypass capability are combined in the same duct.   The ducts
are sized to handle both the flue gas normally bypassed and the emergency

                                    B-29

-------
bypass of 50% of the gas normally scrubbed.   Depending on sulfur in the
coal for the 500-MW power unit, partial scrubbing could involve scrubbing
as little as 375 MW of flue gas.   Three operating scrubbing trains and
one spare scrubbing train are provided for this case.

Ductwork—
     Square ductwork with 2-inch insulation (in standard cases) is used
for the inlet plenum and scrubbing trains.  To prevent ash settling, a
gas velocity of 50 ft/sec is used for the inlet plenum, all ductwork,
and the emergency bypass.  A gas velocity of 25 ft/sec is used for the
reheater section.  Duct material is usually 3/16-inch Cor-Ten® steel
when the gas temperature is higher than 150°F and 3/16-inch stainless
steel when the gas temperature is lower than 150°F.

Removal Efficiencies—
     It is assumed that 50% of the S03, 95% of the HC1, 0% of the NOX,
and 50% of the remaining fly ash in the flue gas are removed in the FGD
system.  For systems requiring a presaturator or humidifier, it is
assumed that 5% of the SC>2 is removed in the presaturator and that the
remaining S02 removal takes place in the FGD absorber.

Spare Equipment—
     Equipment is spared in accordance to general field practice.  For
most processes the following equipment is spared:

  •  Crushing and grinding equipment:  A spare train of crushing and
     grinding equipment

  •  Slakers

  •  Sludge filters

  •  Pumps

  •  Scrubbing trains:  A spare scrubbing train or trains

Mist Eliminator—
     The mist eliminator is a  zigzag-chevron-baffle type.  The mist
eliminator reduces entrained moisture  to a maximum level of 0.1%  (by
weight) of the flue gas.  This maximum level is assumed for calculation
of  the amount of stack gas reheat required.

Stack Gas Reheat—
     Indirect steam reheat is  provided for processes  that cool the  flue
gas below 175°F.  This stack gas reheat is considered necessary both  to
evaporate entrained water droplets not removed by  the mist eliminator
and to increase  plume buoyancy.  Necessary information  for calculating
the steam requirement and reheater surface area is given in Table B-20
and a sample calculation is shown in Table B-21.

     One-half of the reheater  tubes are made of Inconel 625 and one-half
of  Cor-Ten.  Inconel 625 is highly resistant to corrosion and  is  used

                                    B-30

-------
            TABLE  B-21.   SAMPLE  REHEATER CALCULATIONS

Gas to Reheater
co2
HC1
S02
°2
N2
H20 (vapor)
Total gas
H20 (liquid entrainment)
Total
Reheater Heat Duty
co2
HC1
S02
02
N2
H90 (vapor)
Ib/hr
1,008,000
21
2,850
319,800
3,852,000
444,873
5,627,544
5,627
5,633,171
Ib/hr x Cpm(Btu/lb)b =
1,008,000 x 10.8
21 x 9.5
2,850 x 7.9
319,800 x 11.2
3,852,000 x 12.5
444,873 x 22.6




Btu/hr
10,886,400
200
22,515
3,581,760
48,150,000
10,054,130
     Total

HoO (liquid entrainment)

     Total
5,627 x   l,043.2t
72,695,005

 5,870,090

78,565,095  Btu/hr
Steam Requirement

78,565,095 Btu/hr v  751.9  Btu/lb =  104,489 Ib/hr
Reheater Area

78,565,095 Btu/hr T  4  operating  reheaters 4- 20.8 Btu/ft -hr-°F T
3igoFa,b = 2,960 ft2
a.  Log mean temperature  difference  (ATL) =  (T^ - T2) /(ln(TL/T2))

    TI = Tsteam - Tgas in =  470 - 125 = 345
    T2 = Tsteam - Tgas out = 470 - 175 = 295
    ATL = (345 - 295)/(ln(345/295))

b.  For a temperature change from 125°F to  175°F qn_
                                  B-31

-------
                        TABLE  B-20.  REHEATER DATA
- - : . - _ , _ : :
Compound
C02
HC1
S02
803
02
N2
NO
N02
H20 (vapor)
Cpm (Btu/lb)a
10.8
9.5
7.9
8.2
11.2
12.5
12.0
10.2
22.6
                 Steam:
                     sa
                     vaporization 751.9 Btu/lb
saturated at 470°F (500 psig),  heat of
                 Reheater overall heat transfer coefficient:
                     20.8 Btu/ft2-hr-°F

                 Entrained water enthalpy:
                     liquid at T = 125°F:  92.9 Btu/lb
                     vapor at T = 175°F:  1136.1 Btu/lb
                     •*• AHa = 1043.2 Btu/lb
                 a.  For a temperature change from 125°F to
                     175°F only.
for the first bank of tubes, which increases the flue gas temperature to
150 F.  The Cor-Ten tubes follow directly after, raising the temperature
of the gas at the exit to 175°F.  For the partial bypass case, the gas
may not be heated to 175°F because of the smaller percentage of scrubbed
(cool) gas.  In these cases, the percentage of Inconel 625 tubes increases
to as much as 100% (for reheat to 150°F or less).

Raw Materials and Byproducts—
     Raw materials and byproduct storage capacity is normally 30 days
unless process or industry practice differ.  Standard raw material
characteristics are shown in Table B-22.

NO,, Control
     Processes that remove only NOX are combined with a limestone spray
tower, forced-oxidation FGD system with landfill waste disposal for
comparison with processes that remove both NOX and S02-

     Redundancy is included in the NOX control processes to ensure that
removal efficiencies used in each particular economic study are met.
For wet NOX control processes the availability is the same as for FGD
                                    B-32

-------
                  TABLE B-22.   RAW MATERIAL CHARACTERISTICS

Limestone
Size as received
0 x 1-1/2 inch
Ground
size
90% to pass
325 mesh
Analysis3
95% CaC03
0.15% MgO
Bulk
density, Ib/ft"1
95
           Fineness of grind
            index factor = 5.7
           Hardness of work
            index factor = 10
                                              4.85% inerts
                                              5 Ib H20/100 Ib
                                               dry limestone
Lime       3/4 x 1-1/4 inch
 (pebble)
MgO
Crystalline
 powder
Soda ash   100% to pass
           100 mesh
Adipic
 acid
Crystalline
 powder
                                   95% CaO          55
                                   0.15% MgO
                                   4.85% inerts
                                   5 Ib H20/100 Ib
                                    dry lime
98% MgO
2% inerts

99.8% Na2C03
(58.4% Na20)
0.15% NaCl
0.02% inerts
0.03% H20
99.8% (CH2)4     49
 (COOH)2
0.2% inerts
30 (virgin)
15 (regenerated)

35
a.  Limestone and lime analysis on a dry basis.   H20  is  based  on  pounds  of  dry
    limestone or lime.
                                  B-33

-------
systems.  When the number of trains is the same as FGD for the same
boiler size, the redundancy for wet NOX control process trains is the
same as for an FGD system.

     For dry catalytic processes,  catalyst replacement occurs during
boiler outages and does not affect boiler on-stream time.   A sufficient
quantity of catalyst is included to ensure that the desired removal
efficiency is maintained during the entire guaranteed life of the catalyst
load.  Redundancy and the number of trains for all dry processes are
based on NOX removal system module availability and the required NOX
removal efficiency.  Redundancy is achieved through sparing NOX removal
system trains or sparing vital equipment such as NH3 vaporization and
injection equipment.

Solids Disposal

     For FGD processes producing a solid waste, either ponding or
landfill disposal at a site one mile from the FGD facilities is used.
Sufficient land is provided for disposal during the remaining life of
the FGD facility.  Fly ash disposal is not included unless fly ash
collection or use is an integral part of the FGD process.   The disposal
site is assumed to be an area of low relief with sufficient soil for
dike construction or landfill requirements.

Pond-
     Disposal ponds are square, earthen-diked enclosures with a median
diverter dike.  Dikes are constructed from material removed from the
impoundment area as shown in Figure B-4.  The entire impoundment area is
lined with 12 inches of clay (assumed available onsite).  Pond size and
depth are adjusted to minimize the sum of land and construction costs.
Pond costs include a 6-foot security fence around the perimeter dike,
security lighting, a topsoil storage area, and one upstream and three
downstream ground water monitoring wells.

Landfill-
     Landfills are an area-type landfill having a square configuration
with a single 20-foot lift and a 2-degree cap, as shown in Figure B-5,
After topsoil removal the landfill area is lined with 12 inches of clay
(assumed available onsite) and 24 inches of bottom ash.  This bottom ash
layer allows the water to drain into a catchment ditch around the
perimeter.  The ditch drains into a catchment basin for pH adjustment
before discharging into the river.  Land requirements include the landfill,
catchment basin, equipment storage area, topsoil storage area, and a 50-
foot perimeter of undisturbed land.  Costs for access roads, a 6-foot
security fence around the total landfill area, security lighting, and
topsoil stripping, replacement, and revegetation are included.  One
upstream and three downstream ground water monitoring wells are also
included.
                                    B-34

-------
i_n
                             WASTE  DISPOSAL
                                 POND
                                t_
                  J
                                                                                         OUTER BOUNDRY
                                                                                        X OF POND AREA
                                                                                                                                                 10% FREE BOARD
                                                                                                                                                DEPTH OF SLUDGE
                                                                          GROUND LEVEL
                                                                              TOPSOIL
                                                                             EXCAVATION
                                                                              (15 FT)\
                                                                              SUBSOIL '
                                                                            EXCAVATION
                                                                                                               SECTION AA

                                                                                                           POND PERIMETER DIKE
                                                                                                         NAL GROUND LEVEL —^
                                                                                                      ORIGINAL GROUND
                                                                                                                                    TOTAL
                                                                                                                                 EXCAVATION DEPTH
                                                                                                                                                 SUBSOIL
                                                                                                                                                EXCAVATION
                                                                                                                                                 10% FREE BOARD
                                                                                                                              DEPTH OF SLUDGE


                                                                                                                               1   TOTAL
                                                                                                                                 EXCAVATION DEPTH
SUPERNATE                    SLURRY
                              IN
                                                                                                               SECTION BB
                                                                                                           POND  DIVERTER DIKE
       Figure  B-4.    Pond  plan and  dike construction details.

-------
w
LO
N
)
Topsoil Equipment Office -i Catchment
Storage~\ Storages / Basin ~7
* v A v x ^ 	 x — V^f 	 x — /-x 	 * 	 tx 	 >




e
— »
P-^: — i-J. \ / r^ 	 *^
•k . ^
D



/,
\*
Landfill
Area
/
/
^
X XX X)( V X X X X
Ditch -/ ^- 6' Fence
-] — 50'
E 24'
— 40'
, 	 ~ 	 , 	 * 	 ~ 	 .
>
/*
>
*i
, t


                                                                                24'
                                                                                Ditch
                                                                                           ' Clay
                                                                                                     ^
2' Bottom Ash
Figure  B-5.  Landfill plan and  construction  details.

-------
ECONOMIC PREMISES

Schedule and Cost Factors

     The construction schedule used as a cost basis is shown in Figure B-6.
A three-year construction period, from early 1981 to late 1983, is used.
Mid-1982 costs are used for capital investment.  Mid-1984 costs are used
for annual revenue requirements.  These costs represent the midpoint of
construction expenditures in 1982 and the midpoint of the first-year of
operation in 1984.  Costs are projected from Chemical Engineering cost
indexes (12), as shown in Table B-23.  Frequently used costs are shown
in Table B-24.
3





u
-2

1


period
1981 1982
-101
, Operating year




1983
1 	 .tol
1



1984
1 to.
      Begin
  construction
  (early 1981)
                          1
   Midpoint  of
   construction
   expenditure
     (mid-1982)
               End  of
             construction
              (late  1983)
           Begin operation
             in early 1984
  Figure B-6.  Construction schedule.
     Year:
                 TABLE B-23.   COST INDEXES AND PROJECTIONS
1978
1979   1980a   1981£
                                                 1982'
1983C
                                               1984
Plant
Material13
Laborc
218.8
240.6
185.9
238.7
264.4
194.9
257.8
288.2
210.5
277.1
311.2
227.3
297.9
336.1
245.5
320.2
363.0
265.2
342.6
388.4
283.7

     a.   TVA projections.
     b.   Same as "equipment,  machinery,  supports" Chemical Engineering
         index.
     c.   Same as "construction labor" Chemical Engineering index.
                                   B-37

-------
                      TABLE B-24.  COST FACTORS
Project Timing

Start
End
Midpoint
First-year operation
  January 1981
  December 1983
  Mid-1982
  1984
1984 Utility Costs

Electricity
Steam
Eastern bit. coal (<1% S)
Eastern bit. coal (>1% S)
Western bit. coal (0.7% S)
Western subbit. coal (0.7% S)
N.D. lignite (0.9% S)
Fuel oil No. 6
Diesel fuel3
Natural gas
Filtered river water
    $0.037/kWh
    $2.50/klb;
   $53.35/ton;
   $43.30/ton;
   $55.70/ton;
   $30.00/ton;
   $15.00/ton;
    $8.33/MBtu
    $1.60/gal
    $4.29/MBtu
    $0.14/kgal
    $0.12/kgal
    $0.10/kgal
    $0.08/kgal
$3.30/MBtu
$2.30/MBtu
$1.85/MBtu
$2.90/MBtu
$1.80/MBtu
$1.15/MBtu
(up to 0.6 Ggal)
(0.6 - 2 Ggal)
(2-5 Ggal)
(over 5 Ggal)
1984 Labor Costs

FGD
Waste disposal
Analysis
    $15.00/man-hr
    $21.00/man-hr
    $21.00/man-hr
1984 Raw Material Costs

Limestone
Lime
Ammonia
Soda ash
Adipic acid
MgO
    $8.50/ton (95% CaC03, dry basis)
   $75.00/ton (pebble,95% CaO, dry basis)
  $155.00/ton
  $160.00/ton (99.8% Na2C03)
$l,200.00/ton
  $460.00/ton
1982 Land Cost

                               $5,000/acre

These cost factors are based on a north-central plant location.
a.  Cost is based on wholesale price of barge-load quantities.  Road
    taxes are not included.
                                B-38

-------
Capital Cost Estimates

     Four  grades of capital cost estimates are prepared depending upon
the  intended use and the amount of information available.  The grades,
in increasing order of accuracy, are  (1) order of magnitude,  (2) study,
 (3)  preliminary, and (4) definitive.  The two grades normally used are
the  study  and preliminary grades.  The purpose, information required,
and  predicted accuracy are listed in  Table B-25.

     A typical capital investment sheet is shown in Table B-26.  The
capital investment sheet is divided into three major sections:  direct
investment, indirect investment, and  other capital investment.

Direct Investment—
     Direct investment consists of total process capital; services,
utilities, and miscellaneous; and waste disposal investment.  Total
process capital can be determined when an equipment list has been
organized.  Using standard estimating techniques (13,14) and the average
annual Chemical Engineering cost indexes and projections shown in Table B-23,
the  equipment cost and installation costs of each area are estimated.
These installation costs include charges for all piping, foundations,
excavations, structural steel, electrical equipment, instruments, ductwork
 (all included in gas handling area), paint, buildings, taxes, freight,
and  a premium for 7% overtime construction labor as shown in Figure B-7.
The  total  process area costs are summed on the Area Summary Sheet shown
in Figure  B-8 to give the total process capital.

     Service facilities such as maintenance shops, stores, communications,
security,  offices, and road and railroad facilities are estimated or
allocated  on the basis of process requirements.  Included in the utilities
investment are necessary electrical substations, conduit, steam, process
water, fire and service water, instrument air, chilled water, inert gas,
and  compressed air distribution facilities.  Services, utilities, and
miscellaneous are estimated to be in the range of 4% to 8% of the total
process capital.  For most cases 6% is to be used, higher for processes
only and lower for ponds only.  The base case limestone and lime scrubbing
processes are charged 6% for services, utilities,  and miscellaneous.

     All equipment and direct construction costs associated with waste
disposal are included in waste disposal costs.  For ponds, this includes
pond construction costs from the computer pond model.  For landfills,
mobile equipment and construction costs are included.  All mobile equip-
ment involved in loading and transporting the waste from the in-process
storage area, as well as working the landfill, are included in solids
disposal equipment.   The landfill construction cost, as calculated from
the landfill model,  is listed separately from the  solids disposal
equipment.  The sum of total process capital; services, utilities, and
miscellaneous;  and the waste disposal cost is the  total direct investment.

Indirect Investment—
     Indirect capital costs cover fees for engineering design and super-
vision,  architect and engineering contractor, construction expense,

                                    B-39

-------
                                    TABLE  B-25.   CAPITAL  COST  ESTIMATE CLASSIFICATION
              Grade
                Purpose
     Minimum information required
                                                                                                                   Predicted
                                                                                                                   accuracy
ttf
       Order  of magnitude
        (ratio estimate)
        Study
        (factored estimate)
       Preliminary
        (initial budget or
        scope estimate)
       Definitive
        (project control
       estimate)
Preliminary feasibility study  to  deter-
mine whether continued investigation is
merited.  Rough comparison of  alterna-
tives.
Comparison of alternatives.   Prelimi-
nary screening.   Preliminary  budget
preparation.   Authorization for  funding
for an engineering study  or for  develop-
ment of additional information.

Preliminary budget approval.   More
accurate comparison of  alternatives.
Followup of an order of magnitude or
study estimate.
Final capital authorization.   Project
cost control.  Followup  on  order  of
magnitude,  study,  or  preliminary  esti-
mates for more accurate  information.
Generally reserved for a real  construc-
tion project with  a known site.
General design basis,  flowsheet and
material balance, heat and energy
balance.  For the order of magnitude
estimates this information is of a tena-
tive nature, developed from a preliminary
process concept.
All of the above on a firm rather than
tentative basis plus overall layout of
manufacturing and nonmanufacturing
facilities, sized equipment and instru-
ment lists, and performance data sheets.

All of the study estimate requirements
plus process control diagrams, process
piping sketches with sizes, plan and
elevation drawings, offsite descriptions
including sizes and capacities.

All of the preliminary estimate require-
ments plus piping plan and elevation
drawings integrated with the equipment
plan and elevation drawings, electrical
layout single line drawings, detailed
piping and instrumentation flowsheets,
layout of nonmanufacturing facilities,
design sketches for unusual equipment
items, and specific site data including
utilities and transportation availa-
bility, soil bearing, wind and snow
loads.
40   20
30
     15
20   10
           General design basis includes product,  product specifications,  plant  capacity,  storage  requirements,  operating
           stream time, provisions for expansion,  raw materials and their  storage  requirements.

-------
                    TABLE B-26.   CAPITAL INVESTMENT  SHEET
              TABLE     ADVANCED LIMESTONE PROCESS CAPITAL INVESTMENT
                (500-MW new coal-fired power unit,  3.5%  S  in  coal;
                    88.6% S02 removal; onsite solids  disposal)
                                                                   Investment,  k$
Direct Investment

Materials handling
Feed preparation
Gas handling
S02 absorption
Stack gas reheat
Oxidation
Solids separation

     Total process capital

Services, utilities, and miscellaneous

     Total direct investment excluding landfill

Solids disposal equipment
Landfill construction

     Total direct investment

Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Contingency
Disposal area indirects

     Total fixed investment

Other Capital Investment

Allowance for startup and modifications
Interest during construction
Royalties
Land
Working capital

     Tctal capital investment

Dollars of total capital  per kW of generating capacity
Basis:  North-central plant location represents project beginning early  1981,
ending late 1983; average cost basis for scaling,  mid-1982.
Redundant scrubber train, 50% emergency bypass, spare pumps.
Landfill located one mile from power plant.
FGD process investment begins at power plant ID fans.  Stack  plenum and  stack
excluded.
                                    B-41

-------
w
I
% of pro cess equipment
Process equipment
Piping and insulation
Concrete foundations
Excavations , site prepa-
ration, roads, etc.
Structural
Electrical
Instrumentation
Ducts, chutes, expansion
joints , etc .
Paint and miscellaneous
Bui Idings
Trucks and earthmoving
equipment
Subtotal
Freight (3.57 of process
equipment material)
Tax (4% of material
subtota 1 )
Total process
area cost
X










Material















Labor3












">
-------
 contractor  fees, and contingency.  Listed in Table B-27 are the ranges
 to  be  used  to calculate the process and waste disposal indirect investments.
 The base percentages are normally used while the low and high ranges are
 used in cases where the process being studied is either much more complex
 than the typical system (the higher percentage factors are used) or much
 less complex  (the lower percentage factors are used).  Under most conditions
 the base values are used for typical systems.  The limestone and lime
 scrubbing processes use the low percentages for a 1,000-MW unit, base
 percentages for a 500-MW unit, and the high percentages for a 200-MW
 unit.  Contingency is included to compensate for unforeseen expenses.
 The contingency varies depending on the process and the waste disposal
 method, as  shown in Table B-28.  The limestone and lime scrubbing processes
 are assessed a contingency of 10% for the process and 20% for the landfill.

 Other  Capital Investment—
     The allowance for startup and modifications is applied as a percentage
 of  the total fixed investment.  Since the startup and modification costs
 for the waste disposal area are assumed to be negligible, this allowance
 is  calculated as a percentage of the total process fixed investment
 only.  The  values used are shown in Table B-29.  The limestone and lime
 scrubbing processes are assessed at a rate of 8% for this charge.

     The cost of borrowed funds (interest) during construction is 15.6%
 of  the total fixed investment (both process and waste disposal).  This
 factor is based on an assumed three-year construction schedule and is
 calculated  with a 10% weighted cost of capital with 25% of the construction
 expenditures in the first year, 50% in the second year, and 25% in the
 third  year  of the project construction schedule.  Expenditures in a
 given  year  are assumed uniform over that year.  Startup costs are assumed
 to  occur late enough in the project schedule that there are no charges
 for the use of money to pay startup costs.  Table B-30 illustrates the
 calculation of the interest during construction for three- through six-
 year construction schedules.

     Most processes will include a one-time royalty charge using either
 an  actual royalty obtained from the vendor or 1% of the total process
 capital involved.  Processes exempt from royalties due to their generic
 design are  limestone and lime processes, including those with forced
 oxidation or adipic acid or both,  and the magnesia process.

 Land—
     All land associated with the process and waste disposal area is
 charged to  the process.   The cost of land is $5,000 per acre.

Working Capital—
     Working capital is  the total amount of money invested in raw
materials,  supplies,  finished products,  accounts receivable,  and money
 on  deposit  for payment of operating expenses.   For these premises,
working capital is defined as the equivalent cost of 1 month's raw
material cost, 1.5 months'  conversion cost, 1.5 months'  plant and adminis-
 trative overhead costs (all of the above are found on the annual revenue
                                    B-43

-------
                 TABLE  B-27.  RANGE OF INDIRECT INVESTMENTS
Indirect Investment, Process
                                         % of total direct investment
                                      excluding waste disposal investment
                                      	 Low	Base	High	
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
  6
  1
 14
 7
 2
16
 3
18
 6
    Total
 25
30
35
Waste Disposal Indirects FGD Pond,
FGD Landfill, or Ash Pond
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees

    Total
                                           % of total direct waste
                                             disposal investment3
                                            Low
 14
          Base
           2
           1
           8
16
          High
           2
           1
           9
18
Ash Landfill
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees

    Total
% of total direct waste
  disposal investment5
          Base

           6
           3
          10
          25
a.  Pond  (or landfill construction) only.
                                    B-44

-------
                      TABLE B-28.   CONTINGENCY
Process Contingency
Limestone and lime slurry
Limestone and lime - forced oxidation
Limestone and lime - forced oxidation
 with adipic acid
All others
% of total direct investment
excluding waste disposal plus
 process indirect investment

             10
             10

             10
             20
Waste Disposal Contingency
FGD pond
Ash pond
FGD landfill
Ash landfill
                                       %  of  total waste disposal direct
                                            investment plus waste
                                         disposal indirect investment
             10
             10
             20
             10
      TABLE B-29.  ALLOWANCE FOR STARTUP AND  MODIFICATIONS
      Process
      Limestone and lime (generic3)
      All other processes
                                      %  of  total  fixed  investment
                                      	for  process  only	
         10
      Waste Disposal
      Ponds and landfills
                                      %  of  total  fixed  investment
                                        for waste disposal only
          0
      a.  Excludes Chiyoda,  double  alkali,  etc., which have
          unique designs and are not  as  yet proven  technology.
                                   B-45

-------
   TABLE B-30.  INTEREST DURING CONSTRUCTION  ILLUSTRATION

Three-Year Construction Schedule
Years from
startup
3-2
2-1
1-0
Total fixed
Compound amount
factor3
1.2686
1.1533
1.0484
Fraction of total
plant investment
x 0.250
x 0.500
x 0.250
investment plus interest during construction:
Interest during construction =
1.156 - 1.000 = 0.156 or 15


0.317
0.577
0.262
1.156
.6%
Four-Year Construction Schedule
Years from
startup
4-3
3-2
2-1
1-0
Total fixed
Compound amount
factor3
1.3955
1.2686
1.1533
1.0484
Fraction of total
plant investment
x 0.150
x 0.300
x 0.350
x 0.200
investment plus interest during construction:
Interest during construction =
1.204 - 1.000 = 0.204 or 20


0.209
0.381
0.404
0.210
1.204
.4%
Five- Year Construction Schedule
Years from
startup
5-4
4-3
3-2
2-1
1-0
Compound amount
factor3
1.5349
1.3955
1.2686
1.1533
1.0484
Fraction of total
plant investment
x 0.10
x 0.20
x 0.30
x 0.25
x 0.15


0.154
0.279
0.381
0.288
0.157
Total fixed investment plus interest during construction:  1.259




Interest during construction = 1.259 - 1.000 = 0.259 or 25.9%





                        (continued)



                             B-46

-------
                        TABLE B-30 (continued)
Six-Year Construction Schedule
Years from
startup
6-5
5-4
4-3
3-2
2-1
1-0
Compound amount Fraction of total
factor3 plant investment
1.6886
1.5349
1.3955
1.2686
1.1533
1.0484
X
X
X
X
X
X
0.10
0.15
0.25
0.25
0.15
0.10
                                                                0.169
                                                                0.230
                                                                0.349
                                                                0.317
                                                                0.173
                                                                0.105
     Total fixed investment plus interest during construction:  1.343

     Interest during construction = 1.343 - 1.000 = 0.343 or 34.3%
    Present worth and compound amount factor using the 10% cost of
    capital with continuous compounding (13).
a.
          Years from
           startup
                       Uniform expenditure
                        present worth (13)
Compound amount
  factor (13)
            7-6
            6-5
            5-4
            4-3
            3-2
            2-1
            1-0
                              0.5384
                              0.5922
                              0.6515
                              0.7166
                              0.7883
                              0.8671
                              0.9538
      8574
      6886
      5349
      3955
      2686
    1.1533
    1.0484
                                B-47

-------
requirements sheet),  and 3% of the total direct capital investment (from
the capital investment sheet).  One month is defined as 1/12 of annual
costs.  The equation is shown below:

  Working capital = 1/12 (total raw materials cost) +
                    (1.5) (1/12) (total conversion cost) +
                    (1.5) (1/12) (plant and administrative overhead) +
                    0.03 (total direct investment)

Battery Limits—
     Since battery limits costs typically include most of the associated
indirect investments, battery limits costs have their own indirect invest-
ment factors as shown below:

                                                % of battery
                                                limits cost

          Engineering design and supervision         6
          Architect and engineering contractor       1
          Construction expense                      14
          Contractor fees                            0
          Contingency                               10

Retrofit Factor—
     For existing plant cases a retrofit factor is assigned to cover the
additional investment required.  Each of the area investments  (i.e.,
material handling, etc.) is multiplied by the retrofit factor.  Retrofit
factors vary widely depending on the process and the site involved.  For
emission control processes which are close coupled to the boiler, the
following retrofit factors are used:
        Process
Retrofit
 factor
                                                 Reason
  Limestone scrubbing    1.3
  Spray dryer
  1.5
                                These  scrubbing  systems  are  add-on  in  that
                                they require  no  boiler modifications.   This
                                factor for  the retrofit  cases  is  due to the
                                need to fit the  equipment  into available space,

                                These  scrubbing  systems  require relatively
                                minor  modifications  to the boiler and  ESP
                                ductwork.   This  factor also  includes the
                                expense of  fitting the equipment  into  the
                                available space.

                                These  control systems require  extensive modi-
                                fications to  the boiler  economizers and air
                                heaters and the  associated ductwork.   This
                                factor also includes the expense  of locating
                                the equipment in the available space.

It is assumed that most FGD systems will be of the add-on type and  therefore
use the 1.3 retrofit factor.
                                    B-48
  NOX FGT  (SCR)
  1.7

-------
Annual Revenue Requirements

     Annual revenue requirements in these premises consist of various
direct and indirect operating and maintenance costs and capital charges.
Annual revenue requirements normally vary from year to year as operating
and maintenance costs change and capital charges decline.   Thus no
single year is necessarily representative of the lifetime  costs, nor can
single-year undistorted comparisons be made among processes with different
ratios of operating costs to capital charges.  In addition it is necessary
to take into account the effect of time on the value of money (i.e., for
inflation, the future earning power of money spent, and other factors).

     Frequently these factors are accounted for by levelizing (15).
Levelization converts all the varying annual revenue requirements to a
constant annual value, such that the sum of the present worths of the
levelized annual revenue requirements equals the sum of the present
worths of the actual annual revenue requirements.  The levelized value
is calculated by multiplying the revenue requirements for  each year  by
the appropriate present worth factor and summing the present worth
values.  Then the single present worth value is converted  to equal
annual values by multiplying the result by the capital recovery factor.

     In these premises the operating and maintenance costs are levelized
by multiplying the first-year operating and maintenance cost by a levelizing
factor.  The levelized capital charges are determined by levelizing  the
percentage of capital investment applied yearly as capital charges.   The
levelizing factor includes a discount factor reflecting the time-value
of money and an inflation factor reflecting the effects of inflation
during the operating life of the system.  The discount rate used is  10%
and the inflation rate used is 6%.  The levelizing factor  produced
varies with the remaining life of the system.  Calculation of the levelizing
factor for operating and maintenance costs and of levelized capital
charges is discussed below.

     A typical annual revenue requirement tabulation is shown in Table B-31.
Direct costs consist of raw material and conversion costs.  These,
combined with overheads, are the operating and maintenance costs.  For
processes that produce a salable byproduct, byproduct sales are applied
as a credit to the operating and maintenance costs.  Levelized capital
charges are calculated as a percentage of the capital investment and
added to the operating and maintenance costs to provide the first-year
annual revenue requirements.  The levelized annual revenue requirements
are determined by multiplying the operating and maintenance costs by the
levelizing factor and adding the product to the same levelized capital
charges used in the first-year annual revenue requirements.

Operating and Maintenance Costs—
     Frequently used raw material costs and standard conversion costs
were shown previously in Table B-24.  Other costs are obtained from
vendors or published information.  These costs are converted to 1984
costs using the cost indexes in Table B-23 or industry projections.
                                   B-49

-------
        TABLE B-31.   ANNUAL REVENUE  REQUIREMENTS  SHEET
     TABLE     ADVANCED LIMESTONE PROCESS ANNUAL REVENUE  REQUIREMENTS


           (500-MW new  coal-fired power unit, 3.5% S in coal;
              88.6% S02 removal; onsite solids disposal)

Direct Costs - First-Year
Raw materials
Limestone
Annual
quantity
tons
Unit
cost, $
/ton
Total annual
cost, k$

      Total raw materials cost

 Conversion Costs

   Operating labor and supervision
     FGD
     Solids disposal
   Utilities
     Process water
     Electricity
     Steam
   Maintenance
     Labor and material
   Analysis

      Total conversion costs

      Total direct costs

 Indirect Costs - First-Year

 Overheads
   Plant and administrative

   Marketing (10% of byproduct sales)

 Byproduct Credit
man-hr
man-hr
kgal
kWh
klb
/man-hr
/man-hr
/kgal
/kWh
/klb
man-hr
/man-hr
tons
$/ton
     Total first-year operating and maintenance costs

 Levelized Capital Charges (    % of
   total capital investment)

     Total first-year annual revenue requirements

 Levelized First—Year Operating and Maintenance
   Costs (    first-year 0 and M)

 Levelized Capital Charges (   % of total capital
   investment)

                 Levelized annual revenue requirements

                                              M$    Mills/kWh
 First-year annual revenue requirements
 Levelized annual revenue requirements
Basis:   One-year,  5,500-hour  operation  of  the system described in the
capital investment sheet;  1984  cost basis.

                                   B-50

-------
     Raw materials—Consumables required for their chemical or physical
properties, other than fuel for the production of heat, are classified
as raw materials.  Raw material costs are determined as necessary from
vendor quotations or published sources and escalated to 1984 costs.   All
costs are delivered costs.

     Operating labor and supervision—Unit labor costs for 1984 were shown
in Table B-24.  The allocation of operating labor and supervision
depends on the process complexity, number of process areas, labor intensity
of the process, and operating experience.

     Utilities—Services used, such as steam, electricity, process
water, fuel oil, and heat credits, are charged under the utilities
heading.  Unit 1984 costs were shown in Table B-24.   Costs for steam and
electricity are based on the assumption that the required energy is
purchased from another source.  This simplifying assumption eliminates
the need to derate the utility plant.  Process water requirements are
defined as any water used by the process being evaluated and are usually
determined by the material balance.  Steam requirements are for stack
gas steam reheat and process requirements.  Electrical power requirements
are determined from the installed horsepower of operating electrical
equipment (excluding the horsepower of spared equipment).  Each motor in
operation is assumed to be operating at rated capacity although this
results in higher power consumptions than would actually occur.  Electrical
requirements are obtained from the equipment list where the motor horsepower
is identified, plus an additional amount for functions such as lighting.
A sample calculation is shown in Table B-32.

     Maintenance—Process maintenance costs are 3% to 10% of the total
direct process investment depending on process complexity, process
equipment, materials handled, process areas, and unit size.  The per-
centages shown in Table B-33 are used under most circumstances.  For
specific FGD processes the maintenance percentages shown in Table B-34
are used.  For example, a 500-MW limestone and lime scrubbing process
normally has a maintenance factor of 8%.

     Waste disposal maintenance costs are estimated from the appropriate
model and are typically 3% of the waste disposal site construction
costs.  Maintenance costs for waste disposal are not shown separately.
If, and only if, it is required and no other information is available,
the maintenance material-to-labor ratio is 60:40.

     Analysis—Analysis costs are based on process complexity and are
listed as a single entry.

     Plant and administrative overhead—Plant and administrative overheads
include plant services such as safety, cafeteria, and medical facilities;
plant protection and personnel; general engineering (excluding maintenance),
interplant communications and transportation; and the expenses connected
with management activities.  Plant and administrative overheads for  the
FGD process are 60% of the total conversion costs less utilities.

     Marketing overhead—This is calculated as 10% of byproduct sales
income.

-------
           TABLE B-32.   SAMPLE ELECTRICAL  REQUIREMENT CALCULATION
     Electricity requirements are determined by summing the horsepower of
all operating electrical equipment and multiplying by a factor of 0.7457
kW/hp.   It is assumed that the instantaneous load factor and the power
load factor are equal and thus cancel out.  Additional electricity is
added for functions such as lighting.  For the limestone and lime
processes 100 kW is added.  For other processes more or less electricity,
depending on the process type, size, and complexity, may be necessary.
Sample Calculation

                	Area	  Total operating hp

                1  Materials handling           70.5
                2  Feed preparation            797.5
                3  Gas handling              3,580.0
                4  SC-2 absorption            6,189.0
                5  Stack gas reheat              0.0
                6  Oxidation                 4,903.0
                7  Solids disposal              71.0

                     Total                  15,611.0

                15,611 hp x 0.7457 kW/hp = 11,641 kW
                                           +  100 kW
                                           11,741 kW


                11,741 kW x 5,500 hr = 64,575,500 kWh
                                  B-52

-------
               TABLE B-33.  MAINTENANCE FACTORS
                                  % of total direct investment
                                    excluding waste disposal
	Process conditions	Low    Base    High	

Corrosive or abrasive slurry           6       8      10
Solids, high pressure, or high
 temperature                           456
Liquids and gases                      345
  TABLE B-34.  MAINTENANCE FACTORS FOR SPECIFIC FGD PROCESSES

                                    Maintenance, % of total
                                       direct investment
                                   FGD system
                                 200   500   1000    Waste
                                  MW    MW    MW    disposal

Limestone and lime  (generic)      987        3
Double alkali                     765        3
Wellman-Lord                      765
Magnesia                          876
Lime spray dryer  (including
 baghouse)                        765        3
                               B-53

-------
     Byproduct sales—Total revenue from the sale of byproducts is
applied as a credit to processes in which a byproduct is salable.

Capital Charges—
     Capital charges are those costs incurred by construction of the
facility that must be recovered during its life.  They consist of returns
on equity and debt (discount rate), depreciation, income taxes, and
other costs such as insurance and local taxes.  In keeping with common
practice for investor-owned utilities the weighted cost of capital is
used as the discount rate (16).  Depreciation is stated as a sinking
fund factor to simplify calculations.  An allowance for interim replacement
is included to compensate for possible early retirement of the facility.
Credits are also included for tax preference allowances.  The capital
charges are shown in Table B-35 and discussed below.  In keeping with
standard practice, book, tax, and economic lives are used in the following
calculations.  In these premises, however, all three are assumed to be
equal.
               TABLE B-35.  LEVELIZED ANNUAL CAPITAL CHARGES


                                            % of total capital investment
                                          	remaining life, years
                                                     20                30
                                                  (existing           (new
                                            15     plant)	25    jplanjt)

  Weighted cost of capital                10.00    10.00     10.00   10.00
  Depreciation (sinking fund factor)       3.15     1.75      1.02    0.61
  Annual interim replacement               0.72     0.67      0.62    0.56
  Levelized accelerated tax depreciation  (1.44)   (1.43)    (1.40)  (1.36)
  Levelized investment tax credit         (2.39)   (2.14)    (2.00)  (1.93)
  Levelized income tax                     3.96     4.08      4.20    4.31
  Insurance and property taxes             2.50     2.50      2.50    2.50
       Levelized annual capital charge    16.5a    15.4a     14.9a   14.7
  a.   Rounded to three significant figures.
     The capital structure is assumed to be 35% common stock, 15% pre-
ferred stock, and 50% long-term debt.  The cost of capital is assumed to
be 11.4% for common stock, 10.0% for preferred stock, and 9.0% for long-
term debt.  The weighted cost of capital (WCC) is 10.0%.  The discount
rate (r) is equal to the weighted cost of capital.

     Other economic factors used in financial calculations are a 10%
investment tax credit rate, 50% State plus Federal income taxes, 2.5%
property tax and insurance, and an annual inflation rate of 6%.  Salvage
value is assumed to be less than 10% and equal to removal cost.

                                    B-54
                                                                         a

-------
     Weighted cost of capital is calculated as follows:

       WCC = (fraction long-term debt)(long-term debt cost, %) +
             (fraction preferred stock) (preferred stock cost, %) +
             (fraction common stock)(common stock cost, %)

     The sinking fund factor method of depreciation is used since it is
equivalent to straight line depreciation levelized for the economic life
of the facility using the weighted cost  of capital.  The use of the
sinking fund factor does not suggest that regulated utilities commonly
use sinking fund depreciation.  All factors and rates are expressed as
decimals.  The equation is:


                  SFF = (WCC)/((I + WCC)Ne -1)

          where:  SFF = sinking fund factor

                  WCC = weighted cost of capital

                   Ne = economic life in years

     An annual interim replacement (retirement dispersion) allowance of
0.56% for new plants and 0.67% for existing plants is also included as
an adjustment to the depreciation account to ensure that the initial
investment will be recovered within the  actual rather than the forecasted
life of the facility.  Since power plant retirements occur at different
ages, an average service life is estimated.  The type S-l Iowa State
(17) retirement dispersion pattern is used in these premises.  The S-l
pattern is symmetrical with respect to the average-life axis and the
retirements are represented to occur at  a low rate over many years.  The
interim replacement allowance does not cover replacement of individual
items of equipment since these are covered by the maintenance charge.

     Tax preference allowances are incentives designed to encourage
investment as a stimulus to the overall  economy.  The basic accounting
method used is the flow through method which passes the tax advantage to
revenue requirements as soon as they occur.

     Using the sum of the years digits method, which allocates costs
early in the life of the facility, the accelerated tax depreciation
(ATD) is calculated as follows:

            ATD = (2)(CRFe)(Nt - (l/CRFt))/(Nt)(Nt + 1)(WCC)

   where:  CRFe = capital recovery factor (WCC + SFF) for the economic life

           CRFt = capital recovery factor (WCC + SFF) for the tax life

             Nj. = tax life in years
                                    B-55

-------
     Levelized accelerated tax depreciation is calculated as follows:

           LAID = (AID - SLD)(ITR)/(1 - ITR)

    where:  SLD = straight line depreciation
             N^ = book life in years

            ITR = income tax rate

     The levelized investment tax credit is calculated as follows :

           LITC = (CRFe) (investment tax credit rate) /(I + WCC) (1 -  ITR)

     The levelized income tax is calculated as follows:

            LIT = (CRFb + AIR - SLD)(1 - ((debt ratio x debt cost) /WCC))

                  (ITR) /(I - ITR)

   where:   LIT = levelized income tax

            AIR = annual interim replacement

     The capital charges are applied as a percentage of the total capital
investment, including land and working capital.  Although land and  most
of working capital cannot be depreciated and are not subject to investment
tax credit, their inclusion has an insignificant effect on capital
charges.

Levelized Operating and Maintenance Costs —
     Assuming a constant inflation rate, the levelized operating and
maintenance costs are determined by multiplying the first-year operating
and maintenance costs by an appropriate levelizing factor, Lf.   The
levelizing factor is calculated as follows:

             Lf = CRFe  (K + K2 + K3 + --- + KN)
                = CRFe (K(l - K))/(1 - K)

   where:  CRFe = capital recovery factor (WCC + SFF) for the economic
                  life (see the discussion of capital charges)

              K = (1 + i)/(l + r); present worth of an inflationary value

              i = inflation rate

              r = discount rate

             N^ = book life in years

                                    B-56

-------
An inflation rate of 6% (i = 0.06)  and a discount rate of 10% (d = 0.10)
are used for new units.  Values of  Lf for power units with a remaining
life of 15, 20, 25, and 30 (new unit) years are shown in Table B-36.
The first-year operating and maintanance costs are multiplied by the
appropriate Lf to obtain the levelized operating and maintenance costs.
                       TABLE 36.  LEVELIZING FACTORS
1


a.
b.
c.
Book3
.ife, NK
15
20
25
30C
K =
0.
0.
0.
0.
Same as economic
Discount rate (r)
New units.
1 + i K
1 + r
96364
96364
96364
96364
life (Ne)
of 10%.
(1
1
11
13
16
17
and
_KNb)
- K
.2965
.8669
.0028
.7775
tax life
CRFBb
(r, Nb)
0.
0.
0.
0.
(N
13147
11746
11017
10608
t>-
Levelizing
factor, Lf
1
1
1
1

.485
.629
.763
.886




SI SYSTEM NOTATION

     The SI system of metric units is not used as the primary numerical
system in these premises because of the widespread use of traditional
units in correlative and supportive literature and general practice.
Use of the SI system is not standardized in the utility industry although
steps in this direction are being made (18).  The SI system specifies a
number of rules of usage, form, and style in addition to the numerical
standards.  These too are part of the SI system and should be followed
when using it.  Detailed procedures for use of SI conventions in the
primary data or conversion to SI convention are readily available in the
literature.  A detailed general guide to SI convention is available in
ASTM E 380 79 (19).  To provide uniformity in the comparison of data
developed from these premises such a guide should be consulted in using
the SI system.
                                    B-57

-------
REFERENCES

 1.  Federal Register, 1979, New Stationary Sources Performance Standards;
     Electric Utility Steam Generating Units, Vol. 44, No.  113, June 11,
     pp. 33580-33624.

 2.  J. A. Cavallaro, M. J. Johnson, and A. W. Deubrouck, 1976, Sulfur
     Reduction Potential of the Coals of the United States, Bureau of
     Mines Report of Investigation RI 8118, U.S.  Bureau of  Mines,
     Washington, B.C.

 3.  J. W. Hamersima and M. L. Kraft, 1975, Applicability of the Meyers
     Process for Chemical Desulfurization of Coal:  Survey  of Thirty-
     Five Coals.  EPA-650/2-74-025-A, U.S.  Environmental Protection
     Agency, Washington, B.C.

 4.  Bureau of Mines, 1946, Bureau of Mines Information Circular 7346,
     Bepartment of the Interior, Washington, B.C.  Bescribes Rosin and
     Rammler chart.

 5.  National Electric Reliability Council, 1980, 1980 Summary of Projected
     Peak Bemand, Generating Capability, and Fossil Fuel Requirements,
     National Electric Reliability Council, Princeton, New  Jersey.

 6.  National Coal Association, 1979, Steam-Electric Plant  Factors, 1979,
     National Coal Association, Washington, B.C.

 7.  G. R. Fryling,  1966, Combustion Engineering, Second Edition,
     Combustion Engineering, Inc., New York.

 8.  Babcock & Wilcox, Steam/Its Generation and Use, Babcock & Wilcox
     Co., New York,  1975.

 9.  G. D. Friedlander, 1980,  Sixteenth Steam Station Design Survey,
     Electrical World, Vol. 194, No. 8, Nov. 1980, pp. 67-82.

10.  Bepartment of Energy, 1978, Steam-Electric Plant Construction Cost
     and Annual Production Expenses 1977, BOE/EIA-0033/3 (77), U.S.
     Bepartment of Energy, Washington, B.C., BOE, 1979,  Steam-Electric
     Plant Air and Water Quality Control Bata, for the Year Ended
     Becember 31, 1976, BOE/FERC 0036, U.S. Bepartment of Energy,
     Washington, B.C.  These are issued annually.

11.  Federal Register, 1971, Standards of Performance for New Stationary
     Sources, Vol. 36, No. 247, Bee. 23, pp. 24876-24895.

12.  Chemical Engineering, 1976, 1977, 1978, 1979, Economic Indicators,
     Volumes 83, 84,  85, and 86.

13.  V. W. Uhl, 1979, A Standard Procedure  for Cost Analysis of Pollution
     Control Operations, Volumes I and II,  EPA-600/8-79-018a and EPA-
     600/8-79-018b,  Research Triangle Park, North Carolina.

                                    B-58

-------
14.  The Richardson Rapid System, Process Plant Estimation Standards,
     Volumes I, III, IV,  1978-1979 Edition.   Richardson Engineering
     Services, Inc., Solano Beach, California.

15.  EPRI, 1978, Technical Assessment Guide,  EPRI PS-866-SR,  Special
     Report, June 1978, Electric Power Research Institute, Palo Alto,
     California.

16.  E. L. Grant and W. G. Ireson, 1970, Principles of Engineering
     Economy, Ronald Press, New York.

17.  P. H. Jeynes, 1968,  Profitability and Economic Choice, First
     Edition, The Iowa State University Press,  Ames, Iowa.

18.  M. G. McGraw, 1980,  Metrication in the Electric Utility Industry,
     Electrical World, Vol. 194, No. 7, October 1980, pp.  69-100.

19.  ASTM E 380 79, 1980, Annual Book of ASTM Standards, Part 41,
     American Society for Testing and Materials, Philadelphia,
     Pennsylvania.
                                   B-59

-------

-------
                  APPENDIX C




DETAILED DESCRIPTIONS OF MODEL INPUT VARIABLES
                     C-l

-------
                                       TABLE C-l.   MODEL INPUTS - FORTRAN VARIABLE NAMES
   Line
     1   XINPUT  XBC  XALK  XSSV  XSRHT
     2   OUTPUT  XHGAS  XWGAS  XRAIR  XRGAS  XSRHO  XSKGAS   XSSO  XDIS  XSTR  XGPM  XIT
     3   IRPT  IEQPR  IWTBAL
     A   Case identification (up to 72 alphanumeric  characters)
     5   XESP  MW  BHR  HVC  EXSAIR  THG  XRH  KEPASS  KPAS02  PSS02X  KCLEAN  WPRCVR  WPPSAC  WPPSRC  TSK  TSTEAM  HVS
    6A   INPOPT  WPC  WPH  WPO  WPN  WPSUL  WPCL   WPASH   WPH20  SULO  ASHO  IASH  ASHUPS  ASHSCR
    6B   INPOPT  VC02  VHCL  VS02  V02  VN2  VH20  SCFM  WASH  SULO  ASHO  IASH  ASHUPS  ASHSCR
     7   XLG  VLG  VTR  V  VRH  IS02  XS02  TR XSR  SRIN  XIALK  IADD  WPMGO  XMGOAD  AD  ADDC  WPI  WPM  ASHCAO  ASHMGO
     8   WPS  PSD  RS  PSC  IFOX  OX  SRAIR  PSF   FILRAT  PHLIME  IVPD  VPD  DELTAP  PRES  IFAN
o    9   ISCRUB  XNS  XNG  HS  RAIN  SEEPRT  EVAPRT  WINDEX  HPTONW  NSPREP  NOTRAN  NOREDN  PCNTRN
^   10   ISLUDG  SDFEE  PSAMAX  ACRE$  PDEPTH  PMXEXC  DISTPD  ILINER  XLINA  XLINB
    11   ENGIN  ARCTEC  FLDEXP  FEES  CONT  START CONINT  XINT   PCTMNT  PDMNTP  XINFLA  IECON  PCTOVR XLEVEL/PCTADM
         CAPCHG/UNDCAP  PCTMKT/PCTINS
    12   ITAXFR  TXRATE  FRRATE  SERVRT  ROYALT  IOTIME  OTRATE  INDPND  PENGIN  PARCH   PFLDEX  PFEES  PCONT  PSTART
    13   UC(1)  - UC(9)  MINDEX  LINDEX  YRINV  YRREV
    14   IOPSCH  PNDCAP  BAGDLP  BAGRAT  BGCOST  BGLIFE   EFFPS  ESPDLP  RESIST  SCARAT  ICEPYE  CHPIOX
    15   IYROP
    16   IA(1)  - IA(10)
    17   IA(11)  - IA(20)
    18   IA(21)  - IA(30)
    19   END or NEXT


    Note:   Lines 15-18 are needed only if IOPSCH  = 3.  The  number of entries required on lines 16-18 depends on the
           number of years specified with the IYROP  variable on  line 15.  Although 30 years is normally used as a
           maximum plant life, up to 50 years are allowed and up to two additional lines may be used for IA(31) - IA(50) .

-------
TABLE C-2.   MODEL INPUT VARIABLE  DEFINITIONS

Line No. Variable
1 XINPUT





1 XBC

1 XALK

1 XSSV

1 XSRHT

2 OUTPUT





2 XHGAS

2 XWGAS

2 XRAIR

2 XRGAS

2 XSRHO

2 XSKGAS

Definition
Option to control the printing of input data
variables. If a value of zero is selected,
no input data variables are printed; the
options to individually control the printing
of input variables are ignored.

Controls the printing of boiler characteristics
input variables.
Controls the printing of alkali input
variables.
Controls the printing of scrubber system input
variables .
Controls the printing of steam reheater input
variables.
Option to control the printing of model output.
If a value of zero is selected, no output
listings are printed and the options to
individually control the printing of output
listings are ignored.

Controls the printing of calculated properties
of hot gas to scrubber.
Controls the printing of calculated properties
of wet gas from scrubber.
Controls the printing of calculated properties
of reheater air.
Controls the printing of calculated properties
of reheater gas (oil-fired reheater only) .
Controls the printing of calculated properties
of inline steam reheater.
Controls the printing of calculated properties
of stack gas.
Units or values
0 = no input
data printed
1 = print input
variables accord-
ing to individual
input print options
0 = no print
1 = print
0 = no print
1 = print
0 = no print
1 = print
0 = :io print
1 = print
0 = no output data
printed
1 = print output
listings according
to individual
output print options
0 = no print
1 = print
0 = no print
1 = print
0 = no print
1 = print
0 = no print
1 = print
0 = no print
1 = print
0 = no print
1 = print
                (continued)
                     C-3

-------
TABLE C-2 (continued)

Line No.
2
2
2
2
2

3
3
3
4

5


5
5
5
5
5
Variable
XSSO
XDIS
XSTR
XGPM
XIT

IKPT
IEQPR
IWTBAL
CAS BID

XESP


MW
BHR
HVC
EXSAIR
THG
Definition
Controls the printing of calculated scrubber
system parameters.
Controls the printing of calculated properties
of system discharge stream.
Controls the printing of calculated properties
of scrubber system internal streams (excluding
sludge discharge and makeup water) . This
option does not affect the printout of total
stream flow rate.
Controls printing of total flow rates (gpm
and Ib/hr) of internal streams (excluding
sludge discharge and makeup water) .
For the iterative calculation of stoichiometry ,
this option controls the printing of the
iteration number and of the current and the
preceding stoichiometry values.
Option to select either a short-form printout
(totals only) or a long-form printout.
Controls the printing of the equipment list.
Controls the printing of calculated properties
of water balance.
Case identification - this field is free form
and may be up to 72 characters in length.
Particulate collection option
No mechanical collector available
Mechanical collector available
Print internal model examples (costs are not
included in FGD costs)
Electric power output
Boiler heat rate
Heating value of coal
Excess air
Temperature of hot gas to scrubber
Units or values
0 = no print
1 = print
0 = no print
1 = print
0 = no print
1 = print
0 = no print
1 = print
0 = no print
1 = print

0 = short print
1 = long print
0 = no print
1 = print
0 = no print
1 = print


n
1
2
megawatts
Btu/kWh
Btu/lb
percent
°F
      (continued)




          C-4

-------
                                     TABLE C-2 (continued)
Line No.  Variable
                                        Definition
                                                                          Units or values
   6A
XRH        Reheat option
             No reheat
             Inline steam reheater (XRH value = 2)
             is the only type of reheat available at
             this time.

KEPASS     Emergency bypass option
             No emergency bypass
             Emergency bypass

KPAS02     Partial scrubbing/bypass option
             No partial scrubbing/bypass
             Partial scrubbing/bypass

PSS02X     Percent SC>2 removal in the scrubber when
           partial scrubbing/bypass is specified

KCLEAN     Coal cleaning option
             No coal cleaning
             Coal cleaning

WPRCVR     Percent weight recovery (Ib clean coal per
           Ib raw coal) when coal cleaning is specified

WPPSAC     Weight percent of pyritic sulfur plus ash in
           cleaned coal when coal cleaning is specified

WPPSRC     Weight percent of pyritic sulfur in raw coal
           when coal cleaning is specified

TSK        Temperature of stack gas

TSTEAM     Temperature of reheater steam

HVS        Heat of vaporization of reheater steam

           The composition input specified on either line
           6A or 6B depends on the composition option,
           INPOPT.  If a coal composition will be input
           (INPOPT =  1) then line 6A is used.  If a flue
           gas composition will be input
           (INPOPT =  2) then line 6B is used.

INPOPT     Composition input option
             Coal composition will be input using line 6A

                                (continued)
                                                                         0
                                                                         2
                                                                         0
                                                                         1

                                                                         percent  removal
                                                                         0
                                                                         1

                                                                         percent


                                                                         weight  percent


                                                                         weight  percent
                                                                          F

                                                                         Btu/lb
                                           C-5

-------
                                     TABLE C-2 (continued)
Line "No.  Variable
                             Definition
                                                               Units or values
   6A      WPC   }

   6A      WPH   }

   6A      WPO   }

   6A      WPN   }
   6A

   6A

   6A

   6A

   6A


   6A


   6A
   6A
   6A
WPSUL }

WPCL  }

WPASH }

WPH20 }

SULO


ASHO


IASH
ASHUPS
           ASHSCR
           Amount of component (C, H, 0, N,  S, Cl, ash,
           H20) in coal.   WPSUL is the total of both
           organic sulfur and pyritic sulfur.
Sulfur to overhead as SC>2 gas (remainder goes
to bottom ash).

Ash to overhead as particulates (remainder goes
to bottom ash).

Unit of measure option for particulate removal
  Default to model assumptions
  Percent removal
  Pounds particulates  per MBtu
  Upstream removal (percent) with scrubber
  default
(The actual values for particulate removal are
provided by the ASHUPS and ASHSCR variables that
immediately follow.)

Value for particulate removal upstream from
scrubber (Unit of measure is indicated by the
IASH option above.)

Value for particulate removal within scrubber
(Unit of measure is indicated by the IASH
option above.)
                                                   weight percent
weight percent


weight percent
                                           (continued)
                                         C-6

-------
                                     TABLE C-2 (continued)
Line No.  Variable
                                        Definition
                                                                          Units  or values
6B



6B

6B

6B

6B
6B

6B

6B


6B

6B


6B
INPOPT



VC02 1

VHCL 1

VS02) •

V02  }
VN2  }

VH20}

SCFM


WASH

SULO


AS HO
                      Composition input option
                        Flue gas composition will be input  using
                        line 6B
                      Amount of component (C02 ,  HC1,  SC>2,  02,  N
                      and H20) in flue gas
                   Standard cubic feet  per minute (60  F),  gas
                   from boiler

                   Pounds  of ash per hour  in hot  gas from  boiler

                   Should be set to 100 when flue gas  composition
                   is input

                   Should be set to 100 when flue gas  composition
                   is input
6B
6B
6B
7
IASH
ASHUPS
ASHSCR
XLG
See line 6A
See line 6A
See line 6A
L/G ratio ii
                   (Refer to the XSR option on the following
                   page.)

7       VLG        L/G ratio in venturi

7       VTR        Venturi/oxidation hold tank residence time.
                   This variable is used to specify residence time
                   in the second effluent tank when two tanks are
                   specified.   Two tanks may be specified by the
                   forced oxidation option (IFOX,  line 8),  the
                   scrubber option (ISCRUB, line 9), or both.  VTR
                   should be set to zero when only one effluent
                   tank is used (see the TR variable below).

                                       (continued)
                                                                     volume  percent
                                                                        scfm
                                                                         Ib/hr
                                                                        gal /kft
                                                                        gal /kft
                                                                        minute
                                              07

-------
                                     TABLE C-2 (continued)
Line No.  Variable
                                        Definition
                                                                          Units or values
7
7
V
VRH
Scrubber gas velocity (superficial)
Superficial gas velocity through reheater
ft/sec
ft/sec
                      (face velocity)

           IS02       Unit of measure  option for S0_ removal
                        SC>2 to be removed is a percent value
                        S02 emission concentration is a pounds
                         S02/MBtu value
                        S02 emission concentration is a ppm value
                      (The actual value for 862 removal is provided
                      by the XS02 variable that immediately follows.)
                      Revised NSPS (1978 Federal Register)

           XS02       Value for S02 to be removed.  Unit of measure
                      is indicated by  the IS02 option above; refer
                      to the XSR option below for additional require-
                      ments.  The value for XS02 is automatically
                      calculated when  IS02 = 4 and any input value
                      will be ignored.

           TR         Recirculation/oxidation hold tank residence
                      time.  This variable is used to specify
                      residence time in the effluent tank when only
                      one tank is specified.  If two tanks are
                      specified, TR specifies residence time in
                      the first tank (see the VTR variable above).

           XSR        Stoichiometry, L/G in scrubber, and S02 removal
                      option.  This option controls model processing
                      of the Stoichiometry value, SRIN, below; the
                      L/G ratio in the scrubber, XLG, on the preceding
                      page; and the S02 to be removed, XS02, above
                      (if XS02 is required then IS02 is also required).

                      SRIN, XLG, and XS02 (also IS02) will be processed
                      as input variables. (No checks are made for
                      validity or consistency among the specified
                      values.)

                      XLG and XS02 (also IS02) will be processed as
                      input variables  and SRIN will be calculated
                      by the model.

                                      (coninued)
minute
                                       C-8

-------
                                     TABLE C-2 (continued)
Line No.  Variable
                  Definition
 Units  or values
           SRIN
           XIALK
SRIN and XS02 (also IS02) will be processed
as input variables and XLG will be calculated
by the model.

SRIN and XLG will be processed as input
variables; the value for SC>2 to be removed
(XS02) will be calculated by the model; and
all three units of measure (IS02) will be
provided in the calculated results.  Any user
input values for IS02 and XS02 will be ignored.

Value for stoichiometry  (refer to the XSR
option above)
Alkali addition option
  Limestone
  Lime
           IADD       Chemical additive option
                        No chemical additive
                        MgO added
                        Adipic acid added

           WPMGO      Soluble MgO in limestone or  lime
           XMGOAD     Soluble MgO added to  system (used  only  when
                      MgO added,  see IADD above)

           AD         Adipic acid added to  system (used  only  when
                      adipic acid added,  see IADD above)

           ADDC       Adipic acid degradation constant  (used  only
                      when adipic acid added, see IADD above)

           WPI        Insolubles  in limestone-lime additive
           WPM        Moisture in limestone-lime  additive


           ASHCAO     Soluble CaO in particulates

                                      (continued)
mols  CaC03 added
as limestone per
mol S02 absorbed
                                                   0
                                                   1
                                                   2

                                                   weight percent
                                                   dry basis

                                                   pound soluble MgO/
                                                   100 pound limestone

                                                   ppm
                                                   weight percent
                                                   dry basis

                                                   lb/100 pound dry
                                                   additive

                                                   weight percent
                                        C-9

-------
                          TABLE C-2 (continued)

Line No.
7
8
8
8
8
8
Variable
ASHMGO
WPS
PSD
RS
PSC
IFOX
Definition
Soluble MgO in particulates
Solids in recycle slurry to scrubber
Solids in sludge discharge
Clarifier solids settling rate
Percent solids in clarifier underflow
Forced oxidation option
No forced oxidation
Forced oxidation in a single effluent tank
Forced oxidation in the first of two
Units
weight
weight
weight
ft/hr
weight
0
1
2
or values
percent
percent
percent

percent

              effluent tanks
             Forced oxidation in the disposal feed tank

OX         Oxidation of sulfite in scrubber system

SRAIR      Air stoichiometry value


PSF        Percent solids in filter cake

FILRAT     Filtration rate

PHLIME     Recirculation liquor pH for lime system (value
           is ignored for limestone system)

IVPD       Venturi AP option
             AP is input in inches HnO
             Throat velocity (ft/sec) is input and the
              corresponding VPD is calculated

VPD        Value for either AP or throat velocity
           indicated by the IVPD option above

DELTAP     Override AP for entire system

PRES       Scrubber pressure

IFAN       Fan option
             Forced draft fans
             Induced draft fans
mol  percent

g-atoms 0/g-mol
S02 absorbed

percent

tons/ft^/day
 inch  H20  or  (ft/sec)
inch

psia
                           (continued)
                                  C-10

-------
                                   TABLE  C-2  (continued)

Line No.
9
9
9
9
9
9
9
9
9
9
9
9
9
10
Variable
ISCRUB
XNS
XNG
HS
RAIN
SEEPRT
EVAPRT
WINDEX
HPTONW
NSPREP
NOTRAN
NOREDN
PCNTRN
ISLUDG
Definition
Scrubbing option
Spray tower
TCA
Venturi-spray tower, two effluent tanks
Venturi-spray tower, one effluent tank
Venturi-TCA, two effluent tanks
Venturi-TCA, one effluent tank
Number of TCA stages
Number of TCA grids
Height of spheres per stage
Annual rainfall
Seepage rate
Annual evaporation
Limestone hardness work index factor value
5-15. (Example: 10)
Fineness of grind index factor (see Table C-3)
Number of spare preparation units
Number of operating scrubber trains
Number of spare scrubber trains
Entrainment level as percentage of wet gas
from scrubber. (Example: 0.1)
Sludge disposal option
Onsite ponding
Thickener - ponding
Thickener - fixation (fee)
Thickener - filter - fixation (fee)
Units or values
1
2
3
4
5
6


inch
in . /yr
cm/sec
in . /yr
wi
hp/ton
(0-9)


weight percent
1
2
3
4
10       SDFEE      Sludge disposal fee.   (Either  an  actual
                    value or a zero value must  be  provided;
                    refer to the ISLUDG  option  above.)
$/ton dry sludge
                                     (continued)
                                       Oil

-------
TABLE C-2 (continued)
Line No.
10
10
10
10
10
10

10
10
11
11
11
11
11
11
11
11

Variable
PSAMAX
ACRE$
PDEPTH
PMXEXC
DISTPD
ILINER

XLINA
XLINB
ENGIN
ARCTEC
FLDEXP
FEES
CONT
START
CONINT
XINT

Definition
Total available land for construction of pond
Land cost
Final depth of sludge in pond
Maximum excavation depth
Distance from scrubber area to pond
Pond lining option
Clay liner
Synthetic liner
No liner
(Refer to the XLINA and XLINB variables that
immediately follow.)
If ILINER = 1 , XLINA = clay depth
If ILINER = 2, XLINA = material unit cost
If ILINER = 3, XLINA = 0
If ILINER = 1, XLINB = clay cost
If ILINER = 2, XLINB = labor unit cost
If ILINER = 3, XLINB = 0
Engineering design and supervision
Architect and engineering contractor
Construction field expenses
Contractor fees
Contingency
Allowance for startup and modifications
Interest during construction
Cost of capital
(continued)
Units or values
acres
$/acre
feet
feet
feet
1
2
3

inch
$/yd2
$/yd2
percent
percent
percent
percent
percent
percent
percent
percent

     C-12

-------
                                     TABLE C-2 (continued)
Line No.  Variable
                                       Definition
                                                                          Units or values
  11       PCTMNT     Maintenance rate,  applied as percent of  direct        percent
                      investment excluding pond cost

  11       PDMNTP     Pond maintenance rate,  applied as  percent of          percent
                      direct pond investment

  11       XINFLA     Inflation factor (used  only when unlevelized          percent
                      lifetime revenue requirements are  calculated,
                      see Appendix B)

  11       IECON      Economic premises option (see the  Model  Descrip-
                      tion Section and Appendix B)
                        TVA/EPA economic premises beginning 12/5/79          1
                        TVA/EPA economic premises prior  to 12/5/79          0

  11       PCTOVR     Plant overhead rate, applied as percent  of            percent
                      conversion costs less utilities
  11       XLEVEL/     The use of this variable depends on the economic      percent
          PCTADM      premises specified  (IECON, line 11).  If new
                      premises are specified  (IECON = 1), XLEVEL spec-
                      ifies the levelizing factor to be  applied to first-
                      year operating and maintenance costs to obtain
                      levelized lifetime  costs.  If XLEVEL is set to zero
                      there is no levelizing  and a lifetime revenue sheet
                      is generated.  If old premises are specified (IECON
                      = 0), PCTADM specifies  the administrative research
                      and service overhead rate, applied as a percent of
                      operating labor and supervision.

  11       CAPCHG/     If new premises are  specified  (IECON = 1) CAPCHG       percent
          UNDCAP      specifies levelized  annual capital  charges applied
                      as a percent of total capital investment.  If old
                      economic premises are specified  (IECON =0) UNDCAP
                      specifies the annual capital charge basis for
                      undepreciated investment.

  11       PCTMKT/     If new premises are  specified  (IECON = 1) PCTMKT       percent
          PCTINS      specifies marketing  costs applied  as a percent of
                      byproduct credit  (applies only to  processes with
                      a salable byproduct).  If old economic premises
                      are specified  (IECON =0) PCTINS specifies the
                      rate for insurance and interim replacements
                      applied  as a percent of  total capital investment.

  12       ITAXFR      Sales tax and freight option
                       No sales tax or freight                              0
                       Sales  tax and freight  rates applied based            1
                        on TXRATE and FRRATE  below

                                       (continued)
                                          C-13

-------
                                     TABLE C-2 (continued)
Line No.  Variable
                                       Definition
                                                                          Units or values
  12        TXRATE      Sales  tax  rate  (applied  only when  ITAXFR           percent
                      above  set  to  1)

  12        FRRATE      Freight  rate  (applied  only when  ITAXFR             percent
                      above  set  to  1)

  12        SERVRT      Services,  utilities, and miscellaneous, applied    percent
                      as  a percent  of  total  process  capital

  12        ROYALT      Royalties,  applied  as  a  percent  of total           percent
                      process  capital

  12        IOTIME      Overtime labor  option
                       No overtime labor                               0
                       Overtime labor on 7% of  total  labor based  on     1
                         the OTRATE rate  below

  12        OTRATE      Overtime labor  rate (applied  to  7% of  total
                      labor) Example:   1.5

  12        INDPND      Separate indirect investment  factors option  for
                      pond construction
                       No separate indirect factors for pond construe- 0
                         tion  (same as process indirects)
                       Separate indirects for pond  construction speci- 1
                         fied  by PENGIN,  PARCH,  PFLDEX,  PFEES,  PCONT,
                         and PSTART below

  12        PENGIN      Pond construction engineering  design and           percent
                      supervision (applied only  when INDPND  above
                      set to 1)

  12        PARCH      Pond construction architect  and  engineering        percent
                      contractor (applied only when  INDPND above
                      set to 1)
  12       PFLDEX     Pond construction field expenses (applied only
                      when INDPND above set to 1)
percent
  12       PFEES      Pond construction contractor fees (applied         percent
                      only when INDPND above set to 1)

  12       PCONT      Pond construction contingency (applied              percent
                      only when INDPND above set to I)

  12       PSTART     Allowance for pond startup and modification        percent
                      (applied only when INDPND above set to 1)

                                        (continued)
                                             C-14

-------
TABLE C-2 (continued)

Line No.
13
13
13
13
13
13
13
13
13
13
13
13
13
14

14
14
14
14


Variable
UC (1)
UC (2)
UC (3)
UC (4)
UC (5)
UC (6)
UC (7)
UC (8)
UC (9)
MINDEX
LINDEX
YRINV
YRREV
IOPSCH

PNDCAP
BAGDLP
BAGRAT
BGCOST


Definition
Limestone unit cost
Lime unit cost
MgO unit cost
Adipic acid unit cost
Operating labor and supervision unit cost
Steam unit cost
Process water unit cost
Electricity unit cost
Analyses unit cost
Chemical Engineering material cost index
(see Table B-23)
Chemical Engineering labor cost index (see
Table B-23)
Investment year cost basis
Revenue requirement year cost basis
Operating profile option
TVA profile
FERC profile
User input profile (Refer to the IYROP and
IA(n) options on lines 15-18.)
Levelized operating profile, 5500 hr/yr
Expected pond capacity (controls pond design
capacity; if 100% of sludge is to be ponded
over the life of the unit, input 1.0; if 80%
of sludge is to be ponded, input 0.80.)
Baghouse pressure drop
Baghouse ratio (typically = 0.8)
Bag cost
(continued)
C-15
Units or values
$/ton
$/ton
$/ton
$/ton
$/man-hr
$/klb
$/kgal
$/kWh
$/hr


year
year
1
2
3
4

inches H20
open ft2
actual ft2
$/ft2



-------
                                    TABLE  C-2  (continued)

Line No .
14
14
14
14

Variable
BGLIFE
EFFPS
ESPDLP
RESIST

Definition
Bag life
ESP rectification efficiency (Example - .65)
ESP pressure drop
Resistivity option (high or low)
Assume u = 20 ft/min
Assume a) = 30
Units or values
years
decimal
inches t^O
1
2
  14        SCARAT     SCA ratio
                       Contingency or safety factor  (fractional)
                       to apply to calculated collected area

  14        ICEPYE     Chemical Engineering plant index year

  14        CHPIOX     Chemical Engineering plant index  (see
                     Table B-l)

  15        IYROP      Years remaining life (lines  15  through 18  are
                     needed only  if the 10PSCH variable,  line 14,
                     is  set to  3.  Although  only  30  years are
                     shown, up  to 50 years may be used  and up
                     to  two additional  lines are  used  for
                            -  IA(50)
                                                             year
  16
  17
  18
  19
            IA(20)
 IA(30)

END or
 NEXT
           Operating hr/yr (input only 10 years per line)
           Operating hr/yr (input only 10 years per line)
           Operating hr/yr (input only 10 years per line)
"END" terminates further execution.  "NEXT" execu-
tion will continue with the next group of input
variables.  (If variable IOPSCH on line 14 is not
equal to 3, line 15 will be the "END" or "NEXT"
line.)
a.  Required for sizing hot ESP.   Drift velocity (w)  is related to percent sulfur in the
    cold ESP model,  but is an input for the hot ESP model.
                                          C-16

-------
       TABLE C-3.  LIMESTONE FINENESS OF GRIND INDEX FACTOR
Ground limestone product size distribution  Index factor (HPTONW)
80%- micron
129
113
98
85
74
62
58
51
44
40
37
31
24
% -200 mesh
60
65
70
75
80
85
86
90
93
95



% -325 mesh






70
75
80

85
90
95
hp/ton
1.11
1.22
1.35
1.51
1.72
2.04
2.19
2.54
3.04
3.40
3.64
4.44
5.70 Base

Data from KVS Rock Talk Manual, Kennedy Van Saun Corporation,
Danville, Pennsylvania, 1974.  Total ballmill horsepower is
calculated using the limestone hardness work index factor, wi,
and the fineness of grind index factor as follows:  hp = (tons/hr
limestone)(wi)(fineness of grind index factor).
                                C-17

-------
         APPENDIX D




BASE CASE INPUT AND PRINTOUT
             D-l

-------
o
 I
                                                       TABLE  D-l.   BASE CASE PRINTOUT
               11111
               111111111111
               111
               BASE MANUAL
               2  500 9500 11700 39 300 2 1 0  0 0 0 0 0 175 470 751
               1  66.7 3.8 5.6 1.3 3.36 0.1 15.1 4.0 92 80 2 .06 .03
               90 0 0 10 25 4 0.0 10  1 0.0 1  0 0.15 000 4.85 500
               15 40 0.2 40 0 30 0.0  80 1.2 0.0 090 14.7 1
               1  0 0 0 35 .0000005 32 10 5.70 1 4 1 .1
               1  0 9999 5000 0 25 5280 1 12 4.75
               7  2 16 5 10 8 15.6 10  8 3 6 1  60 1.886 14.7 0.0
               1  4 3.5 6 0 1 1.5 1 2  1 8 5 10 0
               8.50 75.00 460 1200 15 2.5 0.14 0.037 21.00 336.1 245.5 1982 1984
               4  1 5 .8 1.0 3 .65 1 1 1.1 1982 297.9
               END
                                                                     (continued)

-------
                                                         TABLE  D-l  (continued)
                                                        TENNESSEE VALLEY AUTHORITY
                                                SHAMNEE LIMESTONE OR LIME SCRUBBING PROCESS
                                                  COMPUTERIZED  DESIGN-COST ESTIMATE MODEL

                                                      REVISION  DATE DECEMBER 10,  1980
G

OJ
                                                                (continued)

-------
                                           TABLE  D-l  (continued)
BASE  MANUAL                                                          CASE   1

                    ***  INPUTS ***

BDILtR CHARACTERISTICS
I'EGiKATTS •   500,
BOILER HEAT RATE  •   9500,  BTU/MH
EXCESS AIR »  39.  PERCF.'IT,  INCLJD1NG LEAKAGE
HUT OAS TEMPERATURE  •  300.  DEG F
COAL Al.ALYSIS..  ,-,-r  1.  AS  FIRED  I
  C      H      Q       N      5      CL    ASH    H20
66.70   3.80   5.60    1.30    3.36   0,10  15,10   4.00
SULFUR OVERHEAD .  92,0 PERCENT
ASH 'JVEKHEAD =   30.C PERCENT
HFATINC VALUE PF  CGAL  * ll'OO, STJ/LB
                       EFFICIEMCY/    EMISSION,
FLY.'liH SsEMCVAL                '/.         LBS/M  BTIJ
         UF  SCRUBBER        99,4          0.06
WITHIN SCRUBBER             50.0          0.03
COST OF UPSTREAi  FLYASH REMOVAL EXCLUDED

ALKALI
LIMESTONE  I
       CAC03       •  95,00 WT * DRY BASIS
       SOLUBLE  HOD  •   0,15
       INERTS       «   *.B5
       MOISTURE  CONTENT •   5.00 LB H20/100 LBS  DRY  LIMESTONE
       LIMESTONE  HARDNESS UORK INDEX FACTOR •  10.00
       LIMESTONE  DEGREE OF GRIND FACT3R  •   5,70
f-LY ASH 1
       SOLUBLE  CAD  •   0,0, WT
       SOLUBLE  IGLI  •   0,0
       INERT5       •  100,00
                                                  (continued)

-------
                                          TABLE D-l  (continued)
PA* MAT1RIAL HAiDLMG ARfcA







 DUMBER JF REDUNDANT ALKALI PREPARATION UNITS
SCFUBBcR SYiTtt- VARIABLES
ClirdER UF L'l-ERATINC, SCRUBBING T^AI'.S »   4




 !U"BFR  IF BcDUNUANT SCRU63ING TRAILS •   1




SPPAY TjwER LlfloIB-Tn-GAS RATIO •  90, GAL/1000 ACFISaTL,)




SPRA/ TilV.ER GAS VELOCITY = 10. C FT/SEC




IIIPUCES DRJlFT SCRUBBER FAN OPTI3N




SCSUijB'P PRFSSUi <• • U.7 P5IA




St'2 CJI-CE'lTkftTlL."! II! SCRUBBER DJTLET GAS TU BE CALCULATED FDR  NSPS




STnICHI.lMET".Y 8,\Tln     TD BE CMCOLATEU




EMTPAMMEUT LEVtL « 0.10 WT %




EHT KEMDEKE TIME >  10.0 HIN




SUJ JXIUlZfu T  SYSTEM >  30.0 PERCENT




SfLIOS IN RECI&UJLATED SLURRY •  15,0 WT X






SI'LIOS ^ISPI'SAL SYSTEii
CC'ST 'IF LAT'I' =  5000,00 DOLLARS/ACRE




SPLICS IN SYSTEI' SLUDGE DISCHARGE •  *0.0 »T %




"AXIl'U" PL'KJ APEA m  9999.  ACRES




riAXIMU" EXCAVATJUN s  25,00 FT




DISTANCE  TO PG'.r »  5280.  FT




POND LINED :. ITH 12.0 INCHcS CLAY
                                                  (continued)

-------
                                                              TABLE  D-l  (continued)
                         STEAM RE-HEATER (IN-LINE)


                         SATURATED STEAfi  TEMPERATURE •  470. DEC F

                         HEAT nf VAPHRIZATinN OF STEAM •  751.  BTU/LB

                         nuTLET FLUE GAS  TEMPERATURE • 175.  DbG F

                         SUPERFICIAL GAS  VELOCITY (FACE VELOCITY) =  25.0  FT/SEC


                         ECONOMIC CHARACTERISTICS
                         1979  TVA-EPA  ECONOMIC PRECISES

                         PROJECTED  REVEfuE KEOU IKEMENTS INCLUDE  LEVELIZEO OPERATING AND MAINTENANCE COSTS
                         RATE .  1.Sat  TIMES FIRST YEAR DERATING  AMD MAINTENANCE COSTS
I—|                        FREIGHT  INCLUDED  III TOTAL INVESTMENT
 |                        FREIGHT  RATc  -  3.5 X
ON
                         SALES  TAX  II.CLUUED IN TOTAL INVESTMENT
                         SALtS  TAX  RATE  »  4,0 %

                         LABOP  rivERTIME  INCLUDED IN TOTAL  INVESTMENT
                         QVFRTIi'E RATE •   1,5

                         INFLATION  OOTE  •  6,0 x

                         PROCESS MAINTENANCE •  8.0 %

                         POI U MAINTENANCE •  3.0 X
                           IT     SR       SROLD
                            1     1.S1     1.50
                            2     1.51     1.51
                                                                      (continued)

-------
o
                                                               TABLE D-l  (continued)
                        BASt  MANUAL



                                           ***  OUTPUTS ***



                        EMERGENCY BY.PASS




                        EMERGENCY BY-PASS DESIGNED FOR  50.0 *


                        HOT  GAS TO SCRU9BEP
                                   CASE   1
                               HOLE PERCENT
                                               LB-MOLE/HP.
                                                              LB/HR
CD2
HCL
S02
02
N2
H20
12.338
0.00*
0,21*
5.560
75.227
6.654
0.2255E*05
0.1145E+02
0.3914E+03
0.1016E+05
0.1375E+06
0.1216E+05
0.9923£*0b
0.4175E+03
0.2508E+05
0.3251E+06
0.3852E+07
0.2191E+06
                        SD2 COi>ICENTRAT!UN IN  SCRUBBER IMLET GAS •  2142, PPM
                                                              •  5.28  LBS / MILLION BTU

                        FLYASH EMISSION •  0.060 LBS/MILLION BTU
                                       •  0,029 GRAINS/SCF (WfT)   OR
                                                                      285. LB/HR
                              SOLUBLE CAG  IN FLY ASH
                              SOLUBLE MGO  IN FLY ASH
0. LB/HR
U.
                        HOT GAS FLOh RATE  •   ,1154E*07 SCF^ (  ftO.  DEG Fj  14.7 PSIA)
                                         «   ,1687E*07 ACFM (300.  DEG f,  14.7 PSIA)

                        CBRReSPUNDIwG COAL FIRING RATE «  ,*060t+06  LB/HR


                        HOT GAS HUMIDITY •  0.042 LB H23/LB DRY  GAS


                        WET BULB TEliPEkaTURE  » 124. DEC F
                                                                       (continued)

-------
                                                              TABLE  D-l  (continued)
                         WET GAS  FROM SCRUBBER



                                 MOLE PERCENT    LB-MQLE/HR     LB/HR
CD?
HCL
02
M2
H20
11.713
0.000
0.023
5.169
70.300
12.795
0.2291E+05
0.5726E+OQ
0.4449E+02
0.10UE+05
0.1375E+06
0.2502E+05
0.1008E+07
0.2088E+02
0.2B50E+04
0.3E35E+06
0.3852E+07
                         502 CONCENTRATION IN SCRUBBER OJTLET  GAS •  228.  PPH


                         FLYASH  EMISSION •  0,030 LBS/MILLION  8TU
                                        •  0.013 GRAINS/SCF  (WET)  OR    1*3.  LB/HR
                         TOTAL  'JATER PICKUP •  *75,  GPM
                                    INCLUDING   11.3 GPM ENTRAINMENT

^                       WET GAS  FLO.! RATE •  ,1235E*07 SCFH  ( 60. DEC ft  U.7  PSIA)
O                                        .  ,1388E*07 ACF«  HZ*. DEC f,  U.7  PSIA)

00                       WET GAS  SATURATION HUMIDITY «  3.087  LB H2D/L8 DRY CAS
                                                                     (continued)

-------
                                         TABLE D-l  (continued)
FLUE GAS TO  STACK


        MOLE PERCENT     L8-MOLE/HR     LB/HR
C02
HCL
S02
02
N2
H20
11.695
0.000
0.023
5,161
70.187
12.934
0.2291E+05
0.5726E+00
0 , 4449E+02
0.1011E+35
0.1375E+06
0.2533E+35
0.1008E+07
0.2088E+02
0.2B50E*04
0.3235E+06
0.3852E+07
0.4564E+06
CALCULATED  SD2 REMOVAL EFFICIENCY •  88.7 X

CALCULATED  S02 tHISSIUN •   0.60 POUND* PER MILLION BTU

CALCULATED  S02 CONCENTRATION  IN STACK GAS •     227. PPM

CALCULATED  HCL CONCENTRATION  IN STACK <5AS •       3. PPM

S02 REMOVAL CALCULATED FROM SCRJBBER OPERATING
PARAMETERS  ANY SPECIFIED REMOVAL/EMISSION VALUES ARE IGNORED


FLYASH  EMISSION •  0.030 L8S/MILLION BTU
               •  0.013 GRAINS/SCF <*F.T)  OR     143. LB/HR

STACK GAS FLOW KATE •  ,1237E*07 SCFM ( 60. DEG  Ft  1*,7 PSIA)
                   •  ,1511E*07 ACFM (175, DbG  ft  14,7 PSIA)
                                                 (continued)

-------
                                                             TABLE  D-l  (continued)
a
i
                      STEAM REHEATER (IN-LINE)






                      SUPERFICIAL GAS  VELOCITY (FACE  VELOCITY)  •   25.0 f-T/SEC




                      SQUARE PIPE PITCH  . 2 TIMES  ACTJAL PIPE O.D.



                      SATURATED STEAM  TEMPERATURE  •   «70. DEG F




                      OUTLET FLUF GAS  TEMPERATURE  "   175. DEG F




                      REOUIRID HEAT INPUT TO REHEATER • 0.7H58E+08 BTU/HR




                      STEAM CUNSUMPTION  • 0.9930E+05  LBS/HR

GUTSIDE PIPE
DIAMETER/ I'l.
1.00




INCCINEL
COPTEN
TOTAL

PRESSURE DROP
IN. H2a
0.75
REHEATER
OUTSIDE PIPE
ARF.A^ SQ FT
PE^ TRAIN
0.1533E+0*
0.1235E+04
0.?768E+0
-------
                     •:iiTc? :mlA';CF  I PUTS
                                                            TABLE D-l  (continued)
                       iAinFALL(IN/VcAR)

                       pu.lD SEEPAGE: (C 1/StC ]*10**8

                       PlilD S-VAPtiPATlOM IN/YEAR)
35.

5".
                     ,.'ATr;o SALA'-ICE OUTPUTS
                      4TLK .WAI L<'-tJLfc
a
 I
h AIMrALL !-l<\ GPl!
ALKALI t) , G p ^
T :TAL '^25. G<>M
i. M T L R K OU I * t LJ
i.'j'nrjFirufir;. <.•><.. G?«
FMRAINMF ,T 11. GC'J
r, ISP'^'L ' AT' H 20P. GP^l
i'Y3RAT!fl" -ATED 1?. GPM
CLAPIFIFR E J APGRAT I D'- n. GPs
P" 1U S-VflPHPATIJI f.30. GPM
?t£PAC,E 11"'. GPf
T JTAL WATbK PtOuIRED I^IA, GP^i
,tT "ATEf PLSbUE^ 7i>',. G"".
30^769,
^789 .
3U579.

231707.
i630.
103836.
5876.
n.
30-.255.
5<,947.
70C7.51.
39J672.
LB/HR
LB/HR
LB/HR

LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
                                                                    (continued)

-------
                                       TABLE  D-l  (continued)
 SCRUBBER SYSTEM


 THTAL  MUMBFR  OF  SCRUBBING TRAIMS (HPfcRATiNG+REOUNuANTI  •   5

 SDE  RE'iljVAL  « 88.fc PERCENT

 PARTICIPATE  REMOVAL IN SCRUBBER SYSTEM •  50.0  PERCENT

 SPRAY  TCJWEP  PRESSUPi: DROP m  2.Z IN.  H20

 TOTAL  SYSTEM  PRESSURE DROP «  7.5 M.  M2Q

 SPtCIFlED    SPRAY TDWER L/G RATIO  «   90,  liAL/1000  ACHSATB)

 LI"t"STGljE  AHDIT1DM « 0.5579t+05 L8/HR  DRY  LIMESTONE
 CALCULATED  LIKESTOJE STQICHIOHETRY   *
                                       1.50  HOLE CAC03  ADDED AS LIMESTONE
                                           PER  MOLE  (SQ2+2HCL) ASSOk^ED
 SOLUBLE CAO FRH, FLY ASrt

 TOTAL SOLUBLE M(,0

 TOTAL
0.0  MOLE  PER  M3LE  (SU2+2HCL)  ABSORBED

O.C1 WLE  PER  MULE  (SU2+2HCL)  ABSORBED

1.5L 1PLE  SOLUBLE  (CA*MG)
     PER  10LE  (S02*2HCL> ABSORBED
SCPUBBSR I'''LET L I1UUR PH •  5.68

I'A> i UP W4T6R •  7B8. GPM

CROSS-SECTICNAL ARFA PER SCRUBBER

SYST5I1 SLUD&E DISCHARGE
          578.  SO  FT
SPECIES
CASU3 .1/2 H20
CAST> .2H20
CACU3
H20
CA-H.
MG++
SU3--
S04--
CL-
LB-MOLE/HR
0,2*28E»03
0,lOe«E+03
0.1795E+03
0.5764E+04
0.5287E+01
0.2075E+01
0.1934E+00
0. 17256+01
0.1088E+OZ
L3/HR
0.313»E»05
0.17626*05
0.17'66*05
0.1033E«06
0.2119E+03
0.50**E+02
C.154DE*02
0.1657E+03
0.3857E+03
bULJP
COMP,
HT %
44.92
29.25
25.75

LIUU1D
CQMP,
PPM
202*.
082.
US.
1583.
3685.
TOTAL DISCHARGE FLHW  RATE  «  0.17*4E*06 LB/HR
                          •   263,     C-PM

TOTAL DISSHLi/ED SULIDS  IN  DISCHARGE LIOUID »

          LIOUIu PM •   7,*2
                  7905. PPM
                                                (continued)

-------
                      SCFUB6ER SLJRKY BLEED
                      SPECIES
                                                             TABLE D-l   (continued)
                                     LP-MOLE/HR   L3/HR
CASU3 .1/2 H2C
CASC14 ,?H20
CACQ3
Hzrj
CA++
KG+*
Sfj3--
SIK--
CL-
AD«
TUTAL F|_Un KATE

0.2428E+03
0.102*E+03
0.1795E+03
0.2177E»05
0.1997E+02
0.7839E+01
0.7305E+OC
0.6515E+01
0,4110t+02
0.0
• 0.4652E+06
> 645,
0.313*E*05
0.17o2t+05
0.1796E+CI5
o!3923E*06
0.80"SE*n3
0.190dt*03
0.58«9E+n2
0 ,625flE+03
0.1»57E+C4
0.0
LB/HR
GP1
 I
M
U>
                      TOTAL 5JPERI.ATE RETURN
                      SPECIES
                      503—
                      SO".—
                      CL-
                      AU>

                      TOTAL FLOW  KATE
                                     LB-NOLE/HR
0.1219E+02
0.478
-------
                         LIf-'ESTONE SLURRY FEEP
                                                                  TABLE D-l  (continued)
                         SPECIES

                         CAC03
                         SOLUBLE MOD
                         INSOLU1LES
                         H2C1
                         CA++
                         MG+ +
                         SI13—
                         SU4--
                         CL-
                         A0>

                         TI1TAL
                                          LB-MQLE/HR   L3/HR
                 0.5294E+03
                 0.2076E+01

                 0.2048E+04
                 0.1752E+01
                 0.6878E+00
                 0.6409E-01
                 0.5716E+00
                 0.3606E+01
                 0.0
             0.5300E+n5
             0.8368E+02
             0.2706E+04
             0.3690E+05
             0.7023E+02
             O.U72E+02
             0.5131E+01
             0.127Bt+03
             0.0
                                    PATE
                                          0.9297E+05 LB/HR
                                             117.    GP1
                         SUPERNATE  RbTURti TO SCRUBBER OR EHT
 I
M
-P-
SPfCIES

H2H
CA + +

SU3 —
504 —
CL-
A0<

THTAL FLOW RATE
                                         LB-MDLE/IIO   L3/HR
0.1138E+03
0.1044E+02
0.4097E+01
0.3818E+00
0.3405E+01
0.2148E+02
0,0
0.2050E+06

oi9959E+n2
0.3056E+02
0.3270E+03
0.7f>l4E+03
0.0
                                          0.2066E+06 LB/HR
                                             413.    GP-I
                         RECYCLE  SLUhRY TO SPRAY TONER
                         SPECIES
                                         LR-MOLE/HR   LB/HR
CAS03 .1/2 H2D
CASQ4 .2H2D
CACD3
INSULUBLES
H20
HG++
S03--
S04—
CL-
AD«
TOTAL FLOU KATE
0.3589E+03
0. 15146+05
0.2A53E+03
0.3219E+07
0.2952E+04
0.1139E+04
0.1080E+03
0.9631E+03
0.6076E+04
0.0
» 0.6876E+08
• 124890,
0.4»33E+07
0.2605E+07
0.2656E+07
0 1 42 1 OE +06
0.3799E+08
0.1183E+06
0.2817E+03
o!925lE+05
o!o
LB/HR
GP1
                                                                        (continued)

-------
                    FLUE GAS CODLIHC SLURRV
                    SPECIES
                                                    TABLE D-l  (continued)
                                 LB-HDLE/HR  L8/HR
C1S03 .1/2 H2D
CASD4 .2H20
CACD3
IMS OLUB L E s
H2D
CA+ +
I16+ +
503 —
S
TI1TAL FLDK hATE

0.1595E*04
0.6727E+03
0.1179E*04
0.1431E*06
0.1312E+03
0.5150E+02
0.4800E+01
0.4280E+02
0.2700E+03
0.0
• 0.3056E+07
• 5551,
0.2059E*06
0.115oE*06
0.11806*06
01 R7 1 £ 4-T "5
• 1 o f i c *L 3
0.2577E*07
0.^2596*04
0 . 1 252E *04
0.3843E+03
0.411ZE*n4
0 ,95736+04
0.0
IB/Hd
GP1
u
I
                                                          (continued)

-------
                                                                 TABLE  D-l  (continued)
                                         POND DESIGN



                       OPTIMIZED TO MINIMIZE TOTAL  COST  PLUS OVERHEAD





                   POND DIMENSIONS
O
 I
DEPTH DF POND                       24.41 FT
OEPTH OF EXCAVATION                 4.0t> FT
LENGTH OF DIVIDER DIKE            Z833,   FT
LENGTH OF POND PERIMETER DIKE     15S37.   FT
LENGTH OF POND PERIMETER FENCE    1S572.   FT

SURFACE AREA OF BOTTOM            1497.   THOUSAND YD2
SURFACE AREA OF INSIDE WALLS        174.   THOUSAND YD2
SURFACE AREA OF OUTSIDE WALLS       133.   THOUSAND YD2
SURFACE AREA OF RECLAIM STORAGE     131,   THOUSAND YD2
LAND AREA nF POND                 1659,   THOUSAND YD2
LA'»D AREA OF POND SITE            2037,   THOUSAND Y02
LA'iD AREA UF PUND SITE             421.   ACRES

VOLUME DF EXCAVATION               2193,   THOUSAND YD3
VOLUME DF RECLAIM STORAGE           908.   THOUSAND YD3
VOLUME OF SLUDGE  TO BE           12900.   THOUSAND YD3
DISPOSED OVER LIFE OF  PLANT        7996.   ACRE FT
                   POKD COSTS  (THOUSANDS  DF DOLLARS!
                                                     LABOR
                                                              MATERIAL    TOTAL
CLEARING LAND
EXCAVATION
HIKE CONSTRUCTION
LI JINGI 12. IN. CLAY)
SODDING DIKE WALLS
ROAD CONSTRUCTION
PERIMETER COSTS/ FENCE
RECLAMATION EXPENSE
MONITOR WELLS
SUBTOTAL DIRECT
TAX AND FREIGHT
POND CONSTRUCTION
LAND COST
POND SITE
OVERHEAD
TOTAL

823,
6576,
3350.
2647,
194.
35.
83.
1200,
4,
14920.

14920,









122.
10.
166,

4.
302,
23,
325,





823.
6576,
3350.
2647.
316.
46.
249,
1208,
8.
15222.
23,
15245,
2104,
17349,
7242,
24591.
(continued)

-------
                                                                 TABLE  D-l  (continued)
                                     BASE  MANUAL
                                                                                                           CASE   1
                     WPSUL  CONTENT  (X)I
                     ASH CONTENT  (X)I
                     BTU RATINGl
                     BOILER TYPEl
                     ND. OF SCRUBBERSi
                     SCRUBBER  VELOCITY  (FT/MJI
                     PLANT  SIZE  (MW)i
                     OPERATING HRS/YRI
                     PUMPING RATE  (SAL/1000 ACFM
                     SCA RATIOI
                       (ACTUAL SQ.FT./CALC. SO.FT.)
                             PARTICULATE REMOVAL

                              3.36
                             15.10
                             11700
                             DRY PULVERIZED COAL
                                 4
                             600,0
                               300
                              5500
                              0.0
                             1.100
INVESTMENT AND OPERATING  COST
          PARTICULATE  EMISSION REGULATION  UB ASH/MILLION BTU)I   0,06
          FLUE GAS  TEMPERATURE (COLD)  
-------
                                                                   TABLE D-l  (continued)
                                       f-i.. -iTERIAL HANTLllS A^D PREPARATION


                          I'.CLUflNG   2  [VERATI\G AN'<  1  5P4RE PREPARATION UNITS



                         ITC.'1                        DESCRIPTION         NO. MATERIAL     LAuOx
U
 I
I—1
C»
                CAR S'A'>I i& I..CLINF  RHT
                               20HP SHAKEK 7.5HP  HOIST

                               25HP PULLER.  ^HP RETURN
                               16FT DIA<  10fT  STrtAIGHT
                               I'iCLjDES b  I' S3 GRATING
                               2JFT HDRIZUJTAL/ 5HP

                               310FT, 50HP
U'lLJA, I  G  PIT  MIST C.)LLKTnk  "


Ur.L~A>I.G  PIT  SJMP PU.'IP

STORAGE  3ELT C I'.VfcYuR

STORAGE  CUf'VFYr'k  TRIPPEa

MLIBILT KllJIPi't .T

RECLAIM  HflFPEH



RcCLAI"  VIBRATING  F6EOEK

RECLAIM  BELT CC1NVEYJR

RECLAIM  I-JCLINF BELT  ccr VEYJR

RECLAIM  PIT DUST COLLECTHR

RtCLAIM  PIT SU'P PU P


RLClAI"'  Bl.CKtlT ^LtViTUi,
                                                OLYPROPYLENE  8AGTYPE,
                                               I'lCt 'DES  JUST  M3DD

                                               hOGPi <  7CFT  HtAO,  5HP

                                                20'^FT.    5HP

                                               30FP-J  IMP


                                               SCRAPPER
                                               ••'IDE BOTT3M, CS

                                               3.5HP

                                                20.TFT.    5HP
                                                                    2FT
                                              PJLYPKDPYLE-IE HAG  TYPE

                                              oOf.P". 70FT  ., t.T,  i.,11

                                              TOFT nijM,  ?s.,t'
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
71916.
63u50.
15508.
5466.
11440.
85295.
11186.
2415.
73092.
27203.
141862,
2415,
10932.
40931,
60253,
7754,
2415,
5^3-J,
13037,


19555,


 593,..



  521.


 1434.


 4B24.



 5213.





 3911,

 912t>,




 1630.



 1043.


 2B6o.


 365*.


 2607.
                                                                           (continued)

-------
                                                   TABLE  D-l  (continued)
 I
I—'
vO
FEED BELT CONVEYOR

FEEO CONVtYUR TRIPPER

FEEO BIN


BIN WFII.H FEEDER

GVRATHRY CRUSHERS

BALL HILL OUST COLLECTORS


BALL -'UL

MILLS PRODUCT TANK


MILLS PRODUCT TANK  AGITATOR

MILLS PRUOL'CT TANK  iLURRY
PUMP


SLU»RY FEED  TA''K



SLURRY FEED  TAI-'K AGITATDR

SLURRY FEED  TANK PUMPS
TUTAL ECUIP.IFNT  COST
                                           60.PT HORIZONTAL  7.3HP

                                         30 FPM, HP
                                         13FT DIA.  21FT STRAIGHT
                                         SIDE HTj  COVERED/  CS
                                         UFT PULLEY CENTERS.  ZHP

                                         73HP
                                         POLYPROPYLENE  BAG  TYPE
                                         2200 CFM>  7.5HP
             793.HP

!500 GAL  10FT  OIA.  10FT
HT.  FLAKE3LASS  LINED CS

10HP

  59.GPM.  60FT  >HEADj
   2.HP.   2  OPERATING
A.JO  1  SPARES

  61977.GAL.  21.9FT DIA/
 21.9FT HT/  FLA
-------
                                                                TABLE  D-l  (continued)
                                                SCRUBBINS

                       INCLUDING   4  OPERATING AND  1 SPARE  SCRUBBING TRAINS

                      ITEM                       DESCRIPTION         NO. MATERIAL    LABOR
KJ
o
              I.D.  PANS


              SHELL
              RUBBER  LINING
              MIST  ELIMINATOR
              SLURRY  HEADER  AMD NOZZLES

                 TOTAL SPRAY SCRUBBER COSTS

              REHEATEkS

              SUOTBL01.ERS


              EFFLUFNT HOLD TANK
  7.3IN H20» WITH   631.
HP MOTOR AND DRIVE
5  33*1982.
               58581.
              EFFLUFNT HOLD TANK AGITATOR

              COOLING SPRAY PUMPS
             ABSORBER RECYCLE PUMPS
             MAKEUP WATER PUMPS
             TOTAL EOUIPMENT COST
 40 AIR-FIXED
 ZO AIR-RETRACTABLE

3*3449.GAL/  38.8FT DIA/
 38.8FT  HT/  FLAKEGLASS-
LINED CS

  82.HP

13B8.GPM 10DFT HEAD,
  64,HP/ I. OPERATING
AND  6 SPARE

13611.GPM» 100FT HEAD/
 723.HP/ 8 OPERATING
AND  7 SPARE

s
s
0
1769029.
1766838.
393830,
853239.
4782970,
264770*.
29*910.

449605,
168446,
182312.
                                                                   10
                                            3469.GPMi  200,FT HEAD/   2
                                            292.HP/  1 OPERATING
                                           AND  1 SPARE
                                                                        373173.    301319,
    5058*9.

    10*732,
                              33169,
207312.

 32268,
                                                                   13   1561896,    139397.
                                         37*2.
                                                                      1366637*.  13*3578,
                                                                       (continued)

-------
                                                             TABLE D-l  (continued)
                                            HASTE DISPOSAL
                      ITEM
                                               DESCRIPTION
                                                                  NO. MATERIAL
                                                                                  LABOR
a
 I
              ABS3RRER BLEED  RECEIVING
              T4N<
              ABSORBER BLEED  TANK AGITATOR

              POND FEED SLURPY PU''PS
              POND SUPERNATt  PUMPS
              TC1TAL EQUIPMENT COST
 85766. GAL/ 19.4FT OIA<
 38.8FT HT/ FLA«GLASS-
LINEO  CS

  47. HP

  845.GPM.  130.FT HEAD
  Sl.HPj   1 OPERATING
AMD  1 SPARE
                                            *83.GPM»  192.FT
                                            39.HPj  I OPERATING
                                           AND  1 SPARE
Z9716.




34390.

18550.




12053,
                                       24569.
2821,

5195.
                                                                                   136C.
                                                                        94708.
                                                                                 33946,
                                                                    (continued)

-------
                                            TABLE D-l  (continued)
                                                                           STARTUP
PROJECTED CAPITAL INVESTMENT REOUIREMENTS - BASE MANUAL
INVESTMENT* THOUSANDS OF 1982 DOLLARS




















O
1
ho
to

























EQUIPMENT
MATERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTWORK
MATERIAL
LABOR
FQUNOATIUNS
MATERIAL
LABOR
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
BUILDINGS
MATERIAL
LABOR
SALES TAX ( 4.0 X) AND FREIGHT ( 3,5 * )
TOTAL PROCESS CAPITAL
SERVICES AND MISCELLANEOUS < 6,0 X)
TOTAL DIRECT PROCESS INVESTMENT
POND CONSTRUCTION MATERIAL
POND CONSTRUCTION LABOR
POND SALES TAX ( 4.0 X) AND FREIGHT ( 3.5 X!
TOTAL DIRECT POND INVESTMENT
TOTAL DIRECT INVESTMENT
ENGINEfRING DESIGN AND SUPERVISION I 7.0 X)
ARCHITECT AND ENGINEERING CONTRACTOR ( 2,0 X)
CONSTRUCTION EXPENSES (16,0 XI
CONTRACTOR FEES ( 5,0 X)
CONTINGENCY (10,0 X)
POND 1ND1RECTS ( 2.0,1 1,0; 8.0* 3.0* 10, D X)
SUBTOTAL FIXED INVESTMENT
STARTUP C. MODIFICATION ALLOWANCE I 8.0, 3,0 *)
INTEREST DURING CONSTRUCTION 115, 6 X)
ROYALTIES ( 0.0 X)
LAND
WORKING CAPITAL
RAW MATERIAL
PREPARATION

3049.
307.

416.
192,

0.
0.

341,
883.

196.
142,

262.
757.

146.
22.

147,
163,
342.
7366,
442.
7808.
0,
0.
0.
0.
7808.
547.
156.
1249.
390,
1015.
0,
11165,
893.
1742.
0.
10,
418.

SCRUBBING

13666.
1544.

5152.
918.

3042.
2723.

172.
37*.

37Z.
648.

813.
1567,

814.
131,

0.
0.
1802.
33740.
2024.
35764.
0.
0.
0.
0.
35764.
2504.
715.
9722.
1788.
4649.
0.
51143,
4091,
7978,
0,
4.
1917,
WASTE
DISPOSAL

95.
34,

1058,
352,

0.
0.

20,
42,

2.
3.

146,
318.

13.
9.

o.
0.
100,
2192,
132,
2324,
302,
14920,
23,
15245,
17569,
163,
46,
372.
116,
302.
4208,
22775,
266,
3553,
0,
2116,
»*2,

TOTAL

16810,
1884,

6627,
146U

3042,
2723.

534.
1299.

570.
794.

1221.
2641,

975.
162.

147.
163,
2244,
43298.
2598.
45896,
302.
14920,
23,
15245,
61141,
3213,
918,
73*3.
2295.
5966,
420».
850(3,
5250,
13273,
0,
2130,
3277,
CASE
DISTRIBUTION
DOLLARS
PER KW

33.62
3.77

13.25
2.92

6.08
3.45

1.07
2.60

1.14
1.59

2.44
5.28

1.93
0.32

0.29
0.33
4.49
86.60
3.20
91.79
0.60
29.84
0,05
30.49
122.26
6.43
1.84
14.69
4.J9
11.93
8.42
170.17
10.50
26.33
0.0
4.26
6,53
.--t-— -..-.-.-
TOTAL CAPITAL  INVESTMENT
                                        14229.       65133.        29632,
                                                   (continued)
                                                                            109014,
                                                                                         218.03

-------
                                                          TABLE  D-l (continued)
                                                           TENNESSEE VALLEY AUTHORITY
                                                   SHAkHEE LIMESTONE OR LIME SCRUBBING PROCESS
                                                     COMPUTERIZED DESIGN-COST ESTIMATE MODEL

                                                         REVISION DATE DECEMBER 10/  1980
                                                                  MESSAGE FILE
                     BASE  MANUAL
                                                                                     CASE
O


K3
                                                                (continued)

-------
                                                               TABLE  D-l  (continued)
            LIMESTuNfc SLURRY PROCESS  --  BASISl  500 1H SCRUBBING UNIT -  500 MW GENERATING  UNIT; 1984 STARTUP

            PROJECTED REVENUE REQUIREMENTS • BASE  MANUAL

                                                  DISPLAY SHEET FDR YEAR*    1
                                                ANNUAL OPERATION KW-HR/KW >  5500

                                     34,89 TONS PE* HOUR                          DRY
                                             TOTAL CAPITAL  INVESTMENT      109013000
                                                  CASE   1
O

Isi
                    DIRECT COSTS


                      RAW MATERIAL


                        LIMESTONE


                           SUBTOTAL RAW MATERIAL


                      CONVERSION COSTS
                                                            ANNUAL QUANTITY
153.4  K  TONS
                                                                                   UNIT COST/t
                   8.50/TDN
                                   SLUDGE
                                        TOTAL
                                        ANNUAL
                                        COST,*
                                       1304000


                                       1304000
OPERATING LABOR AND
SUPERVISIUN 30680.0 MAN-HR 15,00/MAN-HR
UTILITIES
STEAM 546160.0 K LB 2,50/K LB
PROCESS WATER 259930.0 K GAL 0,14/K GAL
ELECTRICITY 47526160.0 KWH 0.037/KWH
MAINTENANCE
LABOR AND MATERIAL
ANALYSES 4940.0 HR 21.00/HR
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
INDIRECT COSTS
OVERHEADS
PLANT AND ADMINISTRATIVE ( 60.0* OF CONVERSION COSTS LESS UTILITIES)
FIRST YEAR OPERATING AND MAINTENANCE COSTS
LEVELIZED CAPITAL CHARGESl 14.70* OF TOTAL CAPITAL INVESTMENT)
FIRST YEAR ANNUAL REVENUE REQUIREMENTS
EQUIVALENT FIRST YEAR UNIT REVENUE REQUIREMENTS* MILLS/KWH (MW SCRUBBED)
LEVELIZED OPERATING AND MAINTENANCE ( 1,886 TIMES FIRST YEAR OPER. C MAIN.)
LEVELIZEO CAPITAL CHARGES! 14.70* DF TOTAL CAPITAL INVESTMENT)
LEVELIZED ANNUAL REVENUE REQUIREMENTS
EQUIVALENT LEVELIZED UNIT REVENUE REQUIREMENTS, MILLS/KMH (MW SCRUBBED)
460200
1365400
36400
1758500
4130100
103800
7854400
9158400

2816500
11974900
16025000
27999900
10,18
22584700
16025000
38609700
14,04

-------
                               TECHNICAL REPORT DATA
                         (Please read Instructions on the reverse before completing)
1. REPORT NO.
 EPA-600/8-81-008
                          2.
                                                     3. RECIPIENT'S ACCESSION" NO.
4. TITLE AND SUBTITLE
Computerized Shawnee Lime/Limestone Scrubbing
 Model Users  Manual
                                 5. REPORT DATE
                                  March 1981
                                 6. PERFORMING ORGANIZATION CODE
7. AUTHORIS)
W. L. Anders and R. L. Torstrick
                                                     8. PERFORMING ORGANIZATION REPORT NO.
                                                      TVA/OP/EDT-81/15
9. PERFORMING ORGANIZATION NAME AND ADDRESS
TVA, Office of Power
Division of Energy Demonstrations and Technology
Muscle Shoals, Alabama  35660
                                                     10. PROGRAM ELEMENT NO.
                                  CAAN1D
                                 11. CONTRACT/GRANT NO.

                                  EPA-IAG-79-D-X0511
12. SPONSORING AGENCY NAME AND ADDRESS
 EPA, Office of Research and Development
 Industrial Environmental Research Laboratory
 Research Triangle Park, NC  27711
                                 13. TYPE OF REPORT AND PERIOD COVERED
                                  Users  Manual; 1979-80 	
                                 14. SPONSORING AGENCY CODE
                                   EPA/600/13
15.SUPPLEMENTARY NOTES IERL-RTP project officer is Michael A.  Maxwell, Mail Drop 61,
919/541-2578. This manual supplements EPA-600/7-79-210.
16. ABSTRACT
          The manual gives a general description of a computerized model for esti-
mating design and cost  of lime or limestone scrubber systems for flue gas desulfur-
ization (FGD).  It supplements EPA-600/7-79-210 by extending the  number of scrub-
ber options which can be evaluated. It includes spray tower and venturi/spray-tower
absorbers, forced oxidation systems, systems with absorber loop additives (MgO or
adipic acid), revised design and economic premises, and other changes reflecting
process improvements  and variations.  It describes all inputs and outputs,  along with
detailed procedures for using the  model and all its options. The model is based on
prototype scrubber data from the  EPA/Shawnee test facility and should be useful  to
utility companies, as well as to architectural and engineering contractors who are
involved in selecting and designing FGD facilities.  As key features, the model pro-
vides estimates of capital  investment and operating revenue requirements. It also
provides a material balance, equipment list, and a breakdown of costs by processing
areas. The primary uses of the model are to project comparative  economics of lime
and limestone FGD processes and to evaluate system alternatives  prior to the devel-
opment of a detailed design.
17.
                            KEY WORDS AND DOCUMENT ANALYSIS
                DESCRIPTORS
                                         b.lDENTIFIERS/OPEN ENDED TERMS
                                             c.  COSATl Field/Group
Pollution
Desulfurization
Gas Scrubbing
Flue Gases
Calcium Oxides
Calcium Carbonates
Mathematical Models
Engineering Costs
Material Balance
Equipment
Industrial Processes
Pollution Control
Stationary Sources
13B
07A,07D
13H
21B
07B
12A
14A
14G
13. DISTRIBUTION STATEMENT
 Release to Public
                                         19. SECURITY CLASS (This Report)
                                          Unclassified
                                              21. NO. OF PAGES
                                                195
                     20. SECURITY CLASS (Thispage)
                      Unclassified
                                              22. PRICE
EPA Form 2220-1 (9-73)

-------