United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
Research and Development
EPA/600/S8-86/031 Feb. 1987
xvEPA Project Summary
User's Manual for the
Integrated Air Pollution
Control System Design and
Cost-Estimating Model
(Version II)
P. J. Palmisano and B. A. Laseke
The Integrated Air Pollution Control
System (IAPCS) is a computerized sim-
ulation model used to estimate the
costs and predict the performance of
sulfur dioxide (SO2), nitrogen oxides
(NOX), and particulate matter (PM)
emission control systems for coal-fired
utility boilers. The model includes
conventional and emerging technolo-
gies that effect pre-, in situ, and post-
combustion emission control. The
model can accept any combination of
the technology modules built into the
system. Interactions are reflected in a
material balance tabulation of the exit
of each module. Alterations in the ma-
terial balance are used to account for
integrated performance and cost ef-
fects. The emission control technolo-
gies contained in IAPCS can be selected
in either isolated or integrated configu-
rations.
This version of IAPCS (IAPCS-II) was
completed in April 1986. It incorporates
a number of enhancements to the de-
sign premises of the emission control
modules as well as the model's user ac-
cess and versatility. Enhancements to
the control modules involved upgrades
to five modules: wet flue gas desulfur-
ization (FGD), low-NOx combustion,
limestone injection multistage burner
(LIMB), electrostatic precipitator (ESP),
and fabric filter (FF). Other important
enhancements to IAPCS-II include ex-
panding the solid waste handling and
disposal module, housing the model on
a microcomputer (personal computer),
providing EPRI and TVA economic
premises, and expanding the user-
activated parameter file.
The User's Manual describes the sec-
ond version of IAPCS. This manual pro-
vides a guide to the user of the model.
It presents the design bases of the indi-
vidual modules comprising the model
and the structure of the program itself,
as well as the bases for a number of
model enhancements now available to
the user.
This Project Summary was devel-
oped by EPA's Air and Energy Engineer-
ing Research Laboratory, Research Tri-
angle Park, NC, to announce key
findings of the research project that is
fully documented in a separate report
of the same title {see Project Report
ordering information at back).
Background and Purpose
Costs of installing and operating air
emission control equipment to meet
sulfur dioxide (S02), particulate matter
(PM), and nitrogen oxide (NOX) emis-
sion standards have grown significantly
and now represent a large portion of the
total powerplant costs. The significance
of these costs has led to the emergence
of the concept of integrated environ-
mental control of utility powerplant air
emissions within the last several years.
One logical means of addressing the
design and operation of an air emission
control system is to consider that sys-
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!•'
tem as an integral part of the power-
plant. By optimizing the interactions of
control devices, the integrated control
concept can effect the necessary control
level at a minimal cost.
The Integrated Air Pollution Control
System (IAPCS) is a computerized simu-
lation model developed for the Air and
Energy Engineering Research Labora-
tory (AEERL) of EPA to estimate the
costs and predict the performance of
S02, NOX, and PM emission control sys-
tems for coal-fired utility boilers. The
model includes conventional and
emerging technologies that effect, pre-,
in situ, and post-combustion emission
control. The model can accept any com-
bination of the technology modules
built into the system. Interactions are
reflected in a material balance tabula-
tion of the exit of each module. Alter-
ations in the material balance are used
to account for integrated performance
and cost effects. The emission control
technologies contained in IAPCS can be
selected in either isolated or integrated
configurations.
The power of IAPCS lies in its ability
to reflect integrated effects of various
control configurations. This allows the
analyst to identify synergistic interac-
tions and thus optimize performance
and cost in terms of integrated cost ef-
fectiveness. The specific technologies
that are contained in IAPCS are pre-
sented in Table 1.
The first version of IAPCS (IAPCS-I)
was developed in November 1983. This
version was a mainframe computer
model housed at EPA's National Com-
puter Center (NCC). The second version
of IAPCS (IAPCS-II) was completed in
April 1986. This version incorporates a
number of enhancements to the design
premises of the emission control mod-
ules as well as the model's user access
and versatility. Enhancements to the
control modules involved upgrades to
five modules: wet flue gas desulfuriza-
tion (FGD), Iow-N0x combustion, lime-
stone injection multistage burner
(LIMB), electrostatic precipitator (ESP),
and fabric filter (FF). Other important
enhancements to IAPCS-II include ex-
panding the solid waste handling and
disposal module, housing the model on
a microcomputer (personal computer),
providing EPRI and TVA economic
premises, and expanding the user-
activated parameter file.
Capabilities of IAPCS-II
The IAPCS-II design and cost-estimat-
ing model was developed to estimate
the cost and performance of air emis-
sion control equipment for coal-fired
utility boilers. The model includes both
conventional and emerging control
technologies. The control technologies
(modules) included are:
• Physical coal cleaning (PCC)
• Low-N0x combustion (LNC)
• Limestone injection multistage
burner (LIMB)
• Electrostatic precipitator (ESP)
• Fabric filter (FF)
• Spray humidification (SH)
• Dry sorbent injection (DSI)
• Lime spray drying (LSD)
• Flue gas desulfurization (FGD)
As designed, the model accepts any
combination of these technologies. Sys-
Table 1. IAPCS Control Modules
Type Technology
Pollutants) controlled
Pre-combustion
In-situ
Physical coal cleaning
Low-NOx combustion
LIMB
SO2/PM/NOX
NOX
S02
Post-combustion
ESP
Fabric filter
Spray humidification
Dry sorbent injection
Wet FGD
Lime spray drying FGD
PM
PM
SO2
SO2/PMC
SO2/PMa
aThe product coal is de-ashed and desulfurized. Some NOX reduction is reflected due to alter-
ation of the combustion conditions and nitrogen content of the cleaned coal.
bSpray humidification improves PM collection by conditioning the gas upstream of the ESP.
Some SO2 may be absorbed by the spray water.
cSome FGD configurations provide supplemental PM control in the scrubbing system.
dRemoval of PM (and the SO2 reaction solid products) occurs in the spray dryer chamber and
downstream PM control system.
tem interactions are reflected in a matefl
rial balance tabulation at the exit of each
module. The PCC, LNC, and LIMB mod-
ules (pre-combustion and in situ tech-
nologies) are applicable to the boiler
unit; the effects of these devices are ac-
counted for in a material balance
column reflecting flue gas conditions at
the air heater exit. An uncontrolled ma-
terial balance column is calculated be-
fore the boiler control modules are ac-
counted for so that the net effect of
emission control can be calculated on a
system basis. Output from the model
reports the reduction in S02, PM, and
NOX emissions; associated capital and
annualized costs of such reductions;
and associated cost-effectiveness val-
ues (dollars per ton of pollutant re-
moved across the entire emission con-
trol system).
A parameter file and a user-prompted
optimization routine are important fea-
tures of this model. As each module
was developed, the important design
parameters were included in a parame-
ter file. These parameters may be sub-
sequently changed by the user for a
given application. The parameter file is
designed to permit the user to modify
the important values to reflect those of
choice. M
The first run of the model for a use*
specified control configuration makes
use of default performance values for
each module (i.e., the costs reflect the
design-specified maximum perform-
ance levels of the control equipment).
When the output from the initial run has
been completed, the user can exercise
the option to enter an optimization rou-
tine which permits sequential revision
of the performance levels of certain
modules for a single pollutant. The user
must iterate runs to effect a desired pol-
lutant mass emission rate/overall sys-
tem removal efficiency.
The model also includes other impor-
tant design features, including an op-
tional debug output in identifying in-
terim calculated values for each control
module in the control system. An input
summary for each run ensures that cost
and performance data are attached to
the specifics and date of that run.
General Model Description
Input Requirements
A typical run entails a number of re
quests for input from the user. The inpu
questions are presented in Figure 1.
These items either provide basic daji
for the given run or specifically affef
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ENTER FIRING CONFIGURA TION OF BOILER:
1. WALL-FIRED
2. TANGENT/ALLY FIRED
ENTER BOILER SIZE IN MW>
ENTER BOILER CAPACITY FACTOR (%)>
ENTER CONSTRUCTION STA TUS (1=NEW, 2=RETROFIT)>
ENTER DA TE AND COMMERCIAL OPERA TION OF BOILER>
ENTER TEMPERA TURE A T AIR HEA TER EXIT>
ENTER A CFM A T THE AIR HEA TER EXIT-ENTER 0 TO CALCULA TE>
ENTER SELECTION OF TYPICAL COAL(1) OR SPECIFIC CHARACTERISTICS(2)>
ENTER COAL CHOICE:
1. BITUMINOUS - PENNSYLVANIA
2. BITUMINOUS - OHIO
3. BITUMINOUS - WEST VIRGINIA
4. BITUMINOUS - ILLINOIS
5. SUBBITUMINOUS -WYOMING
6. LIGNITE - NORTH DAKOTA>
ENTER COAL CLEANING LEVEL:
1. RUN-OF-MINE SORTED AND SCREENED
2. PHYSICAL COAL CLEAN/NO
ENTER BOILER BOTTOM ASH CONFIGURA TION:
1. DRY-BOTTOM
2. WET-BOTTOM>
SELECT IAPCS CONFIGURATION FROM THE FOLLOWING:
MODULE POLLUTANTS
1. LOW-NO, BURNERS. OVERFIRE AIR NO,
2. LIMB /VO» SOi
3. COAL CLEANING PART. SO*
4. SPRA Y HUMIDIFICA TION fSH) PART. SO2
5. ESP PART
6. FABRIC FILTER (FF) PART
7. LIME SPRA Y DRYING /LSD) S02
8. LIMESTONE/LIME FGD (FGD) S02
9. DRY SORBENT INJECTION (DSI) SOt
| THE FOLLOWING RULES APPL Y TO SELECTING A CONFIGURA TION:
1 - METHOD 4 MAY NOT BE USED WITH METHODS 7 OR 9
2 - METHOD 5 OR 6 MAY NOT PRECEDE (BUT MAY FOLLOW) 7 OR 9
3 - METHODS MUST BE IN ASCENDING NUMERICAL ORDER (EXCEPT AS IN 2 ABOVE)
4 - METHODS MAY NOT BE REPEATED IN THE SAME SYSTEM. (GENERALLY THE POST
COMBUSTION MODULES FOLLOW THE GAS PA TH)
ENTER OPTION NUMBERS IN ORDER (SEPARA TE BY COMMAS)
SELECT OUTPUT OPTION:
1. OUTPUT TO PRINTER
2. OUTPUT TO SCREEN
3. BOTH ABOVE
Figure 1. IAPCS-II Input requirements.
on the IBM PC AT or XT microcom-
puter.* The model cannot be used on a
floppy-disk-based system. The model is
available as a computer program
through NTIS in the form of MS-DOS
formatted microcomputer diskettes
(5.25-in. double-sided floppy disks). The
system must include at least 512 kilo-
bytes of random access memory and
run under the DOS 2.1 (XT) or 3.1 (AT)
(or higher) operating system. The user
should have at least 1.5 megabytes
available on the hard disk.
The executable program files and all
supporting data files are provided on
floppy disks in the PC DOS BACKUP for-
mat. Table 2 describes these files.
The original version of IAPCS was de-
signed as an interactive system; IAPCS-
II allows input via a batch file created
with a word processor or spreadsheet
program. Output reports can be trans-
mitted to either the console screen or
the printer, or to both, at the user's op-
tion.
(*)IBM PC AT and IBM PC XT are trademark names
of the IBM Corporation.
the outcome of the run. Input requests
include boiler data, fuel characteristics,
and the control configuration. The
boiler data are used to quantify the unit/
system generating performance. The
coal characteristics are used to estimate
the emissions from firing a given quan-
tity of coal, and the user specifies the
controls to be utilized. The firing config-
uration is used to estimate uncontrolled
emissions and to specify the appropri-
ate NOX control device from the LNC
module.
Cost Formats
Emission control cost estimates must
be comparable in terms of base year
jllars, cost categories, and overall
Intent (i.e., cost components). To facil-
itate comparisons, IAPCS-II has adopted
the bases and format of cost estimation
used by the Tennessee Valley Authority
(TVA) and the Electric Power Research
Institute (EPRI), which are generally ac-
cepted as industry standards.
Output Format and Options
The model provides the user with
eight outputs: (1) user input summary,
(2) module-specific output, (3) boiler
performance, (4) material balance,
(5) emission reduction, (6) capital cost
estimate, (7) annual cost estimate, and
(8) cost-effectiveness (or unit cost) of
S02 removal.
Computer Program Structure
IAPCS-II has been converted to Micro-
soft FORTRAN 77 (Version 3.2) for use
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Table 2. IAPCS-II Disk Files3
File Name
Description
MODULES.EXE
INPUT.EXE
OUTPUT.EXE
IAPCS.BAT
PARMFILE.TVA
PARMFILE.EPR
LOSTHELP.DOC
OPTHELP.DAT
PAftMHELP.DAT
Program executable file to size and cost control mod-
ules.
Program executable file to gather input data and per-
form initial gas stream and coal-cleaning calculations.
Program executable file to site and cost system fans
and waste disposal. Also makes economic calcula-
tions and prints output reports.
DOS batch command file to run executables sequen-
tially.
TVA default parameter file.
EPRI default parameter file.
Help information for escalation.
Help information for optimization.
Help information for parameter editor.
"Other temporary files are created by the program.
P. J. Palmisano and B. A. Laseke are with PEI Associates. Inc., Cincinnati,
OH 45246.
Norman Kaplan is the EPA Project Officer (see below).
The complete report consists of three parts, entitled "User's Manual for the
Integrated Air Pollution Control System Design and Cost-Estimating Model
(Version II):"
"Volume I." (Order No. PB 87-127 7677AS; Cost $18.95)
"Volume II. Appendix C."(Order No. PB 87-127 759/AS; Cost: $30.95)
"Volume III. IAPCS2 (floppy diskette)," (Order No. PB 87-127 775; Cost:
$75.00)
The above items will be available only from: (costs subject to change)
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Air and Energy Engineering Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection
Center for Environmental Research
Information
U.S. OFFICIAL MAS!
Agency Cincinnati OH 45268
Official Business
Penalty for Private Use S300
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EPA/600/S8-86/031
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STREET
60604
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