United States
Environmental Protection
Agency
Air and Energy Engineering
Research Laboratory
Research Triangle Park NC 27711
Research and Development
EPA/600/S7-90/022 Feb. 1991
EPA Project Summary
Integrated Air Pollution Control
System, Version 4.0
M. Maibodi, A. L. Blackard, and R. J. Page
The integrated Air Pollution Control
System (IAPCS) was developed for the
U.S. Environmental Protection Agency's
Air and Energy Engineering Research
Laboratory to estimate costs and per-
formance for emission control systems
applied to coal-fired utility boilers. The
model is capable of projecting a mate-
rial balance, an equipment list, and
capital investment and revenue require-
ments based upon user-specified input
data. Included in the model are con-
ventional and emerging technologies
for controlling sulfur dioxide, nitrogen
oxide (NO,), and paniculate emissions
using pre-combustion, in-situ, and post-
combustion emission controls. A vari-
ety of technology modules built into the
model can be incorporated and com-
bined. Cost and performance estimates
can be analyzed in terms of integrated
technologies. Conventional and emerg-
ing technologies included in the IAPCS
Version 4.0 are overfire air/low NOX
burners, lime injection multistage burn-
ers, physical coal cleaning, coal
switching and blending, spray humidifi-
cation, electrostatic precipitator, fabric
filter, lime spray drying, wet limestone
flue gas desulfurization, dry sorbent in-
jection, natural gas reburning, selective
catalytic reduction, atmospheric fluid-
ized bed combustion, pressurized fluid-
ized bed combustion, integrated
gasification combined cycle, and pul-
verized coal burning boiler.
This Project Summary was developed
by EPA's Air and Energy Engineering
Research Laboratory, Research Triangle
Park, NC, to announce key findings of
the research project that is fully docu-
mented in three separate reports of the
same title (see Project Report ordering
information at back).
Introduction
The Integrated Air Pollution Control
System (IAPCS) was developed for the
U. S. EPA's Air and Energy Engineering
Research Laboratory to estimate costs and
performance for emission control systems
applied to coal-fired utility boilers. The
model generates a material balance and
an equipment list from which capital in-
vestment and revenue requirements are
estimated based upon user-specified input
data. The model includes conventional and
emerging technologies for controlling sul-
fur dioxide (SO2), nitrogen oxides (NOX), and
paniculate matter (PM) emission. The vari-
ous technology modules can be combined
with interaction and integrated effects for
various control configurations reflected in
the material balance, cost, and performance
estimates.
Background
The IAPCS computer model was de-
veloped to estimate cost and performance
of air emission control equipment for coal-
fired utility boilers. The IAPCS model
evolved over the years from a FORTRAN-
coded mainframe computer model (the
Shawnee Model) which was developed by
the Tennessee Valley Authority. The first
version (unpublished) of IAPCS (IAPCS-
1), a mainframe computer model, was
completed in November 1983 and was
housed at U.S. EPA's National Computer
Center (NCC). An IBM PC version of IAPCS
Printed on Recycled Paper
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(IAPCS-2) was published in September
1986; this version incorporated a number
of enhancements and upgrades to the
various pollution control modules. A third
version of IAPCS (IAPCS-3) was not pub-
lished, but incorporated additional en-
hancements and added several new
technology modules, including selective
catalytic reduction (SCR), natural gas
roburning (NGR), and gas conditioning
(GC). The latest version (IAPCS-4) includes
further enhancements to technology mod-
ules and a number of new technologies.
Model Description,
Organization, and Capability
IAPCS-4 is a personal computer-based
model for cost and performance estimates
of pollution control systems for coal-fired
utility boilers. In this current and latest
version, a C language User Interface has
been added to the original model to facili-
tate the input of data for the FORTRAN
model.
IAPCS-4 consists of three volumes and
three diskettes: Volume 1: User's Guide,
Volume 2: Technical Documentation
Manual, and Volume 3: Programmer's
Maintenance Manual. Diskette 1 contains
the Executable Files. Diskettes 2 and 3
contain the Source Code Files in FOR-
TRAN and C language and other files re-
quired to create an Executable File.
Instructions for compiling the program
to produce an Executable File from the
Source Code Files are in Volume 3:
Programmer's Maintenance Manual, Sec-
tion 1.8, Procedures for Building the IAPCS
Program.
The IAPCS-4 documentation format
was selected to facilitate future mainte-
nance and enhancement of the IAPCS
model. This includes correction of software
errors, correction of existing deficiencies,
and enhancement of the modeling system
with new capabilities.
Conventional and emerging technolo-
gies which are included in IAPCS-4 are:
* Physical coal cleaning/coal switch-
Ing and blending (PCC/CS/B)
• Overfire air/tow NOX burners (OFA/
LNB)
• Natural gas reburning (NGR)
• Lime injection multistage burners
(LIMB)
• Advance silicate process
(ADVACATE)
• Electrostatic preciphator (ESP)
• Fabric filter (FF)
Gas conditioning (GC)
• Lime/limestone flue gas desuffuriza-
tipn (LLS/FGD)
• Lime spray drying/duct spray drying
(LSD/DSD)
• Dry sorbent injection (DSI)
Selective catalytic reduction (SCR)
• Atmospheric fluidized bed combus-
tion (AFBC)
• Pressurized fluidized bed combus-
tion (PFBC)
• Integrated gasification combined
cycle (IGCC)
Pulverized coal burning boiler (PCBB)
The program will accept any reason-
able configuration of these technologies.
Exceptions include:
• Spray humidification cannot be uti-
lized with DSI or LSD.
LSD or DSI is not to be preceded by
a FF or an ESP.
Identical control devices in series are
not permitted.
Control technology interactions are
shown in the material balance tabulation at
the exit of each module.
Parameter files are an important fea-
ture of the IAPCS-4 program. The param-
eter file has specific default values for
program operation and calculation. Based
on a recent program, the user may then
modify these default values for preference
and site-specific needs.
System Flow Chart
Figure 1 is a System flow chart for the
IAPCS program. The symbols and format
are for a Yburdon Context Diagram. A
single "bubble" represents an overview of
the entire program, with external sources
(permanent data files) and sinks (output
files and reports) depicted as blocks. Data
Stores (internal and temporary files) are
shown.
IAPCS uses four permanent files
(sources) to operate:
1) A User Screen Menu and Message
Database used for all user screens*
and messages;
2) A Default Parameter File for TVA
format runs;
TVA Default
Parameter
File
EPRI
Default
Parameter
File
Coal-
Cleaning
Factors
Database
User Screen
Menu and
Message
Database
— , .
'Batch' File
Figure 1. IAPCS system flow chart.
2
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3) A Default Parameter File for EPRI
format runs; and,
4) A Database of Coal Cleaning Fac-
tors.
The main data store is a file called the
Batch File which contains the actual nu-
meric parameters to use for each of a
series of IAPCS runs. Each segment of the
Batch File is derived from numeric values
in the corresponding Default Parameter
File.
Only one of the two Output Reports
(Data Sinks) is produced for a given run:
each run is specific to either the TVA or
EPRI Format. Optionally, these Output Re-
ports may be appended to previously cre-
ated reports.
System Module Hierarchy Chart
Figure 2 is a system module hierarchy
chart for IAPCS. For the purpose of inter-
preting this diagram, a module means a
collection of functionally related subrou-
tines. Figure 2 shows these functional ar-
eas further subdivided by the computer
programming language used for each (C
or FORTRAN).
IAPCS can be generalized into three
components:
1) A small C language control routine;
2) A mixed language user-interface
component (C and FORTRAN); and,
3) A FORTRAN cost modeling compo-
nent.
Looking at the top of Figure 2, the Main
Control Routine is the top-most module.
Proceeding in a top-down fashion, the User-
Interface is represented by the entire sub-
tree shown at the left below the Control
Routine. The Cost Modeling Component
MODEL, appears as the right sub-tree be-
low the Control Routine, and also as a
sub-component of the User-Interface.
The FORTRAN Cost Modeling Compo-
nent (MODEL) is invoked directly by the
main Control Routine for batch mode ex-
ecution, or indirectly from the User-Interface
component for interactive mode execution.
IAPCS uses a set of files called Param-
eter Files, alternatively called Input Files.
Two special Parameter Files called
PARMFILE.TVA and PARMFILE.EPR
contain the default values for the TVA and
EPRI constants used in the costing model.
These default parameter files (or any other
user-specified parameter files) may be
loaded into the input screen of the interac-
tive user interface and modified. Param-
eter file data from the user interface may
then be used to create new parameter files
or may be passed directly to the cost mod-
eling subsystem. Parameter file data from
the user interface may also be stored in
FORTRAN
MODEL
Subsystems
CUser
Screen
Subsystem
FORTRAN
MODEL
Subsystems
Figure 2.
IAPCS system module hierarchy chart.
the form of Batch Mode Data Files for later
use, as shown in Figure 1.
Model Cost Results
IAPCS-4 can present estimates for
capital costs, levelized costs, and unit costs.
These costs can be presented in constant
or current dollars for any specified year.
To demonstrate this capability, FGD
cost estimates were generated for a 500
MW unit having a capacity factor of 65%
and burning Illinois No. 6 coal. The capital
cost estimate was $180/kW. The levelized
annual cost was 8.0 mills/kWhr, and the
unit cost was $220/toh of SO2 removed.
Costs presented were in constant 1988
dollars.
-frU. S. GOVERNMENT PRINTING OFFICE: 1991/548-028/20162
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M. Maibodl, A. L Blackard, andR. J. Page are with Radian Corp., Research Triangle
Park, NC 27709.
Normsn Kaplan Is the EPA Project Officer (see below).
The complete report consists of three volumes entitled "Integrated Air Pollution Control
System, Version 4.0" and three diskettes:
Volume 1 is the User's Guide.
Volume 2 discusses technical documentation.
Volume 3 discusses programmer's maintenance.
Disk 1 is the executable file.
Disks 2 and 3 contain the source code.
Costs (subject to change) and PB numbers are:
PB91 133512, cost $17.00: Volume 1.
PB91 133520, cost$31.00:Volume2.
PB91 133538, cost $23.00: Volume 3.
PB91506469, cost $80.00: Volumes 1 and 2 and Disk 1.
PB91506477, cost $130:.00 Volumes 1, 2, and 3, and Disks 1, 2, and 3.
Volumes and disks of this report will be available only from:
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
Agency
Center for Environmental Research
Information
Cincinnati, OH 45268
BULK RATE
POSTAGE & FEES PAID
EPA PERMIT NO. G-35
Official Business
Penalty for Private Use $300
EPA/600/S7-90/022
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