C D A U.S. Environmental Protection Agency
(•• I f\ Office of Research and Development
                      National Fertilizer
                      Development Center
                      Muscle Shoals, Alabama 35660
Industrial Environmental Research
Laboratory
Research Triangle Park, North Carolina 27711
                   TVA BULL. Y-123
EPA-600/7-78-0233
February 1978
            ECONOMICS OF DISPOSAL

            OF LIME/LIMESTONE

            SCRUBBING WASTES:

            UNTREATED AND CHEMICALLY

            TREATED WASTES

                                »
            Interagency
            Energy-Environment
            Research and Development
            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 en-
vironmental 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 INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND  DEVELOPMENT series. Reports in this  series result from the
effort funded  under the  17-agency  Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems: The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by  providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the  transport of energy-related pollutants and their health and ecological
effects; assessments  of,  and development of, control technologies for energy
systems; and integrated assessments of a wide'range of energy-related environ-
mental issues.
                        EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for  publication. Approval does not signify that the contents necessarily reflect
the  views and policies of the Government, 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.

-------
                                  TVA BULL. Y-123
                                  EPA-600/7-78-023a
                                      February 1978
   ECONOMICS  OF DISPOSAL
       OF LIME/LIMESTONE
       SCRUBBING WASTES:
UNTREATED AND CHEMICALLY
         TREATED WASTES
                     by

                J.W. Barrier, HI. Faucett,
                  and L.J. Henson

                Tennessee Valley Authority
             National Fertilizer Development Center
               Muscle Shoals, Alabama 35660
            EPA Interagency Agreement No. IAG-D7-E721
               Program Element No. INE624A
              EPA Project Officer: Julian W. Jones

            Industrial Environmental Research Laboratory
             Office of Energy, Minerals, and Industry
              Research Triangle Park, N.C. 27711
                   Prepared for

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

-------
                               DISCLAIMER


     This report was prepared by the Tennessee  Valley Authority and has
been reviewed by the Office of Energy,  Minerals,  and  Industry,  U.S.  Environ-
mental Protection Agency,  and approved  for publication.   Approval  does  not
signify that the contents  necessarily reflect the views  and  policies of the
Tennessee Valley Authority or the U.S.  Environmental  Protection Agency, nor
does mention of trade names or commercial products constitute  endorsement
or recommendation for use.
                                   11

-------
                                  ABSTRACT
     A study was conducted to provide a detailed, comparative economic evalu-
ation of four alternatives available to the utility industry for the disposal
of wastes produced from flue gas desulfurization (FGD)  using limestone or lime
slurry scrubbing.  The four disposal alternatives evaluated were untreated
sludge (pond or landfill) and sludge chemically treated by three different
commercial processes—Dravo Corporation's Synearth process (pond and landfill),
I.U. Conversion System's Poz-0-Tec process (landfill),  and Chemfix's ultimate
disposal process (landfill).  The processes were assumed to be technically
proven and applicable to full-scale installations.

     Design and economic premises for the power plant,  scrubber system, and
sludge disposal systems were established and used, along with the latest avail-
able technology, to prepare (1) material balances, (2)  equipment lists and
specifications,  (3) capital investments, and (4) revenue requirements for a
base case system for each alternative.  The base case was a new 500-MW power
plant burning coal with 3.5% sulfur, 16% ash, and 10,500 Btu/lb heating value.
A limestone wet scrubbing FGD system (1.5 stoichiometry) was used to remove
flyash and SC>2 to meet New Source Performance Standards.  Underflow from the
scrubber system to the waste disposal system is a 15% solids slurry.  The
effects of power plant size and remaining life, coal analysis, scrubber proc-
ess, distance to disposal site, fixation additive rate, and mode of transpor-
tation were considered.  A total of 121 variations of system design and opera-
tion was prepared for the alternative processes.  Total capital investments,
annual revenue requirements, and lifetime revenue requirements for power plants
operating over both declining- and constant-load 30-yr  profiles are included
for the 121 cases.  Capital investments are based on mid-1979 costs and rev-
enue requirements, mid-1980.  A 3-yr construction schedule is assumed for a
midwestern plant location.

     Capital investments range from $10,717,000 ($21.4/kW) to $24,114,000
($48.2/kW) for the four base cases.  Base case annual revenue requirements
are between $3,280,000 (0.94 mills/kWh) and $6,988,000   (2.00 mills/kWh).
These costs can be combined with the base case FGD system costs (500-MW, new
plant, etc.) to yield the total FGD-waste disposal system costs.  The FGD
system costs without any disposal provisions are (1) capital investment of
$36,368,000 ($72.74) and (2) revenue requirements of $11,841,500 (3.38 mills/
kWh).  The investments and revenue requirements vary considerably for the 121
case variations.  The most economical disposal alternative for a particular
power plant cannot be chosen by using generalities since the costs are depend-
ent upon site-specific variables, such as plant size, remaining life, land
availability and cost, coal analysis, and disposal system location.

      This report was submitted by  the  Tennessee Valley Authority,  Office
 of Agricultural and Chemical Development, in  partial  fulfillment  of  Energy
 Accomplishment  Plan 79-BBI under  terms  of Interagency  Agreement EPA-IAG-D8-
 E721 with the U.S. Environmental Protection Agency.  Work was  completed
 as of June  1977.

                                    iii

-------
                                 CONTENTS
Abstract	ill
Figures	vii
Tables 	     x
Glossary, Abbreviations, and Conversion Factors	xii

Executive Summary	    xv

Introduction 	     1

Process Background and Description 	     9
  Untreated Sludge 	     9
    Ponding	    10
    Landfill	    10
  Treated Sludge 	    10
    Dravo	    n
    IUCS	    12
    Chemfix	    ^3

Design and Economic Premises 	    15
  Design Premises	    15
    Power Plant	    15
    FGD System	    15
    Sludge Disposal System 	    19
  Economic Premises  	    21
    Plant Location	    21
    Capital Investment 	    21
    Revenue Requirements 	    25

Systems Estimated	    31
  Untreated Sludge 	    31
    Major Equipment	    33
    Field Equipment	    33
    Case Variations	    35
  Treated Sludge 	    38
  Dravo Process	    33
    Major Equipment	    39
    Field Equipment	    39
    Case Variations	    47
  IUCS Process	    49
    Major Equipment	    49
    F-ield Equipment	    49
    Case Variations	    56
                                    v

-------
  Chemfix Process	->7
    Major Equipment	^
    Field Equipment	-*9
    Case Variations	65

Economic Evaluation and Comparison	
  Capital Investment	67
    Estimating Procedure	67
    Results	68
  Revenue Requirements	69
    Estimating Procedure	69
    Results	83
  Sensitivity Analyses	93
    Power Plant Size	93
    Sludge Rate	93
    S Content in Coal	93
    Ash in Coal	93
    Independent Flyash Removal	93
    Distance to Disposal Site	107
    Plant Remaining Life	107
    Optimum Pond Cost	107
    Settled Sludge Density	107
    Pond Liners	116
    Stabilization Additive Rate 	  116
    Ponding versus Landfill - Dravo Process 	  116
    Truck versus Pipeline Transport - Chemfix 	  116

Conclusions and Recommendations 	  119

References	129

Appendices
  A.  Total Capital Investment and Annual Revenue Requirement
      Tables - All Processes and Case Variations	133
  B.  Declining Operating Profile - Lifetime Revenue Requirements  .  . .  377
  C.  Constant On-Stream Time - Lifetime Revenue Requirements  	  391
                                    vi

-------
                                  FIGURES

Number                                                                 Page

 S-l    Simplified flow diagram for four disposal alternatives  .  .  .    xvii
  1     Limestone slurry process dike construction diagram 	      36
  2     Dravo process.  Flow diagram and material balance - base
        case	      40
  3     Dravo process.  Control diagram - base case	      41
  4     Dravo process.  Elevation - base case	      42
  5     Dravo process.  Overall plot plan - base case	      43
  6     IUCS process.  Flow diagram and material balance  - base
        case	      50
  7     IUCS process.  Control diagram - base case	      51
  8     IUCS process.  Elevation - base case	      52
  9     IUCS process.  Overall plot plan - base case	      53
 10     Chemfix process.  Flow diagram and material balance -
        base case	      58
 11     Chemfix process.  Control diagram - base case	      62
 12     Chemfix process.  Elevation - base case	      63
 13     Chemfix process.  Overall plot plan - base case	      64
 14     All processes.  Effect of power plant size on total
        capital investment.  New plants	      94
 15     All processes.  Effect of power plant size on total
        annual revenue requirements.  New plants 	      94
 16     All processes.  Effect of power plant size on total
        capital investment.  Existing plant with 25-yr remaining
        life	      95
 17     All processes.  Effect of power plant size on total
        capital investment.  Existing plant with 20-yr remaining
        life	      95
 18     All processes.  Effect of power plant size on total
        capital investment.  Existing plant with 15-yr remaining
        life	      96
 19     All processes.  Effect of power plant size on total
        annual revenue requirements.  Existing plant with 25-yr
        remaining life	      96
 20     All processes.  Effect of power plant size on total
        annual revenue requirements.  Existing plant with 20-yr
        remaining life	      97
 21     All processes.  Effect of power plant size on total
        annual revenue requirements.  Existing plant with 15-yr
        remaining life	      97
 22     All processes.  Effect of power plant size on unit
        capital investment.  New plants	      98
                                   vii

-------
                            FIGURES (continued)

Number                                                                Page

  23    All processes.  Effect of power plant size on annual unit
        revenue requirements.  New plants	   98
  24    All processes.  Effect of power plant size on annual unit
        revenue requirements.  New plants 	   99
  25    All processes.  Effect of power plant size on annual unit
        revenue requirements.  New plants 	   99
  26    All processes.  Effect of power plant size on annual unit
        revenue requirements.  Existing plant with 25-yr remaining
        life	100
  27    All processes.  Effect of power plant size on levelized
        unit revenue requirements.  New plants	100
  28    All processes.  Effect of power plant size on total
        capital investment.  New plant, operating constant 5,000
        hr/yr throughout its 30-yr life .	101
  29    All processes.  Effect of power plant size on total
        annual revenue requirements.  New plant, operating constant
        5,000 hr/yr throughout its 30-yr life	101
  30    All processes.  Effect of power plant size on total capital
        investment. New plant, operating constant 7,000 hr/yr
        throughout its 30-yr life	102
  31    All processes.  Effect of power plant size on total annual
        revenue requirements.  New plant, operating constant 7,000
        hr/yr throughout its 30-yr life	102
  32    Untreated disposal and Dravo processes.   Effect of sludge
        rate on annual unit revenue requirements	103
  33    IUCS and Chemfix processes.  Effect of sludge rate on
        annual unit revenue requirements	103
  34    All processes.  Effect of S content of coal on total
        capital investment.  New 500-MW plant 	  104
  35    All processes.  Effect of S content of coal on total
        annual revenue requirements.  New 500-MW plant	104
  36    All processes.  Effect of ash in coal on total capital
        investment.  New 500-MW plant 	  105
  37    All processes.  Effect of ash in coal on total annual
        revenue requirements.  New 500-MW plant 	  105
  38    All processes.  Effect of size of power plant having a
        separate ash disposal system on total capital investment
        for sludge disposal systems.  New plants	106
  39    All processes.  Effect of size of power plant having a
        separate ash disposal system on total annual revenue
        requirements for sludge disposal systems.  New plants ....  106
  40    All processes.  Effect of distance to disposal site on
        total capital investment.  New 500-MW plant 	  108
  41    All processes.  Effect of distance to disposal site on
        total annual revenue requirements.  New 500-MW plant	108
  42    Untreated process.  Effect of distance to disposal site
        and mode of transport on total capital investment.  New
        500-MW plant	109

                                   viii

-------
                            FIGURES (continued)

Number                                                                 Page

  43    Untreated process.  Effect of distance to disposal site
        and mode of transport on total annual revenue require-
        ments.  New 500-MW plant	    109
  44    All processes.  Effect of remaining plant life on total
        capital investment.  200-MW plant	    110
  45    All processes.  Effect of remaining plant life on total
        capital investment.  500-MW plant	    110
  46    All processes.  Effect of remaining plant life on total
        capital investment.  1500-MW plant 	    Ill
  47    All processes.  Effect of remaining plant life on total
        annual revenue requirement.  200-MW plant	    Ill
  48    All processes.  Effect of remaining plant life on total
        annual revenue requirements.  500-MW plant 	    112
  49    All processes.  Effect of remaining plant life on total
        annual revenue requirement.  1500-MW plant 	    112
  50    Untreated process.  Effect of available pond acreage
        and power plant size on total capital investment 	    113
  51    Untreated process.  Effect of available pond acreage
        and power plant size on total annual revenue requirements. .    113
  52    Dravo process.  Effect of available pond acreage and
        power plant size on total capital investment 	    114
  53    Dravo process.  Effect of available pond acreage and
        power plant size on total annual revenue requirements. ...    114
  54    Untreated process.  Effect of settled density in
        disposal pond on total capital investment.   New 500-MW
        plant	    115
  55    Untreated process.  Effect of settled density in disposal
        pond on total annual revenue requirements.   New 500-MW
        plant	    115
  56    Untreated process.  Effect of unit cost of pond liners on
        total capital investment.  New 500-MW plant	    117
  57    Untreated process.  Effect of unit cost of pond liners on
        total annual revenue requirements.  New 500-MW plant ....    117
                                     IX

-------
                                  TABLES

Number

 S-l    Summary of Total Capital Investment - All Processes	    xxv
 S-2    Summary of Total Annual Revenue Requirements - All
        Processes	   xxvi
 S-3    Summary of Lifetime Revenue Requirements  (All Processes) -
        Actual and Discounted  Cumulative  Total  and Unit  (Mills/kWh)
        Revenue Requirements Over the  30-Yr Life  of the  Power
        Plant	   xxix
 S-4    Summary of Lifetime Revenue Requirements  for Systems
        Operating at  Constant  Load of  7,000 Hr/Yr During 30-Yr
        Life - Actual and Discounted Cumulative Total and Unit
        Revenue Requirements Over the  Life of the Plant	   xxxi
 S-5    Summary of Lifetime Revenue Requirements  for Systems
        Operating at  Constant  Load of  5,000 Hr/Yr During 30-Yr
        Life - Actual and Discounted Cumulative Total and Unit
        Revenue Requirements Over the  Life of the Plant	xxxii
 S-6    Effect of Total Capital Investment and  Annual Revenue
        Requirement by Case Variations for All  Processes	xxxiv
   1     Summary of Information for FGD Systems  Under Construc-
        tion  in the U.S	       2
   2     Summary of Information for FGD Systems  in Operation
        in  the U.S	       4
   3     Projects  in FGD Waste  and Water Program	       6
   4     Power Unit Input Heat  Requirements 	      17
   5     Coal  and  Flue Gas Compositions and Amounts for Various
        S Contents in Coal  (500-MW Unit)  	      18
   6     Cost  Indexes  and Projections	      2?
   7     Project Expenditure Schedule 	      24
   8     Projected 1980 Unit Costs for  Raw Materials	      25
   9     Projected 1980 Unit Costs for  Labor	      25
  10     Annual Capital Charges for Power  Industry Financing
         (Landfill Disposal of  Fixed Sludge)	      27
  11     Annual Capital Charges for Power  Industry Financing
         (Pond Disposal of FGD  Sludge)	      28
  12     Quantities of Sludge for Disposal - All Processes and
        Case Variations	      32
  13     Material Balance - Untreated Process 	      33
  14     Untreated Disposal - Base Case Equipment List	      33
  15     Dravo Process - Base Case Equipment List	      44
  16     IUCS Process  - Base Case Equipment List	      54
  17     Chemfix Process - Base Case Equipment List	      59

-------
                            TABLES (continued)

Number                                                                 Page

  18    Total Capital Investment Summary - Untreated Sludge
        Disposal	70
  19    Total Capital Investment Summary - Dravo 	  72
  20    Total Capital Investment Summary - IUCS	73
  21    Total Capital Investment Summary - Chemfix 	  74
  22    Capital Investment Analysis - Untreated Process	75
  23    Capital Investment Analysis - Dravo Process	76
  24    Capital Investment Analysis - IUCS Process 	  77
  25    Capital Investment Analysis - Chemfix Process	78
  26    Capital Investments for Systems Operating at Constant
        Load During 30-Yr Life	79
  27    Summary of Land Requirements - All Processes	80
  28    Summary of Total Annual Revenue Requirements - Untreated
        Disposal	84
  29    Summary of Total Annual Revenue Requirements - Dravo
        Process	85
  30    Summary of Total Annual Revenue Requirements - IUCS
        Process	86
  31    Summary of Total Annual Revenue Requirements - Chemfix
        Process	87
  32    Summary of Unit Revenue Requirements - All Processes	88
  33    Summary of Lifetime Revenue Requirements for All Processes
        (Actual and Discounted Cumulative Total and Unit Values) ...  89
  34    Annual Revenue Requirements for Systems Operating at
        Constant Load During 30-Yr Life	90
  35    Summary of Lifetime Revenue Requirements for Systems
        Operating at Constant Load of 5,000 Hr/Yr During 30-Yr
        Life (Actual and Discounted Cumulative Total and Unit
        Values)	91
  36    Summary of Lifetime Revenue Requirements for Systems
        Operating at Constant Load of 7,000 Hr/Yr During 30-Yr
        Life (Actual and Discounted Cumulative Total and Unit
        Values)	92
  37    Effect of Stabilization Additive Rate on Total Capital
        Investment and Annual Revenue Requirements 	 118
  38    Effect of Case Variations on Total Capital Investment and
        Annual Revenue Requirements - Untreated Disposal 	 122
  39    Effect of Case Variations on Total Capital Investment and
        Annual Revenue Requirements - Dravo Process	123
  40    Effect of Case Variations on Total Capital Investment and
        Annual Revenue Requirements - IUCS Process 	 124
  41    Effect of Case Variations on Total Capital Investment and
        Annual Revenue Requirements - Chemfix Process	125
                                    xi

-------
             GLOSSARY, ABBREVIATIONS, AND CONVERSION FACTORS
GLOSSARY
Cementitious:  A chemically precipitated binding of particles resulting
in the formation of a solid mass.

Fixation:  The process of putting into a stable or unalterable form.

Impoundment:  Reservoir, pond, or area used to retain, confine, or accumu-
late a fluid material.

Leachate:  Soluble constituents removed from a substance by the action of
a percolating liquid.

Leaching agent:  A material used to percolate through something that results
in the leaching of soluble constituents.

Pozzolanic reaction:  A reaction producing hydraulic cement or a similar
material.

Stabilization:  Making stable by physical or chemical treatment.
                                  XII

-------
ABBREVIATIONS

Btu       British thermal unit
cm        centimeter
cm/sec    centimeter per second
°C        degrees Centigrade
°F        degrees Fahrenheit
ESP       electrostatic precipitator
FGC       flue gas cleaning
FGD       flue gas desulfurization
ft        feet
ft/sec    feet per second
g         gram
gal       gallon
gpm       gallons per minute
hp        horsepower
hr        hour
in.       inch
j         joule
j/s       joule per second
k         thousand
kg        kilogram
km        kilometer
kW        kilowatt
kWh       kilowatthour
1         liter
Ib        pound
M         million
m^        square meter
m^        cubic meter
MW        megawatt
ppm       parts per million
psi       pounds per square inch
sec       second
TDS       total dissolved solids
                                   xiii

-------
CONVERSION FACTORS
   To convert from
	English units	

acre
barrels of oil
British thermal unit
degrees Fahrenheit-32
feet
square feet
cubic feet
feet per minute
cubic feet per minute
gallons
gallons per minute
grains  (troy)
grains per cubic  foot
horsepower
inches
pounds
pounds per cubic  foot
pounds per hour
miles
revolutions per minute
standard  cubic  feet
  per minute  (32°F)
tons  (short)3
tons  (long)3
tons  per  hour
     To metric units
hectare
liters
gram-calories
degrees Centigrade
centimeters
square meters
cubic meters
centimeters per second
cubic meters per second
liters
liters per second
grams
grams per cubic meters
kilowatts
centimeters
kilograms
kilograms per cubic meter
grams per second
meters
radians per second
normal cubic meters
 per hour (0°C)
metric tons
metric tons
kilograms per second
Multiply by

    0.405
    158.97
      252
    0.5555
    30.48
    0.0929
  0.02832
    0.508
  0.000472
    3.785
  0.06308
    0.0648
    2.288
    0.7457
      2.54
    0.4536
    16.02
    0.126
    1609.
    0.1047

    1.695
  0.90718
    1.016
    0.252
 a.   All tons,  including tons  of  S,  are  expressed in  short tons  in  this
     report.
                                     xiv

-------
          ECONOMICS OF DISPOSAL OF LIME-LIMESTONE SCRUBBING WASTES:

                   UNTREATED AND CHEMICALLY TREATED WASTES


                             EXECUTIVE SUMMARY
     Emission standards for coal-fired power plants promulgated by the U.S.
Environmental Protection Agency  (EPA) under the Clean Air Act have made
necessary the installation of systems for flue gas cleaning (FGC).  Flue gas
desulfurization  (-FGD) by the lime-limestone wet-scrubbing method is the most
advanced technology for S02 removal and at least 90% of the full-scale FGD
systems existing or under construction are lime-limestone processes ( 1 ).

     Use of the lime-limestone process results in the production of very
large quantities of calcium-based waste materials (sludge) that must be
disposed of within the constraints of land and water quality regulations.

     Many research and development efforts have been centered around the
sludge disposal problem associated with FGD and a number of these efforts
have been funded by EPA ( 2 ) .  The EPA efforts in the FGD sludge area are
part of a program titled "Control of Waste and Water Pollution from Combustion
Sources," or simply "Waste and Water Program."  These efforts were designed
to evaluate, develop, demonstrate, and recommend environmentally and econom-
ically acceptable methods for disposal and utilization of FGC waste.  The
FGC waste efforts of  the EPA program encompass the following major areas of
interest:

      Environmental assessment of FGC waste disposal and utilization processes
      Assessment of process technologies
      Studies of process economics
      Development of alternative methods for FGC waste disposal
      Development of FGC waste utilization methods

This study is within the category of process economic studies.  The study
provides a detailed economic evaluation of disposal practices which are either
currently used by the utility industry or are potentially applicable to the
utility industry.

     The disposal of FGD sludge is usually in a landfill or pond.  However,
before disposal, the material may be subjected to a number of mechanical and
chemical treatments which include dewatering and chemical fixation.  Several
processes are currently being used by utilities or being marketed by vendors
                                     xv

-------
to utilities for the disposal of FGD sludge.  Four processes considered to
represent the wide range of available alternatives were selected for evalua-
tion in this study.  These processes are untreated disposal and treated
disposal methods developed by Dravo Corporation, IU Conversion Systems, In-
corporated  (IUCS) , and Chemfix, Incorporated  (a division of the Carborundum
Company).

     The base case for the untreated sludge disposal  option is  for  the direct
ponding of  wastes  in a clay-lined  pond  located  1  mi from  the  scrubber  facil-
ities.  A total  of 40 case variations including dewatering, landfill disposal,
transport by truck, and  distance  to  the disposal  site were studied.

     The base Dravo system is  for  pond  disposal of treated, partially  dewatered
(35% solids) sludge.  The final product is reported  to be a soillike material
that can be mechanically handled  and- can support  varying  loads  depending  on
the degree  of stabilization  resulting from chemical  treatment.   The base  IUCS
and Chemfix systems, which chemically differ  in the  types of stabilization
additives,  are  for landfill  disposal of a soillike material.   The scrubber
system effluent  (15%  solids)  is dewatered, using  a thickener and rotary drum
filter,  to  a sludge material containing 60% solids.   Chemical fixation addi-
tives  are mixed  with  the dewatered sludge to  produce  a chemically and  mechan-
ically stable material.  The fixed sludge can be  easily handled, hauled by
truck, and  compacted  to  meet the  needs  of the utility, depending on geograph-
ical location,  land availability,  and disposal regulations.  A total  of 80
case variations  for these three treated sludge disposal alternatives were
evaluated.

     The objective of this study  was to prepare detailed  estimates of  total
capital investment and annual  revenue requirements for each disposal  alter-
native including case variations  of  significant process parameters.   Since
these  processes  are being used in either demonstration- or full-scale  appli-
cation,  information is available  for defining the necessary equipment  and*
establishing accurate cost-size relationships.  Although  the cost estimates
 for  the various  systems  are  not considered absolute for site-specific  con-
ditions,  they have uniform bases  and, therefore,  can  be subjected to  a general
economic  comparison and  evaluation.
 PROCESS BACKGROUND AND DESCRIPTION

      The four disposal processes  are briefly described  in the following
 discussion.   Specific data concerning the design  of  these systems,  along
 with the necessary proprietary information for  evaluating these designs,
 were obtained from the company marketing  the process.   Figure S-l shows
 simplified process flow diagrams  for the  four alternatives.

      Several assumptions such  as  FGD system effluent solids  (15%),  pond
 settling (50% solids), thickener  dewatering (35%  solids)  are  reported for
 the four alternatives evaluated.   The values used are based on pilot- or
 demonstration-scale test work  and do not  necessarily represent actual oper-
 ating conditions for any specific installation  or the limits  of capability
 for a particular site.

                                     xv i

-------
              TRUCK
               OR
              RAIL
LIME
UNLOADING


LIME
STORAGE
   SLURRY
   FROM
  SCRUBBER
                                         TRUCK
                                          OR
                                         RAIL
     TO
 ^DISPOSAL
 ^  AREA
  (LANDFILL)
 SLURRY
  FROM
SCRUBBERS
                           IUCS  PROCESS
    TO
  DISPOSAL
+  AREA
 (LANDFILL)
                                         TRUCK
                                          OR
                                         RAIL
                                                                                                    CHEMFIX PROCESS
I-1-
H-
        TRUCK
         OR
        RAIL
       SLURRY
        FROM  H
      SCRUBBERS
        TRUCK
         OR
        RAIL
  TO
DISPOSAL
 POND
                                                                             SLURRY
                                                                             fROM
                                                                            SCRUBBER
                                                                   RECYCLE
                                                                    WATER
                                                                                         UNTREATED PROCESS
                         DRAVO PROCESS
                            Figure S-l.   Simplified  flow  diagram  for  four  disposal  alternatives.

-------
Untreated Sludge Disposal

     Effluent from the scrubber system can be (1) directly ponded, (2) de-
watered and ponded, or (3) dewatered and chemically treated for pond or
landfill disposal.  The disposal of sludge that has not been chemically
treated is one of four disposal alternatives considered in this study.
Direct ponding of scrubber effluent  (15% solids) in a clay-lined  pond  is a
common alternative used by the utility industry.  This system, the simplest
alternative, requires a minimum amount of additional equipment as compared
to other disposal alternatives, but  the investment for a  disposal pond can
be very large.  The ponded sludge  settles to a  50% solids material and
excess water is returned  to  the scrubber system.   Some utilities  are not
lining the disposal pond.  Other industries are using a variety of synthetic
linings for lining waste  disposal  ponds.  In all ponding  cases, local  ground
and surface water should  be  monitored  for contamination by leachate from the
disposal pond.  Settled sludge  containing more  than 40% moisture  is not
structurally stable and is often covered with water to improve safety  and
aesthetic requirements.

     Thickeners may be used  for dewatering  untreated sludge  (from 15%  solids
slurry to 35%)  to reduce  the quantity  of material  for pumping  to  the pond.
Additional dewatering  is  sometimes used  to  yield a 60% solids material that
is assumed to be  suitable for handling belt conveyors, trucks, and earth-
moving equipment.  This material is assumed suitable  for  landfill disposal.

Dravo Process

     The product  for disposal is a chemically treated slurry which contains
35% solids and  can be pumped to a  disposal  pond.   The ponded material  upon
settling contains about 50%  solids,  and with 15-30 days of curing, is  reported
to stabilize as a soillike material.   Excess water is returned to the  scrubber
systems.  Effluent from the  scrubber system is  dewatered  to  form  a 35% solids
slurry using a  thickener  and pumped  to an agitated mix tank  where Dravo's
chemical fixation agents  (Calcilox and Thiosorbic  lime) are  added.  These
agents and the  entire fixation process are patented (called  the Synearth
process)  ( 3).

     The additives (Calcilox at an amount of 7%  by wt of  dry sludge solids
and Thiosorbic  lime at an amount of  1%) combine with sludge  components in
cementitious reactions that  result in the formation of a  crystalline-interlacing
structure of molecules that  tie up free water resulting in stabilization of
the sludge material ( 4).

     Dravo offers another process  that involves  intermediate ponding of
treated 35% solids sludge in small (15-30 day capacity) curing ponds.  The
stabilized, soillike sludge  is then taken from the curing ponds and is suit-
able for handling with belt  conveyors and can be hauled by truck  to a  land-
fill for placement and compaction.
                                    xviii

-------
IUCS Process

     The proprietary process offered by IUCS for stabilization of FGD sludge
is marketed as the Poz-0-Tec process.  Sludge is dewatered with a thickener
and rotary drum filter to form a cake containing 60% solids; stabilization
is then accomplished by mixing this cake with the IUCS additive lime (5 ).
Flyash is a necessary ingredient for stabilization and, according to IUCS,
can be either removed with the sludge slurry from the precooling and scrubbing
stages of the FGD process or blended with the sludge cake at the additive
mixing stage of processing.

     The sludge stabilization results from two sets of simultaneous reactions
that occur when additives are mixed with the dewatered sludge.   The first set
of reactions occurs over the first 24-72 hr and involves additives and soluble
sulfate-sulfite compounds to produce gypsum.  The second set of reactions
begin immediately after mixing sludge and additives, but continue over a
period of several months; these are pozzolanic reactions between the alumina-
silica compounds of the flyash and the lime compounds.  The second set of
reactions  is impeded, but not impaired, by temperatures below 40 F.  The
water content of the mixture has a significant effect on the reactions and
must be no more than 40%  (6 ).

     The physical and chemical properties of the final product can be con-
trolled by adjusting the additive amount, water content of sludge, and
sludge composition.  IUCS reports that material suitable for landfill disposal
is produced from the sludge if it is dewatered to 60% solids and lime is
added to the sludge (flyash is in the dewatered sludge) such that the amount
is 4% by wt of dry sludge solids (7 ).

     The final product is reported by IUCS to be a claylike material that
can be easily handled, hauled, placed, and compacted.  The landfill is
structurally suitable for future reclamation.  Surface and ground water in
the area of the landfill is monitored to determine if contamination by
leachate occurs.

     The IUCS Poz-0-Tec process is based on another IUCS process that has
been successfully used for 20 yr to produce a construction material from
flyash, lime, and aggregate (Poz-0-Pac process).  Several utilities are
now using the Poz-0-Tec process in full-scale FGD sludge treatment and
disposal systems (8 ).

Chemfix

     Chemfix offers a process that yields a treated, stabilized sludge
that can be handled, hauled, and placed for landfill disposal.  This propri-
etary process uses a two-part inorganic chemical system which reacts with
all polyvalent metal ions and sludge components.  The slurry from the scrubber
is dewatered to form a 60% solids material.  The cake is then mixed with
additives (sodium silicate and Portland cement) to begin the fixation reac-
tions.
                                   xix

-------
     Three classes of reactions are responsible for fixation of the sludge.
The first is between soluble silicates and polyvalent metal ions.   The second
reactions occur between the soluble silicate and the reactive components of
the Portland cement.  The third reactions are between the Portland cement
and the sludge components.

     The extent of each of these reactions influences the characteristics
of the final product.  For the sludge in  this  study, the material produced
is a chemically and physically stable material suitable for  landfill disposal.
Sodium silicate is added  such that  the amount  is  2%  by wt of dry sludge solids
and Portland cement, 7%.  These rates can be varied  to yield desirable prod-
uct characteristics.

     Chemfix has been  successfully  applying this  technology  to  sludges pro-
duced by metal finishing, automotive  assembly, sewage treatment, and elec-
tronics operations.  The  technology for  FGD sludge stabilization has been
applied on  the demonstration  scale  (9).
DESIGN AND  ECONOMIC  PREMISES

     A comparative economic evaluation of  several sludge  disposal process
systems  requires  that  the basis  for  all processes be for  a specific set of
design and  economic  premises.  These design and economic  premises which
encompass the  power  plant, scrubber  system, and sludge disposal  system are
summarized  in  the following paragraphs.

Base Case

     A base case  was established for the power  plant,  FGD system, and four
sludge disposal alternatives.  A listing of the base case power  plant prem-
ises is  as  follows:
    1.  New  plant  with  30-yr life.
    2.  Single, 500-MW,  coal-fired unit.

    3.  Total operating  life of 127,500 hr with  average annual  capacity of
       4,250 hr-

    4.  Power unit input heat  requirement of 9,000  Btu/kWh.
    5.  Coal heating  value of  10,500  Btu/lb.

    6.  Coal analysis (wt %):  3.5% sulfur  (S),  dry;  16.0%  ash.

     The following is a list  of  FGD  system  base case premises:

    1.  Limestone  scrubbing process with  1.5 stoichiometry  based  on S02 removed
    2.  S02  removed to meet New Source  Performance  Standards  (NSPS).

    3.  Eighty  percent of the  ash present in the coal is emitted  as flyash.
    4.  Ninety-five percent of the S  in the  coal is emitted as  S02.
    5.  Fifteen percent  of the S02 removed is  converted  to  gypsum.
                                     xx

-------
   6.   Flyash and 862 are removed simultaneously in the scrubber system.
   7.   Effluent from the FGD system is 15% solids.
     The following is a listing of base case premises for the four disposal
alternatives.
   Untreated
   1.   Pump 15% solids to a clay-lined disposal pond.
   2.   Pond located 1 mi from scrubber facilities.
   3.   Sludge settles in pond to 50% solids and excess water is recycled  to
       the scrubber system.
   Dravo
   1.   Thickened sludge (35% solids) is treated with Dravo additives:
       Calcilox (7% of dry sludge) and Thiosorbic lime (1% of dry solids).
   2.   A gravity thickener is used for dewatering the sludge.
   3.   Treated sludge is pumped to a clay-lined pond located 1 mi from the
       scrubber facilities.
   4.   The ponded sludge settles in the pond to 50% solids and excess  water
       is recycled to the scrubber system.
   5.   The treated, settled sludge fixes as a soillike material in the pond.
   IUCS
   1.   Effluent from the scrubber system is dewatered (60% solids) using  a
       thickener and rotary drum filter.
   2.   The dewatered sludge is fixed by mixing with lime (4% of dry sludge).
   3.   Trucks are used to transport the treated sludge to the landfill
       disposal site located 1 mi from the scrubber facilities.
   4.   The treated material is assumed to have claylike properties and can
       be placed and compacted in the landfill using earthmoving equipment.
   Chemfix
   1.   Effluent from the scrubber system is dewatered (60% solids) using  a
       thickener and rotary drum filter.
   2.   Dewatered sludge is fixed by mixing with Chemfix additives:  Portland
       cement (7% of dry solids)   and sodium silicate (2% of dry solids).
   3.   Thickened sludge (35% solids) is pumped 1 mi to the disposal site
       where it is filtered to remove additional water and mixed with
       additives.
   4.   The treated material is then hauled to the landfill, placed and com-
       pacted using typical earthmoving equipment.
                                    xxi

-------
Design Premises

     Design premises are the same for all alternatives, making the basis for
comparison equal.  The following is a summary of these assumptions.

   1.  Three plant sizes are considered—200, 500  (the base case), and  1500
       MW.  The  1500-MW plant is assumed to be three 500-MW units.

   2.  S in coal is 3.5% for the base case.  Two alternative  cases include
       2.0 and 5.0% S.

   3.  The base  case ash content of the  coal is  16%.   Case variations for
       12 and 20% ash are  also  evaluated for each  alternative.

   4.  Case variations are considered for  existing 5-,  10-, and  15-yr-old
       plants.   All other  cases are for  new plants with  a 30-yr  operating
       life and  a total operating  time of  127,500  hr.

   5.  Flyash is removed simultaneously  with S02 in the  scrubber system.
       Case variations are estimated  for systems with  separate flyash
       removal facilities—electrostatic precipitator  (ESP).

   6.  Limestone systems are operated at a stoichiometry of 1.5  mol  CaO:
       1 mol S02 removed and lime  systems  at a  stoichiometry  of  1.1  mol
       CaO:l mol S02 removed.

   7.  Scrubber  system spent slurry is assumed  to  contain 15% by wt  solids
       from the  limestone  systems  and 10%  by wt  from the lime systems.

   8.  Sludge is assumed to be  primarily calcium sulfite hemihydrate with
       15% of the total S02 removed being  oxidized to  gypsum.

   9.  All raw materials used in the three proprietary processes for fixa-
       tion are  received by rail or truck  transportation.  Storage facilities
       are for 30-day capacity  and feed bins, intermediate storage tanks,
       etc., are 8-hr capacity.

Economic Premises

     A midwestern plant location was selected.   Raw materials are readily
available and a  large amount of coal-fired generating capacity exists in
this region.  Land costs are assumed $3500/acre.   Economic assumptions  are
summarized as follows (10):

   1.  All cost  estimates  are based on Chemical Engineering cost  indices
       (labor index - 237.9, material index - 264.9).  Capital costs are
       projected to mid-1979 and revenue requirements are for mid-1980
       The project is assumed to start in mid-1977 and be completed  in'
       mid-1980.  The midpoint for construction costs is mid-1979; startup
       mid-1980.
                                    xxii

-------
   2.  Direct capital costs cover process equipment, piping and insulation,
       transport lines, foundations and structural, excavation site prepara-
       tion, roads and railroads, electrical, instrumentation, buildings,
       pond construction, and earthmoving equipment.  Material and labor
       (fabrication and installation) costs for each of these items were
       estimated.  These estimates are based on costs obtained from vendors
       (equipment companies, contractors, etc.) and related literature
       information.

   3.  Indirect capital costs include engineering design and supervision,
       architect and engineering contractor expenses, construction expenses,
       contractor fees, contingency, allowance for startup and modifications,
       and interest during construction.  Two other capital cost items not
       included as indirect costs, but in the total capital requirements,
       are working capital and land.  These estimates are based on current
       industry practice and authoritative literature sources.

   4.  Direct costs for revenue requirements include raw materials, labor,
       and electricity and are projected to mid-1980.  Other direct costs
       are operating expenses for earthmoving equipment.  These costs were
       also based on authoritative literature sources and current market
       prices obtained from vendors and utility companies.

   5.  Indirect costs for revenue requirements are capital charges and
       overheads.

   6.  Capital charges are based on regulated utility economics.

   7.  Revenue requirements are projected for an annual 7000-hr operation.
       Other estimates for lifetime revenue requirements are based on the
       declining operating time for the plant.  Also estimates are made
       for constant annual operating loads (7000 and 5000 hr) throughout
       the life of the plant.

   8.  The revenue requirement estimates of systems with landfill disposal
       include a cost for land preparation.  This annual cost is based on
       the annual quantity of land used for the landfill.  A unit cost of
       $1700/acre is used which covers the preparation of land before dis-
       posal and the recovery of the land following disposal.  These costs
       include excavation and return of topsoil, landscaping to minimize
       seepage, and diversion of runoff from the disposal site.
RESULTS

     A base case was established for each of the four primary disposal
alternatives.  A material balance, flow diagram, equipment description list,
instrumentation diagram, and overall plant layout drawing for each system
were prepared.  This information was used to make an estimate of the total
capital investment for each system.  Case variations were estimated for each
of the four primary alternatives resulting in a total of 121 estimates.


                                   xxiii

-------
These case variations included power plant size, remaining plant lif£» coa
analysis, distance from scrubbing facility to disposal area, transportation
mode, sludge composition, and fixation additive rates.

     Tables S-l and S-2 are summaries of the total capital and annual revenue
requirements for the  121 estimates.  Appendix A includes a detailed tabula-
tion of costs for each of the estimates  (capital and  annual revenue require-
ments) .

Total Capital Investment and Annual  Revenue  Requirements

     The relative ranking of the  total  capital  investments  for  the four base
case disposal alternatives  is as  follows:

                                        Total capital
                                       investment,  M$    $/kW

              IUCS  stabilization           10,717        21.4
              Chemfix stabilization       13,531        27.1
              Untreated  ponding           17,211        34.4
              Dravo stabilization         24,114        48.2

     The IUCS and  Chemfix  base  case processes are similar and therefore the
difference  between  the capital  investment is relatively small (compared to
the  Dravo and untreated  alternatives).   Chemfix's capital investment  is
greater than  IUCS  primarily because of the difference in the method of
transporting  the material  to the  disposal site  (pumping vs truck).  The
capital investments for  these  two processes  is  significantly lower  than
for  the Dravo and  untreated alternatives because  of  the pond construction
costs  for Dravo and untreated.  Pond construction costs are very large and
represent a large  portion  of the  total  capital  investments for the  untreated
and  Dravo processes.   The  Dravo process requires  a greater capital  investment
than the untreated  process  because of  the costs of dewatering,  handling,
additive storage, and treatment  equipment needed for  the Dravo system.

      The unit revenue requirements for  the four base  case estimates are as
 follows:

                            $/ton  (dry  solids)   Mills/kWh

                Untreated          8.08             0.94
                IUCS              12.55              1.51
                Dravo             15.32              1.91
                Chemfix           16.51             2.00

      Revenue  requirements  are lowest for the untreated  alternative because,
 (1)  there are no  raw materials  (fixation additives)  required,  and  (2) labor
 costs for operation and  maintenance  are low  because  of  the  relative simplicity
 of the process.  The IUCS  process is similar to the Chemfix process,  but  raw
 material costs  are much  greater,  and therefore  the revenue  requirements are
 much greater  for  Chemfix.   Both Chemfix and  IUCS  require  earthmoving  equip-
 ment for transport, placement,  and compaction of  treated  sludge in a  landfill.

                                     xxiv

-------
       TABLE  S-l.   SUMMARY OF  TOTAL  CAPITAL  INVESTMENT3  - ALL PROCESSES
Untreated
Case
b
Base case
Variation from base case
200 MW new
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S in coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive amount - variation 1
Fixation additive amount - variation 2
Lime scrubbing process
Intermediate ponding and truck to landfill
Transport by truck to disposal area
Clarify (35% solids) and pump 1 mi
Clarify (35% solids) and pump 5 mi
Clarify (35% solids) and pump 10 mi
Clarify, filter (60% solids) and truck 1 mi
Clarify, filter (60% solids) and truck 5 mi
Clarify, filter (60% solids) and truck 10 mi
200 MW, constrained pond acreage (50% of optimum)
200 MW, constrained pond acreage (75% of optimum)
Constrained pond acreage (50% of optimum)
Constrained pond acreage (75% of optimum)
1500 MW, constrained pond acreage (50% of optimum)
1500 MW, constrained pond acreage (75% of optimum)
Pond settled density (40% solids)
Pond settled density (60% solids)
Unlined pond
Synthetic pond lining ($1.50/yd2)
Synthetic pond lining ($2.50/yd2)
Synthetic pond lining ($3.50/yd2)
Synthetic pond lining ($4.50/yd2)
k$
17,211C

9,800
8,480
6,844
5,511
14,578
11,399
8,822
36,455
30,212
22,904
16,999
15,031
19,055
13,390
20,655
6,716
11,397
23,595
26,836
37,420
-
-
16,226
-
-
18,490
24,881
31,458
8,294
8,825
9,249
12,774
10,203
22,676
17,985
48,917
38,228
20,070
15,194
14,391
20,994
23,070
24,959
26,707
$/kW
34.

49.
42.
34.
27.
29.
22.
17.
24.
20.
15.
11.
30.
38.
26.
41.
33.
22.
15.
53.
74.


32.


37.
49.
62.
16.
17.
18.
63.
51.
45.
36.
32.
25.
40.
30.
28.
42.
46.
49.
53.
4°

0
4
2
6
2
8
6
3
1
3
3
1
1
8
3
6
8
7
7
8


5


0
8
9
6
7
5
9
0
4
0
6
5
1
4
8
0
1
9
4
Dravo
k$
24,114d

13,942
13,258
11,597
10,239
21,416
18,281
15,553
48,235
41,382
33,924
27,905
21,446
26,028
19,251
28,523
12,242
19,745
38,722
30,994
37,765
23,120
25,209
21,318
12,670







20,701
17,305
37,697
31,061
80,098
64,503
-
-
-
-
-
-

$/kW
48.

69.
66.
58.
51.
42.
36.
31.
32.
27.
22.
18.
42.
52.
38.
57.
61.
39.
25.
62.
75.
46.
50.
42.
25.







103.
86.
75.
62.
53.
43.







2d

7
3
0
2
8
6
1
2
6
6
6
9
1
5
0
2
5
8
0
5
2
4
6
3







5
5
4
1
4
0







IUCS
k$
10,717e

7,193
7,428
7,351
7,295
10,591
10,402
10,269
20,105
19,952
19,382
18,976
9,345
11,957
9,025
12,283
7,301
9,839
18,103
11,377
11,891
10,302
10,748
10,383
-
-
-



-














Chemfix
$/kW
21.

36.
37.
36.
36.
21.
20.
20.
13.
13.
12.
12.
18.
23.
18.
24.
36.
19.
12.
22.
23.
20.
21.
20.




-
-


-


-

-







4e

0
1
8
5
2
8
5
4
3
9
7
7
9
1
6
5
7
1
8
8
6
5
8





















k$
13,531f

9,259
9,448
9,367
9,311
13,400
13,204
13,077
24,104
23,922
23,337
22,915
11,879
14,192
11,123
14,854
7,767
10,124
18,313
20,227
26,988
16,270
14,757
12,431
-
11,740
-

-
-
-
-
-












$/kW
27. lf

46.3
47.2
46.8
46.5
26.8
26.4
26.2
16.1
15.9
15.6
15.3
23.8
28.4
22.2
29.7
38.8
20.2
12.2
40.5
54.0
32.5
29.5
24.9

23.5
-



















a.  Basis:  Midwest plant location,  mid-1979 costs; SO  and  flyash removed together to  meet NSPS.
b.  New 500-MW plant; 30-yr life;  coal analysis (by wt) :   3.5%  S  (dry basis), 16% ash;  flyash and
    SO  removed together to meet NSPS, limestone process  with 1.5 stoichiometry based on  SO  removed.
c.  Direct  ponding of 15% slurry clay-lined pond; 1 mi from  scrubber facilities; 50% solids settled
    density.
d.  Ponding of 35% solids slurry;  clay-lined pond; pump 1 mi to pond from scrubber facilities; 50% solids
    settled density in pond; treated with Calcilox (7% of dry sludge) and Thiosorbic lime (1% of
    dry sludge).
e.  Landfill  disposal of 60% solids  material; 1 mi to landfill  from scrubber facilities;  trucks used for
    transport of treated sludge; treated with lime (4% of dry sludge).
f.  Landfill  disposal of 60% solids  material; 1 mi to landfill  from scrubber facilities;  pipeline used
    for transport of thickener underflow to disposal and  treatment area, treated with Portland cement
    (7% of  dry sludge) and sodium  silicate (2% of dry sludge).
                                                XXV

-------
TABLE  S-2.    SUMMARY  OF TOTAL  ANNUAL REVENUE  REQUIREMENTS3  -  ALL  PROCESSES
Untreated
Annual
amount ,
Case k$
Mills/
kWh
Dravo
Annual
amount ,
k$

Mills/
kWh
IUCS
Annual
amount ,
k$
Chemfix
Mills/
kWh
Annual
amount ,
kS __
Mills/
kWh
Base case
Variation from base case
  200 MW new
  200 MW existing, 25-yr remaining life
  200 MW existing, 20-yr remaining life
  200 MW existing, 15-yr remaining life
  Existing ,  25-yr  remaining life
  Existing ,  20-yr  remaining life
  Existing ,  15-yr  remaining life
  1500 MW new
  1500 MW existing, 25-yr remaining
   life
  1500 MW existing, 20-yr remaining
   life
  1500 MW existing, 15-yr remaining
   life
  12% ash in coal
  20% ash in coal
  27. S in coal
  57. S in coal
  200 MW, no flyash
  No flyash
  1500 MW, no flyash
  5 mi to disposal
  10 mi  to disposal
  Fixation additive rate   variation 1
  Fixation additive rate   variation 2
  Lime scrubbing process
  Intermediate ponding and truck to
   landfill
  Transport by truck to disposal area
  Clarify  (35% solids) and pump 1 mi
  Clarify  (35% solids) and pump 5 mi
  Clarify  (35% solids) and pump 10 mi
  Clarify, filter  (60% solids) and
   truck 1 mi
  Clarify, filter  (60% solids) and
   truck 5 mi
  Clarify, filter  (60% solids) and
   truck 10 mi
  200 MW, constrained pond acreage
   (50%  of optimum)
  200 MW, constrained pond acreage
   (75%  of optimum)
  Constrained pond acreage (50% of
   optimum)
  Constrained pond acreage (75% of
   optimum)
   1500 MW, constrained pond acreage
   (50%  of optimum)
   1500 MW, constrained pond acreage
   (75%  of optimum)
  Pond settled density  (40% solids)
  Pond settled density  (60% solids)
  Unlined pond
  Synthetic pond lining ($1.50/yd2)
  Synthetic pond lining ($2.50/yd2)
  Synthetic pond lining ($3.50/yd2)
  Synthetic pond lining ($4.50/yd2)
                                         3,280°    0.94C   6,701d   1.91    5.2916   1.51*   6,988    2.00
                     2,014
                     1,841
                     1,605
                     1,433
                     2,906
                     2,135
                     2,130
                     6,746

                     5,827

                     4,726

                     3,969
                     2,902
                       609
                       639
                       869
                       495
                       289
                       546
                     5,527
                     7,504
                     3,694
                     5,195
                     6,450

                     3,809

                     4,925

                     5,818

                     2,462

                     2,033

                     4,119

                     3,365

                     8,985

                     7,037
                     3,747
                     2,949
                     2, 765
                     3,882
                     4,253
                     4,590
                     4,900
1.44
1.32
1.15
1.02
0.83
0.70
0.61
0.64
 0.38
 0.83
 1.03
 0.75
 1.10
 1.07
 0.65
 0.43
 1.58
 2.14
                     3,136    0.90
 1.06
 1.48
 1.84

 1.09

 1.41

 1.66

 1.76

 1.45

 1.18

0.96

0.86

0.67
1.07
0.84
0.79
1.11
1.21
1.31
1.40
 3,643
 3,672
 3,461
 3,390
 6,377
 5,941
 5,728
 14,264
0.55    13,821

0.45    12,749
 12,138
  5,924
  7,406
  5,314
  8,007
  3,063
  5,073
 10,448
  8,124
  9,360
  6,052
  7,577
  6,168

  6,620
2.60
2.62
2.47
2.42
1.82
1.70
1.64
1.36
1.32
1.21
1.16
1.69
2.12
1.52
2.29
2.19
1.45
1.00
2.32
2.67
1.73
2.16
1.76
3,567
3,699
3,725
3,822
5,402
5,430
5,559
10,411
10,656
10,684
10,900
4,533
5,971
4,654
6,188
3,396
A, 650
8,162
6,490
7,475
4,994
5,511
5,093
2.55
2.64
2.66
2.73
1.54
1.55
1.59
0.99
1.01
1.02
1.04
1.30
1.71
1.33
1.77
2.43
1.33
0.78
1.85
2.14
1.43
1.57
1.46
4,529
4,695
4,730
4,856
7,152
7,191
7,359
14,362
14,749
14,791
15,053
6,229
7,600
5,935
8,263
3,766
5,184
9,771
8,675
10,003
13,651
10,099
6,200
3.24
3.35
3.38
3.47
2.04
2.05
2.10
1.37
1.40
1.41
1.43
1.78
2.17
1.70
2.36
2.69
1.48
0.93
2.48
2.86
3.90
2.89
1.77
                                               1.89
 4,423    3.16

 4,134    2.95

 9,109    2.60

 7,901    2.25

20,366    1.94

17,290    1.65
                                                                       6,698    1.91
     Basis:   Midwest
     New 500-MW plant
     SO,, removed toge
     Direct  ponding o
     Ponding of 357. s
     settled density
     Landfill disposa
     transport of tre
     Landfill disposa
     transport of thi
     dry sludge) and
plant location; mid-1980 operating costs; 7,000 hr/yr on-stream time
.; 30-yr life; coal analysis  (by wt):  3.5% S (dry basis),  16% ash;  fiyash  and
tther to meet NSPS, limestone  process with 1.5 stoichiometry based on  SO, removed
>f 15/ slurry; clay-lined pond; 1 mi from scrubber facilities; 50% solids settled'densifv
:olids slurry; clay-lined pond; pump 1 mi to pond from scrubber facilities-  507 solid,
in pond; treated with Calcilox (7% of dry sludge) and Thiosorbic lime (l%'of „'   ,"'  .
.1 of 60% solids material;  1 mi to landfill from scrubber facilities,  trucks uslri ^Udge)'
:ated sludge; treated with  lime (4% of dry sludge).
il of 60% solids material;  1 mi to landfill from scrubber facilities;  pipeline used f
.ckener underflow to disposal  and treatment area, treated with Portland cement IT/  t
sodium silicate (27. of dry sludge).                                          v

                                 xxvi

-------
This equipment requires more operators, maintenance, and must be replaced
more often than most chemical process equipment (6 yr vs 20 yr)and therefore
their use causes an increase in annual revenue requirements.  The annual
charges for equipment depreciation and the annual cost of capital greatly
increase the revenue requirements for the Dravo process.  Dravo process
additive costs are much more than the IUCS additive costs.  Additive costs
are greatest for the Chemfix process.

     These rankings are for base case systems which are for new 500-MW plants
burning coal with 3.5% S and 16% ash.  The relative position of the four
alternatives changes for some of the case variations.  The unit revenue
requirements for all case variations are included in the section Economic
Evaluation and Comparison.

     The total capital investments and annual revenue requirements for the
three plant sizes considered in this study are as follows:

                          	Capital investment, k$	
               Process    200 MW   500 MW  (base)   1,500 MW

              Untreated    9,800      17,211        36,455
              Dravo       13,942      24,114        48,235
              IUCS         7,193      10,717        20,105
              Chemfix      9,259      13,531        24,104
                        Total annual revenue requirements, k$
             Process	200 MW   500 MW (base)   1,500 MW

            Untreated      2,014       3,280         6,746
            Dravo          3,643       6,701        14,264
            IUCS           3,567       5,291        10,411
            Chemfix        4,529       6,988        14,362
     Another factor significantly affecting costs is the distance to the
disposal site.  The following is a summary of costs for the disposal site
distance variations considered in this study.  All estimates are for a new
500-MW  (base case) plant.

                               Capital investment, k$	
                 Process	1 mi (base)	5 mi	10 mi

                Untreated     17,211      26,836   37,420
                Dravo         24,114      30,994   37,765
                IUCS          10,717      11,377   11,891
                Chemfix       13,531      20,227   26,988
                                    xxv ii

-------
                            Total annual revenue requirement,  k$
Process
Untreated
Dravo
IUCS
Chemf ix
1 mi (base)
3,280
6,701
5,291
6,988
5 mi
5,527
8,124
6,490
8,675
10 mi
7,504
9,360
7,475
10,003
     The quantity of land available for construction of disposal ponds can
be a significant factor for many plant sites in selecting a disposal alter-
native.  Several cost estimates were made  to evaluate  the effect of land
availability on total capital investments  and  annual revenue requirements.
In every ponding case considered in this study (except these particular
variations described here), the pond construction  cost was minimized by
optimizing between pond construction and land  costs.   The following estimates
show the effect of limiting the pond acreage to 50 and 75% of  the optimum
acreage for an untreated  system.

                                Capital investment, k$
Plant size
200 MW
500 MW
1500 MW
Optimum land
9,800
17,211
36,455
75% optimum
10,203
17,985
38,228
50% optimum
12,774
22,676
48,917
          Plant  size
  Total annual revenue requirements, k$
Optimum land   75% optimum   50% optimum
200 MW
500 MW
1500 MW
2,014
3,280
6,746
2,033
3,365
7,037
2,462
4,119
8,985
Lifetime Revenue Requirements

     Lifetime  revenue  requirements were calculated  for three  cases  (200-,
500-, and  1500-MW new  plants) of each disposal alternative.   Table  S-3
presents a summary of  the cumulative discounted process costs and equivalent
levelized  unit increase  in revenue requirements over the life of the power
plant for  the  four disposal alternatives.  Lifetime levelized unit  revenue
requirements are slightly higher than corresponding annual unit revenue
requirements due to  the  declining operating profile of the power plant.  The
average annual on-stream time over the life of,the plant is 4250 hr ; however,
the  annual revenue requirement estimates are based on 7000 hr of operating
time (first year).
                                    xxviii

-------
 TABLE S-3.  SUMMARY OF LIFETIME REVENUE REQUIREMENTS (ALL PROCESSES) -

     ACTUAL AND DISCOUNTED CUMULATIVE TOTAL AND UNIT (MILLS/KWH)

    REVENUE REQUIREMENTS OVER THE 30-YR LIFE OF THE POWER PLANT3


Case
Untreated
200 MW
500 MW
1500 MW
Dravo
200 MW
500 MW
1500 MW
IUCS
200 MW
500 MW
1500 MW
Chemfix
200 MW
500 MW
1500 MW

Total
actual
lifetime
revenue
requirement, $

58,750,000
97,757,800
203,309,200

94,392,200
175,764,900
375,002,700

89,013,000
131,224,200
254,498,000

111,241,300
167,942,300
33^,190,900

Lifetime
average
unit revenue
requirements ,
mills /kWh

2.30
1.53
1.06

3.70
2.76
1.96

3.49
2.06
1.33

3.36
2.63
1.74
Total
present
worth
lifetime
revenue
requirement , $

20,204,800
33,612,100
69,819,400

33,368,200
62,052,600
133,456,200

30,584,100
45,381,700
88,798,600

38,655,100
59,099,300
119,154,500

Levelized
unit revenue ,
requirements ,
mills/kWh

2.03
1.35
0.94

3.36
2.50
1.79

3.08
1.83
1.19

3.89
2.38
1.60

c.
d.
Basis
  Over previously defined power plant operating profile.  30-yr life:
  7,000 hr for first 10 yr; 5,000 hr for next 5 yr;  3,500 hr for next
  5 yr; 1,500 hr for next 10 yr.
  Midwest plant location, 1980 operating costs.
  Constant labor cost assumed over life of project.
New plants, coal analysis (wt %):  3.5% S (dry), 16% ash, flyash removed
with SO  to meet NSPS.
Discounted at 10% to initial year.
Equivalent to discounted process cost over life of power plant.
                                      xxix

-------
Constant Operating Load - Cost Requirements

     To evaluate the effect of a constant annual operating load over a
plant's life, estimates were made for disposal systems (each of the four
alternatives) to use on 200-, 500-, and 1500-MW plants.  Estimates for these
12 cases were made for both 5000 and 7000 hr/yr operation over the 30-yr
system life.  Tables S-4 and S-5 are summaries of these estimates.  Both
total capital investment and annual revenue requirements are increased over
the corresponding values for systems with  the declining operating profile.

Land Requirements

     The cost of land  represents a  significant portion of the  total investment
required for a  sludge  disposal  system.  The cost  of  land was estimated to be
$3500/acre.  A  computer program developed  by TVA  to  estimate the cost of a
disposal pond was used.  The program determines the  optimum pond acreage
based on land and pond construction costs.  Land  requirements  for the four
base case alternatives are  as  follows:

                                        Percent of
                                        total capital
                     Process    Acre    investment
                     Untreated    407         8.3
                     Dravo         414         6.0
                     IUCS          193         6.3
                     Chemfix       198         5.1

Land  requirements  for  the  case  variations  evaluated  in this  study  varied
from  21  to  1454  acres.  The  variations  in  land  requirements  are a  result of
the type of disposal process used.  For the  Dravo  and  untreated alternatives,
ponding  is  used  and  land requirements are  in excess  of 400 acres (base  cases).
These requirements are  a function of pond  depth (average  of  21  ft  total depth
and 3.0  ft  excavation  depth)  and  the quantity (50% solids) of material  for
disposal.   A landfill  is used for disposal of treated  material  from  the Chem-
fix and  IUCS process.   The average  landfill  depth  is 30 ft and  the material
for disposal is  about  60%  solids.   Land requirements are  less than 200  acres
for these two processes (base cases).
 CONCLUSIONS AND RECOMMENDATIONS

      Two  categories  of  conclusions are discussed.  The first  is concerned
 with  the  economic  comparisons of disposal process alternatives.  The second
 category  pertains  to the effects of case variations for each  of the disposal
 process alternatives.

 Economic  Comparison  of  Alternatives

      The  initial comparison between alternatives that should  be made is
 between the base case systems for the four alternatives.  The IUCS process
                                    XXX

-------
 TABLE S-4.  SUMMARY OF LIFETIME REVENUE REQUIREMENTS FOR SYSTEMS OPERATING

  AT CONSTANT LOAD OF 7,000 HR/YR DURING 30-YR LIFE - ACTUAL AND DISCOUNTED

 CUMULATIVE TOTAL AND UNIT REVENUE REQUIREMENTS OVER THE LIFE OF THE PLANT3


Case
Untreated
200 MW
500 MW
1500 MW
Dravo
200 MW
500 MW
1500 MW
IUCS
200 MW
500 MW
1500 MW
Chemfix
200 MW
500 MW
1500 MW

Total
actual
lifetime
revenue
requirement , $

80,584,600
137,899,200
293,677,800

129,537,700
243,352,900
538,992,900

111,398,500
167,635,400
335,937,400

140,934,100
219,892,700
457,926,200

Lifetime
average
unit revenue
requirements ,
mills /kWh

1.92
1.31
0.93

3.08
2.32
1.71

2.65
1.60
1.07

3.36
2.09
1.45
Total
present
worth
lifetime
revenue
requirement , $

26,228,200
45,197,300
96,399,600

41,066,500
76,570,300
167,889,600

33,019,700
49,563,800
98,617,900

41,840,600
64,816,200
133,464,500

Levelized
unit revenue,
d
requirements ,
mills /kWh

2.26
1.56
1.11

3.53
2.64
1.93

2.84
1.80
1.25

3.60
2.23
1.53

c.
d.
Basis
  Midwest plant location, 1980 operating cost.
  30-yr life at 7,000 hr/yr, 210,000 hr total operating time.
New plants, coal analysis (wt %):  3.5% S (dry), 16% ash, flyash removed
with SO  to meet NSPS.
Discounted at 10% to initial year.
Equivalent to discounted process cost over life of power plant.
                                      xxxi

-------
TABLE S-5.  SUMMARY OF LIFETIME REVENUE REQUIREMENTS FOR SYSTEMS OPERATING

 AT CONSTANT LOAD OF 5,000 HR/YR DURING 30-YR LIFE - ACTUAL AND DISCOUNTED
                                                                          o
CUMULATIVE TOTAL AND UNIT REVENUE REQUIREMENTS OVER THE LIFE OF THE PLANT




1
Case
Untreated
200 MW
500 MW
1500 MW
Dravo
200 MW
500 MW
1500 MW
IUCS
200 MW
500 MW
1500 MW
Chemfix
200 MW
500 MW
1500 MW

Total
actual
lifetime
revenue
requirement , $

68,635,900
113,972,700
238,074,400

111,652,500
202,043,900
432,232,700

105,897,500
154,682,700
297,631,200

135,579,800
194,309,700
382,117,300

Lifetime
average
unit revenue
requirements,
mills /kWh

2.29
1.52
1.06

3.72
2.69
1.92

3.53
2.06
1.32

4.52
2.59
1.70
Total
present
worth
lifetime
revenue
requirement , $

22,269,300
37,296,900
78,056,500

35,498,100
63,826,800
135,328,300

31,497,700
45,980,100
88,019,300

40,359,100
57,798,000
112,489,900


Levelized
unit revenue
requirements ,
mills /kwh

2.68
1.80
1.25

4.28
3.08
2.17

3.79
2.22
1.41

4.86
2.79
1.81

 a.


 b.

 c.
 d.
Basis
  Midwest plant location, 1980 operating cost.
  30-yr life at 5,000 hr/yr, 150,000 hr total operating time.
New plants, coal analysis (wt %):   3.5% S (dry),  16% ash, flyash removed
with SO  to meet NSPS.
Discounted at 10% to initial year.
Equivalent to discounted process  cost over life of power plant.
                                       XXXll

-------
requires the lowest total capital investment of the four processes and the
Dravo process requires the highest.  The total annual revenue requirement
is least for the untreated ponding base case and is highest for the Chemfix
system.

     As comparisons between the four alternatives are made for the case
variations (plant size, age, etc.), the relative ranking of costs sometimes
changes.  These results can be seen in Tables 1  and  2 .   As the remaining
life of the power plant is reduced, the untreated ponding alternatives
become the least costly (capital investment) alternative.  This decrease in
capital investment is due to the large reduction in the pond construction
costs for the older plants, while the reduction in costs for the IUCS land-
fill system is only slightly reduced as the remaining plant life is reduced.

     The relative ranking of the capital investments  is  unchanged for the
case variations involving a change in power plant size, coal analysis, and
distance to the disposal site.

     As comparisons between the revenue requirements are made for the case
variations, the relative ranking of the costs seldom changes from that of
the base cases.  One set of cases that does change is the 200-MW plants.
The Dravo alternative is ranked second behind untreated ponding in these
cases.  This reflects the effect of the smaller depreciation charges for
the smaller plants (due to smaller capital investment for pond construction).

Effect of Case Variations for Each Alternative

     Table  S-6  shows the degree of change from the base case of capital
investments and revenue requirements for the case variations of the four
alternatives.  The following is a discussion of major variations.

   Plant size— In every case because of economies of scale this factor
   resulted in a large change from the base case capital investment and
   revenue requirements.

   Remaining plant life — The effect of this variable on costs depends on
   the particulate process and plant size.  In general, the alternatives
   with disposal ponds (untreated and Dravo) were more sensitive to changes
   in remaining plant life.  This sensitivity is due to the effect of pond
   size and cost on the total costs for the systems.

   Coal composition—This variation involved only a small change in the
   quantity of material and therefore resulted in small to moderate (i 40%)
   changes in costs.

   Distance to disposal — Both total capital investments and annual revenue
   requirements were significantly changed from the base case as the distance
   to the disposal site was increased.  Only for the IUCS system was the
   increase in capital investment rated as small (from ± 10% to ± 20% change
   from the base case).  This increase resulted from the small change in
                                   xxxiii

-------
TABLE  S-6.   EFFECT  OF TOTAL  CAPITAL  INVESTMENT AND ANNUAL  REVENUE REQUIREMENT

                        BY CASE VARIATIONS  FOR ALL  PROCESSES
                                              Degree of change from base case
Capital investment
Case variations
Plant size
Remaining plant life
Ash in coal
S in coal
No flyash in sludge
Distance to disposal
Fixation additive rate
Limestone vs lime
scrubbing process
Thickened sludge
Thickened sludge and dis-
tance to disposal site
Filtered sludge
Filtered sludge and dis-
tance to disposal site
Constraint of available
pond acreage
Pond lining
Truck to disposal
Intermediate ponding
and truck to landfill
Settled density in pond
Untreated
Large
Large
Small
Moderate
Moderate
Large
-

Slight
Small

Large
Large

Large

Moderate
Large



Small
Dravo
Large
Moderate
Small
Small
Small
Large
Slight

Small
-




-

Large



Large

IUCS
Large
Slight
Small
Small
Slight
Small
Slight

Slight
-




-





-

Chemfix
Large
Slight
Small
Small
Moderate
Large
Small

Slight



-



-
-
Small



Revenue requirements
Untreated
Large
Moderate
Small
Small
Moderate
Large


Slight
Small

Large
Small

Large

Moderate
Large



Small
Dravo
Large
Small
Small
Moderate
Moderate
Large
Small

Slight







Large



Slight

IUCS
Large
Slight
Small
Small
Small
Large
Slight

Slight
-

-
-









Chemfix
Large
Slight
Small
Small
Moderate
Large
Large

Small









Slight



     An arbitrary scale is established with the following rating criteria being applied.
       Slight:    <±10% change from the base case
Slight
Small:    from ±10% to ±20%
Moderate:  from >±207. to -40!
Large:    >+40%
                                          XXXIV

-------
   costs for truck transporting of sludge to the disposal area.  All other
   processes use pipelines for sludge transport.

   Fixation additive rate—This variation applies only to the treatment
   processes.  All costs, except the revenue requirement of the Chemfix
   system, had only a slight to small change for this variation.

   Sludge solids— One variation of the base case untreated process was the
   amount of dewatering  (thickening, filtration) used before the sludge was
   transported to the disposal area.  Costs were slightly changed (increased)
   if the slurry was thickened (35% solids) before pumping to the pond.  A
   large reduction in costs  was  found for capital investment of systems
   where the sludge was  filtered (60% solids), trucked, and placed in a land-
   fill for disposal.

   Pond acreage — Changes were from moderate to large for this case variation
   and resulted from increased pond construction costs.  These cases were
   considered to evaluate the effects of the available pond acreage (constrained)
   on costs.

   Pond lining—A large change (increase) in costs is experienced if syn-
   thetic pond linings are used instead of typical clay linings (base case).

   Chemfix - truck transport — The base case for the Chemfix process was for
   the pipeline transport of partially dewatered sludge to the disposal site
   where it was dewatered further and chemically treated before placement
   in a landfill.  One case variation was included to evaluate the effect
   of the transportation mode on costs (truck transport vs pipeline trans-
   port).  Only a small  change (10-20% increase) in capital costs was found
   and revenue requirements were slightly increased (<1%).

   Dravo - landfill disposal— One case variation to evaluate the Dravo
   landfill process was  included.  This Dravo system involves intermediate
   ponding, truck transport, and landfill disposal of Dravo treated sludge.
   The capital investment for this system was much less than that of the
   base case ($24,114,000 vs $12,670,000).  This change is due primarily to
   the absence of larger pond construction costs.  Revenue requirements were
   only slightly changed.

   Pond settled density— A small (i 10% to 1" 20%) change in costs was
   experienced as the settled density in the disposal pond was varied.
RECOMMENDATIONS

     The state of technology, environmental regulations, and economic factors
are expected to be continuously changing for sludge disposal alternatives.
In order to provide usable information concerning the economics of FGD sludge
disposal, additional evaluations are needed to consider the changing conditions
mentioned above.  Studies should be initiated to evaluate processes for gypsum
disposal, physical stabilization, Dravo landfill process, and mine disposal.


                                   xxxv

-------
         ECONOMICS OF DISPOSAL OF LIME-LIMESTONE SCRUBBING WASTES;

                  UNTREATED AND CHEMICALLY TREATED WASTES


                               INTRODUCTION
     The promulgation of emission standards for large fossil fuel-fired
power stations by the U.S. Environmental Protection Agency (EPA) has created
the need for reliable pollution control techniques.  Most (over 90%) systems
used for flue gas desulfurization (FGD) are based on processes that use lime
or limestone as the reactant source.  Tables  1  and  2  list the FGD systems
either in operation or under construction in the U.S.  With each FGD system
listing is additional information including the type of system and FGD sludge
disposal alternative being used or considered for use.   These lime-limestone
FGD (wet scrubbing) systems produce calcium-based waste products that present
an enormous solid waste handling and disposal problem (11).

     A broad range of research, development, and demonstration programs
related to the disposal of these FGD wastes are underway.  These programs
are supported and funded by utilities, research organizations, and government
agencies.  A significant portion of this effort has been sponsored by EPA.
Nineteen different EPA projects have been undertaken to evaluate, develop,
demonstrate, and recommend environmentally acceptable cost-effective tech-
niques for disposal and utilization of flue gas cleaning (FGC) wastes.  These
projects are part of an EPA program titled "Control of Waste and Water Pollu-
tion from Combustion Sources" or simply "Waste and Water Program."  Projects
generally fall into six primary categories:  (1) environmental assessment of
FGC waste disposal, (2) technology assessment development, (3) disposal eco-
nomics, (4) alternative disposal methods, and (5) utilization of wastes.
Table  3  lists the projects (June 1977) that make up EPA's waste and water
program with other pertinent information concerning each project included (11).

     This study is in the category of "disposal economics," and involves the
conceptual design and economic evaluation of selected waste disposal systems
currently being used by the utility industry or marketed for utility use by
the process developers.  The primary disposal alternatives that are most
commonly being used or planned for use by the utility industry are  (1) ponding
in a lined pond and (2) landfill disposal.  The waste material may be sub-
jected to a number of mechanical and chemical processing operations before
ultimate disposal.  These operations include dewatering and chemical fixation.

     Since there are several disposal alternatives available to the utility
industry, a few promising processes and disposal methods for a detailed
economic evaluation must be selected.  The alternatives chosen for  this study
are grouped into two general categories.

-------
TABLE 1.  SUMMARY OF  INFORMATION FOR FGD SYSTEMS  UNDER CONSTRUCTION IN THE U.S.
Powei

South Carolina
Public Service
Public Service
Utah Power &
Light
Louisville
Gas d Electric
Louisville Gas
& Electric
Southern Illinois
Power Cooperative
Springfield
City Utilities
|SJ Minnkota Power
Cooperative
Indianapolis
Power & Light
Pennsylvania
Power
Texas
Utilities
Texas
Utilities
Texas
Utilities
Public Service
Company of
New Mexico
Public Service
Company of
New Mexico
So. Mississippi
Electric Power
' plant

Winyah

Huntlngton
Mill Creek
Cane Run
Marlon
Southwest
Milton R.
Young
Petersburg
Bruce
Mansfield
Martin
Lake
Martin
Lake
Monticello
San Juan
San Juan
R. D.
Morrow

Boiler FGD
2 140

1 415
3 425
5 183
6 184
1 200
2 450
3 530
2 835
1 750
2 750
3 750
1 375
2 340
1 180

FGD
6/77

6/77
7/77
12/77
1/78
8/77
8/77
9/77
10/77
10/77
3/78
3/78
11/77
11/77
11/77
FGD installation
New or
Limestone N
scrubbing

Lime N
scrubbing
Lime N
scrubbing
Lime R
scrubbing
Limestone N
scrubbing
Limestone N
scrubbing
Lime- N
alkaline
flyash
scrubbing
Limestone N
scrubbing
Lime N
Limestone N
scrubbing
Limestone N
scrubbing
Limestone N
scrubbing
Sodium N
solution*
S02
reduction
Sodium R
solution-
so2
reduction
Limestone N
scrubbing

Total Fuel
1 Coal 11,800 1.1
1.0
Coal - .0.5
Coal 11,000 3.5-
4.0
Coal 13,000 3.5-
4.0
2 Coal
2 Coal 12,500 3.5
2 Lignite 6,500 0.7
4 Coal . 3.0-
3.5
6 Coal 11,900 3.0-
6 Coal 7,380 1.0
6 Coal 7,380 1.0
3 Lignite - 1.0
4 Coal , 0.8
4 Coal - 0.8
Coal - 1-0
Pollution removal
Particulate SO? FGD prodi
12-13 ESP 99.4 - 69 Unstabilized
sludge
scrubber
ESP ... Stabilized
sludge
Mobile-bed - Stabilized
contactor sludge
Marble bed
ESP _ Spray tower 89.4 Unstabilized
sludge
12-14 ESP . Three-bed TCA - Stabilized
sludge
ESP 99.6 75
ESP 99.3 TCA 85 Stabilized
sludge
8-15 Variable-throat 99.8 Fixed-throat 92 Stabilized
ESP ... Stabilized
sludge
ESP _ stabilized
sludge
ESP . .
ESP, venturi 99.7 .
scrubber
18 ESP, venturi 99.7
scrubber
ESP 99.6 - 85 Stabilized
sludge

jet
Unlined
pond

-
-
-
-
-
*
-
Unlined
-
-
-
~
-
-
                                    (continued)

-------
TABLE 1 (continued)
Power
Utility
So. Mississippi
Electric Power
Louisville Gag
& Electric
Alabama Electric
Cooperative
Alabama Electric
Cooperative
Arizona Electric
Power Cooperative
Arizona Electric
Power Cooperative
Kansas Power
(. Light
Kansas Power
& Light
Central
Illinois
Public Service

Central
Illinois
Light
Allegheny
Power System
Allegheny
Power System
plant
Station
R. D.
Morrow
Mill
Creek
Tomblgbee

Tombigbee

Apache

Apache

Jeffery

Jeffery

Newton


Duck Creek


Pleasants
Pleasants

Bo tier
No,
2

4

2

3

2

3

1

2

1


1


1
2

FGD
HW
180

425

160

160

200

200

340

340

575


400


625
625
f
FGD
6/78

7/79

3/78

3/79

6/78

6/79

6/78

6/79

7/78


8/78


3/79
3/80
'GD installation
New or Total
Limestone N - Coal
scrubbing
Line N - Coal
scrubbing
Limestone N 2 Coal
scrubbing
Limestone N 2 Coal
scrubbing
Limestone N 2 Coal
scrubbing
Limestone N 2 Coal
scrubbing
Limestone N - Coal
scrubbing
Limestone N . Coal
scrubbing
Sodium- N 4 Coal
lime
double
alkali
Limestone N 4 Coal
scrubbing

Lime N 4 Coal
scrubbing
Lime N It Coal
scrubbing

Fuel
1.0

3.5-4.0 .

0.8-
1.5
0.8-
1.5
10,200 0.5-
0.8
10,200 0.5-
0.8
8,000 0.32 6

8,000 0.32 6

10,900 4.0-
0.2
Cl.

0.6


4.5
max.
4.5
Pollution removal
Particulate S02
99.6 - 85

-

ESP -

ESP -

ESP 99,4 Packed tower 85

ESP 99.4 Packed tower 85

ESP 90 Spray tower 60

ESP -

ESP, cocurrent 99.5 Two-tray 95
spray precoolers mobile-ball
scrubber

ESP 99.8 Packed-rod 75
venturi

scrubber reaction tray
ESP, venturi 99.5 Perforated-plate 90
scrubber reaction tray

FGD product
Stabilized
sludge
-

-

-

-

-

-

-

Unstabllized
filter cake


-


sludge
Stabilized
sludge

-------
                  TABLE  2.   SUMMARY OF  INFORMATION FOR FGD  SYSTEMS IN OPERATION IN THE U.S.
•P-
PC
Utility
Kansas City
Power & Light

Kansas City
Power I, Light

Commonwealth
Edison

Kansas City
Power & Light
Kansas City
Power & Light
Kansas City
Power & Light

Louisville
Gas & Electric

Duquesne
Light
Duquesne
Lighr
Arizona
Public Service

Nevada
Power
Nevada
Power

Nevada
Power

Kentucky
Utilities
Montana
Power Company

Dwer plant
Station
Lawrence

Lawrence

Will
County
Hawthorn
Hawthorn
La Cygne

Cane
Run

Phillips
Elrama
Cholla

Reid
Gardner
Reid
Gardner

Reid
Gardner

Green
River
Colstrip


Boiler FGD FGD
No. MU start!
4 125 12/68,
1/77

5 400 11/71,
6/78

1 167 2/72

4 90 8/72,
1/77
3 90 11/72,
1/77
1 820 2/73

4 178 8/76

1-6 410 7/73
1-2 510 10/75,
2/76
1 115 10/73

2 125 12/73
1 125 4/74

3 125 7/76

1-3 64 9/75
1 360 10/75

FGD install.
ip Process
, Limestone
scrubbing

Limestone
Injection

Limestone
scrubbing
Lime
scrubbing
Lime
scrubbing
Limestone
scru ing
Carbide
lime
scrubbing
Lime
scrubbing
Lime
scrubbing
Limestone
u ng
Sodium
carbonate
scrubbing
Sodium
scrubbing
Sodium
carbonate
scru Ding
Lime
scrubbing
Lime-
alkaline
flyash
scrubbing
ation
New or Total
retrofit trains Tvoe
R 1 Coal
(gas-
oil)
" 8,2 Coal
(gas-
oil)
R 2 Coal

R 2 Coal
(gas)
R 2 Coal
(gas)
N 8 Coal

R 2 Coal

8 4 Coal
R 5 Coal
R 1 Coal

R 1 Coal
R 1 Coal

» 1 Coal

R 1 Coal
1 3 Coal

Fuel
10,000

10,000

9,463

9,800
11,400
9,800
11,400
9,000
9,700
11,500

11,350

12,146

12,450
12,450

12,450

11,000
8,800


0.5

0.5

2.0-
3.5
0.6-
3.0
0.6-
3.0
3.0-
6.0
3.5-
4 .0
1.0-
2.8
1.0-
2.8
0.4-
1.0
0.5-
1.0
0.5-
1.0
0.5-
1.0

3.5-
4.0
0.8

Polluti
Particulate
11 ESP, venturi rod 99

11 Single-stage 99
marble bed

15 ESP, variable- 98
throat venturi
11-14 Marble bed 99
11-14 Marble bed 99
15-30 Variable-throat 98
venturi
11-12 ESP 99

18.2 ESP, variable- 99
throat venturi
ESP, venturi
scrubber
12.3 Flooded-dlsc 99.7
venturi scrubber
8-10 Multlcyclone i 99.4
two parallel
venturi scrubbers
8-10 Multlcyclone S,
two parallel
venturi scrubber 8
Multlcyclone 4 79
two parallel
venturi scrubbers
Variable-throat 99.7
venturi scrubber
Variable-throat 99
venturi scrubber

on removal
S02
Spray tower 75

Single-stage 65
marble bed


B-TCA
Marble bed 70
Marble bed 70
Perforated-plate 72
reaction tray
Mobile-bed 90
contactor
Three single- 83
stage & one dual-
Single-stage 83
venturi scrubber
Packed 76
tower
Single-stage 85
wash tray
Single-stage 85
wash tray
Single-stage 85
wash tray

Ten-compartment 80
mobile bed
Variable-throat 88
venturi scrubber



FGD product
Unstabilized
sludge

Unstabilized
sludge

Stabilized
sludge
Unstabilized
sludge
Unstabilized
sludge
Unstabilized
sludge
Stabilized
sludge
Stabilized
sludge
Stabilized
sludge
Unstabilized
sludge
Spent
liquor
Spent
liquor
Spent
liquor

Stabilized
sludge
Unstabilized
sludge

Unlined
pond

UnliMd
pond

Clay— lined
pond
Unlined
pond
Unlined
pond
Unlined
pond
Unlined
pond
Unlined
pond
Unlined
pond
Unlined
pond
Unlined
pond
Unlined
pond
Unlined
pond

Unlined
pond
Unlined
pond

                                                      (continued)

-------
TABLE 2 (continued)
Power plant
Utility
Montana
Power


Northern States
ower



Pennsylvania
Power
Columbus & So.
Ohio Electric
Northern States

Tennessee Valley
Authority

FGD installation
Boiler FGD FGD New or
Colstrip 2


Sherburne 1



Bruce 1
Mansfield
Cones- 5
ville
Sherburne 2

Widows 8
Creek

360 7/76 Lime- N
flyaah
scrubbing
700 3/76 Limestone- N
alkaline
flyash
scrubbing
835 4/76 Lime N
scrubbing
400 2/77 Lime N
scrubbing
680 4/77 Limestone N

550 5/77 Limestone R
scrubbing


Total Fuel Particulate
3 Coal 8 , 800 ° - 8 Variable-throat 99


12 Coal 8 300 °-8 9 Flxed & adJuat- "
able rod venturi


6 Coal 11 900 3-°~ 8~15 Variable-throat 99.8
4.5 venturi scrubber
3 Coal 10,800 4.5- 15 ESP 99.5
4.9
12 Coal 8 , 300 0.8 9 Fixed-rod 99
venturi
4 Coal 10,000 3.7 25 ESP, variable- 99.0
throat venturi
scrubber
so,
Variable-throat


Single-stage
marble bed


Fixed-throat
venturi scrubber
Two -bed TCA
Single-stage
marble bed
Grid tower or
TCA

FGD product
88 Unstabilized


50 Oxidized,
unstabilized
sludge

92 Stabilized
sludge
89.6 Stabilized
sludge
50 Unstabilized
sludge
75 Unstabilized
sludge

Unlined


Lined
pond


Unlined
pond
Lined
pond
Lined
pond
Pond


-------
             TABLE  3.    PROJECTS  IN  FGD WASTE  AND  WATER  PROGRAM
          Project
                                           Contractor
                                                                         Primary area of  interest
FGC waste characterization
and disposal evaluation

Shavmee FGD waste disposal
field evaluation
Laboratory and field evalua-
tion of FGC treatment
processes

Characterization of effluents
from coal-fired power plants
Flyash characterization
and disposal
Attenuation of FGC waste
leachate by soils

Establishment of data base
for  FGC disposal standards

Evaluation of FGD waste
disposal options
 FGD waste leachate
 liner compatibility
 Scrubber waste
 characterization
 Dewatering principles and
 equipment design

 Conceptual design-cost
 studies of alternative
 methods for FGC waste
 disposal

 Gypsum byproduct
 marketing studies
 Evaluation of alternative
 FGC waste disposal sites

 Scrubbing waste conversion
 studies

 Fertilizer production using
 scrubbing wastes
 Use of FGD gypsum in
 Portland cement
  FGD waste and flyash
  beneficiation

  Assess and demonstrate
  power plant water reuse
  and recycle
The Aerospace Corporation
El Segundo, California

Tennessee Valley Authority
Division of Chemical Development
Muscle Shoals, Alabama

The Aerospace Corporation
El Segundo,. California

U.S. Army Engineer Waterways
 Experiment Station
Vicksburg, Mississippi

Tennessee Valley Authority
Power Research Staff
Chattanooga, Tennessee

Tennessee Valley Authority
Power Research Staff
Chattanooga, Tennessee

U.S. Army Material Command
Dugway Proving Ground, Utah

SCS Engineers
Long Beach, California

Louisville Gas and Electric
 Company
Louisville, Kentucky

U.S. Army Engineer Waterways
 Experiment Station
Vicksburg, Mississippi

Tennessee Valley Authority
Power Research Staff
Chattanooga, Tennessee

Auburn University
Auburn, Alabama

Tennessee Valley Authority
Office of Agricultural and
 Chemical Development
Muscle Shoals, Alabama

Tennessee Valley Authority
Office of Agricultural and
 Chemical Development
Muscle Shoals, Alabama

Arthur D. Little, Inc.
Cambridge, Massachusetts

Pullman Kellogg Company
Houston, Texas

Tennessee Valley Authority
Office of Agricultural and
 Chemical Development
Muscle Shoals, Alabama

South Carolina Public Service
 Authority
Moncks Corner, South Carolina

Santee Portland Cement Corporation
Holly Hill,  South Carolina

Babcock &  Wilcox
Barberton, Ohio

TRW Systems  Group
Redondo Beach, California

Radian, Inc.
Austin, Texas
Environmental assessment


Environmental assessment






Environmental assessment



Environmental assessment



Environmental assessment



Environmental assessment


Environmental assessment
Technology assessment and
development
Technology assessment
and development
Technology assessment
and development
Technology assessment
and development

Economic study
Economic study




Alternative disposal methods


Utilization methods development


Utilization methods development




Utilization methods development
 Utilization methods development


 Overall power plant water use

-------
     The first is untreated sludge disposal, with the base case being the
direct ponding (without prior dewatering) of untreated, scrubber system
effluent in a clay-lined pond located 1 mi from the scrubber facilities.
Case variations include (1) ponding of dewatered sludge, (2) use of an
unlined pond, (3) distance of 5 and 10 mi to the disposal pond, and (4)
sufficient dewatering to allow transport by truck to a landfill for disposal.

     The second category is treated sludge disposal, using three proprietary
processes (Dravo, IUCS, and Chemfix).   The Dravo process base case is for
the ponding of chemically treated dewatered sludge  (containing 35% solids)
in a clay-lined pond.  The chemical treatment consists of adding adequate
quantities of fixation materials to stabilize the settled slurry in the
disposal pond.  The stabilized material has physical properties similar to
typical soil.

     The IUCS and Chemfix processes involve dewatering to form a 60% solids
material and mixing this cake with additives to produce a soillike material
which can be easily handled, transported, and compacted in a landfill dis-
posal area.

     The technologies associated with these disposal alternatives are
currently being applied by several utilities on either a full- or
demonstration-scale size.  Sufficient information is available concerning
equipment, materials, and design parameters to make meaningful cost esti-
mates (2,  12 )•

     All cost estimates are based on the latest available process and equip-
ment development, design, and economic information.  A wide range of case
variations was considered for each of the four disposal alternatives so that
the cost estimates may be used by the utility industry to reflect trends
generally applicable to most power plants in the U.S. (13).  A specific base
case is discussed in detail for each process.  The evaluation of each process
included developing flow and instrumentation diagrams, material balance,
equipment list and layouts, and detailed capital investment and revenue
requirement breakdowns.

     Case variation cost estimates for each disposal alternative provide
data for sensitivity analysis.  The effect of changes in design and economic
premises for the base cases include power plant size and remaining life,
sulfur  (S) and ash content of coal, distance and mode of transportation to
disposal site, type of pond liner, and quantity of sludge for disposal.

-------
                   PROCESS BACKGROUND AND DESCRIPTION
     Alternatives for disposal of FGD sludges currently being considered
by the utility industry are ponding and landfilling (including mine disposal).
In selecting alternatives, an evaluation of pertinent plant conditions and
factors, such as land availability, soil characteristics, sludge properties,
and environmental regulations, must be made (14).

     Sludge may contain trace elements and dissolved salts which in an
unstabilized state could contaminate surface or ground water.  The ability
of soil to prevent the leaching of harmful constituents into water supplies
is not well understood (15).  Therefore, the impoundment (pond or landfill)
of sludge must be accompanied by specific safeguards that allow a significant
margin of safety to prevent seepage.  A number of studies are underway (2 )
at this time that will provide more usable information concerning water
supply contamination, soil leaching mechanics, and their effect upon sludge
disposal.

     The disposal processes considered in this study are believed to repre-
sent a range of alternatives that reflect the necessary economic trends which
would allow the more desirable options to be identified for a variety of
plant characteristics (13).  As stated earlier, the conditions for each
specific plant site vary and factors such as land availability, soil character-
istics, sludge properties, and environmental regulations, will determine the
most desirable disposal option.

     The sludge being considered for disposal in this study is produced by
lime and limestone FGD systems.  Flyash is removed with the S02 in the scrubber
system in all base case alternatives.  One variation of each primary disposal
method will be disposal of sludge from a scrubber system downstream of an
electrostatic precipitator  (ESP).  In this variation almost all of the flyash
is removed and, therefore, it has not been included in the material for dis-
posal (IUCS is an exception because dry flyash is added to the dewatered
sludge with lime to stabilize the material).
UNTREATED SLUDGE

     Untreated sludge is material that has not been treated with chemical
additives to change chemical or physical characteristics.  Typical ranges
of composition for untreated sludge are as follows:  flyash (5-50%), calcium
sulfite (25-40%), calcium sulfate (4-8%), unreacted lime or limestone  (5-20%).
These percentages are based on dry sludge analysis.

-------
     The untreated sludge can be pumped to a pond for impoundment or it can
be dewatered with thickeners and filters for transport by truck, rail, or
barge to a disposal  site  (landfill, ocean, mine, ravine, etc.).  The options
being considered in  this  study  include ponding a 10,  15, or  35%  solids slurry
in a lined or unlined pond  and  landfill disposal of 60%  solids sludge.

Ponding

     Sludge ponds may be  lined  with clay,  synthetic material,  or treated
sludge.  In some situations,  it may be possible  to pond  without  using a
liner.  In these alternatives,  the effect  of  leachate on the water  supplies
in the general  area  of  the  pond should be  monitored  to determine the extent
of contamination, if any.   Experience shows  (16)  that in many  cases an un-
lined pond is not environmentally  acceptable  and a  liner is  needed. The
sludge is allowed to settle in  the pond  as a  40-60%  solids material.  The
settled sludge  is a  mudlike material that  cannot support loads normally
supported by  typical soil.   This  sludge  can be covered with  a  layer of water
to improve safety and aesthetic requirements.   Water  can be  recycled from
the  pond to the scrubber  facility  as  scrubber slurry  makeup  water.  In most
cases  the recycle water cannot  be  put back into  the natural  water system due
to higher than  acceptable levels  of dissolved solids  and trace elements.

Landfill

      In this  study  it is  assumed  that a  dewatered untreated  material con-
taining 60% solids  can  be handled  with belt conveyors, trucks, and  earth-
moving equipment.   This material  is similar to moist  clay soil and  allows a
landfill disposal option  to be  used for  untreated sludge.  The addition of
water or  excessive  mechanical working will result in  the return  of  the  sludge
 to  a fluid  state that makes handling difficult.   These two restrictions must
be  considered for  the  landfill  disposal  of untreated  sludge.  The material
 can contaminate ground  and surface water supplies  if  care is not taken  to
 assure minimum runoff  and seepage  from exposed areas  of  untreated sludge
 landfill.   Although the landfill  area may  be  reclaimed by covering it with
 a layer of  soil and vegetation, it is necessary  that  the reclaimed  land be
 contoured  to  control the flow of  rainwater through  the reclaimed area  (17).
 TREATED SLUDGE

      There are three companies that have developed technology for the chemi-
 cal fixation of a wide variety of sludge materials.  These companies are
 Dravo, IUCS, and Chemfix.  These companies have each conducted studies with
 lime-limestone FGD sludges and two (Dravo and IUCS) now have full-scale
 operating plants for the processing and disposal of power plant FGD sludge.
 In each case, a material is produced that offers improvement over the untreated
 sludge.  The treated material is easier to handle, has lower permeability
 and solubility, thereby reducing the problem of contamination of surface
 and ground water supplies, and can be placed in a landfill which can later
 be reclaimed for commercial use (18).  Each of the three fixation processes
 uses a different type of chemical reaction system to achieve stabilization
 and fixation of the sludge (19).

                                     10

-------
     The product of fixation is also different for the three processes.
Chemfix produces a material with soillike characteristics while Dravo pro-
duces a claylike material and IUCS, a clay-concrete-type material.  The prop-
erties of each final product can be changed with a variation in either the
addition of fixation materials or sludge properties.

Dravo

     Dravo offers a process for the chemical fixation of FGD sludge by
mixing the untreated sludge with granulated blast furnace slag and lime.
The inclusion of these two additives—Calcilox (granulated blast furnace
slag) and Thiosorbic lime (lime with higher than normal MgO content)—with
dewatered sludge containing 35% solids results in the stabilization of the
sludge.  This process is patented by Dravo as the Synearth process ( 20, 21)•

     Sludge produced in a lime or limestone FGD system is especially diffi-
cult to handle because of certain physical characteristics.  The sludge in
the thickener underflow contains about 35% solids which are very fine par-
ticles.  Calcilox and Thiosorbic lime are added to the sludge at which time
complex chemical reactions begin and continue to occur over several days
(1-21) between the Calcilox, Thiosorbic lime, and various sludge components.
These pozzolanic reactions result in the formation of a crystalline inter-
lacing structure of molecules which ties up water molecules and yields a
solid, stable material.

     Immediately after the mixing of the two additives with sludge, there is
no apparent change in the physical or chemical properties of the sludge.
The material can be pumped to an impoundment for ultimate disposal.  The
solids will settle from the 35% solids slurry to form a material containing
about 50% solids.  The excess water can be recycled for use in scrubber
slurry makeup.  The settled sludge will gradually solidify.  During this
stabilization period the aesthetic acceptability is enhanced by a covering
of water over the settled slurry; this water will not impede the stabiliza-
tion process.  The rate of solidification can be controlled by varying the
quantities of Calcilox and Thiosorbic lime added and by varying the percent
solids in the slurry before the additive mixing step.  After the impoundment
area is completely filled with treated sludge, it can be used for light
industrial and residential construction (14).

     To obtain a fixed sludge suitable for ponding and ultimate reclamation
for light construction, Calcilox is added in the amount of 7% of the weight
of dry solids in the sludge and Thiosorbic lime, 1%.  The treated sludge
has properties similar to silty clay with water permeation of approximately
2 x 10~5 cm/sec.  Permeability, bearing strength, and other physical and
engineering properties can be manipulated by varying the amount of additive
(20).

     Although several power plants are now using this Dravo fixation scheme,
other schemes are also offered by Dravo, i.e., a material suitable for  land-
fill can be produced with additional dewatering and increased additive
amounts.  The resulting landfill material is suitable for hauling by truck


                                    11

-------
to a disposal area where it is handled using typical landfill  earthmoving
equipment.  Another scheme requires intermediate ponding of  treated  sludge
(35% solids) for 15-30 days in small curing ponds before transport by truck
to a landfill for ultimate disposal.

IUCS

     lUCS offers a complete waste system  (patented  as  Foz-0-Tec process)
that can be used for the disposal of sludge produced by  lime or limestone
FGD systems.  The process requires that the scrubber underflow slurry be
dewatered through thickening and filtration to  form a  60%  solids material
which is  then mixed with lime for stabilization.  The  dewatered sludge must
contain flyash, which may be added at the mixer or  may have  been included
in the scrubber underflow.  Two primary reactions are  responsible for the
sludge fixation.  The first reaction occurs within  the first 24-72 hr follow-
ing mixing  and results in the formation of a fibrous gypsum  with low perme-
ability  (10"-* cm/sec) and improved bearing properties.   This reaction is
between lime and soluble sulfates.  The second  reaction  is between the
silica-alumina components of the flyash and the lime compounds.   This reac-
tion occurring over several months involves pozzolanic reactions and results
in  a significant improvement in structural and  engineering properties. The
reaction  is a function of temperature and at temperatures  below 40°F is
somewhat  inactive; however, no permanent  impairment of the sludge fixation
process  occurs below 40°F, and the reaction continues  at a normal rate when
the temperature  rises above 40°F.  A variety of materials  produced by the
IUCS process includes landfill material for ravines and  strip mines, imperme-
able pond liner, and road base material.  The  type  of  final  product  depends
upon the quantity  of lime added and the chemical  and physical characteristics
 of the untreated sludge  (5, 7 ).

     The FGD sludge produced in the lime-limestone  scrubber  under considera-
 tion in this study is treated with a quantity  of  lime  equal  to 4% of the
 total  dry solids in  the  sludge.  The stabilized material is  reported by IUCS
 to be  suitable  for landfill disposal  (22, 23).

      For landfill  disposal, the sludge is treated such that  its physical
 characteristics  are  similar to a claylike soil.   The sludge  is structurally
 acceptable for handling  with belt conveyors, hauling by  truck, and placement
 in a landfill with typical earthmoving equipment.   The product of the IUCS
 process has a more clay-concretelike character  than the  products of  other
 fixation processes.

     For a landfill  to be environmentally acceptable,  the  leachate passing
 through the disposal material must meet certain physical and chemical prop-
 erty requirements.  The  quantity of leachate from a landfill with sludge
 treated by IUCS  is very  low since the  treated  sludge has claylike character-
 istics.   IUCS has  reported that leachate  samples  were  found  to contain very
 low concentrations of objectionable trace elements  and dissolved solids (22).
                                     12

-------
     Sludge used for landfill must meet certain engineering property require-
ments.  lUCS-treated sludge is reported to be suitable with respect to these
parameters.  Bearing quality and unconfined compressive strength measurements
have been made and are indicated by IUCS as being within acceptable limits.
These properties are also a function of the additive quantities and the un-
treated sludge physical and chemical properties.

     IUCS reports that the Poz-0-Pac process has been successfully used for
20 yr to produce a road-base material from flyash and that several utilities
are now using the IUCS Poz-0-Tec process (based on Poz-0-Pac process) on a
full scale for disposal of FGD scrubber sludge.  These utilities include
Duquesne Power and Light's Elrama and Phillips stations and the Columbus and
Southern Ohio's Conesville plant (8 ).

Chemfix

     The Chemfix process uses a two-part, inorganic chemical system which
reacts with all polyvalent metal ions and with certain other waste components.
This patented system is based on the reaction between soluble silicates, i.e.,
sodium silicate, and silicate setting agents, i.e., Portland cement, which
react in a controlled manner to produce a solid matrix.  The reaction between
these chemical compounds occurs at normal ambient temperatures and is report-
edly not affected by temperature variations.  No heating or other special
conditions, such as pressure, catalysis, or long residence times, are nec-
essary ( 9 ).

     Three classes of interactions are responsible for the fixation of solid-
ification of the sludge.  The chemistry of these reactions is very complex.
The first reaction is between soluble silicates (added to sludge) and poly-
valent metal ions.  The second set of reactions occurs between the soluble
silicate and the reactive components of the setting agent.  The reaction
results in the formation of a gel.  As a result of the water being contained
in the gel, the material tends to solidify.  The final reaction is between
the setting agent and the various components of the sludge.  This reaction
results in further stabilization, both chemically and physically.  The rate
and extent of each of these three reactions are functions of additive type
and amount and sludge chemical and physical properties.

     There are several chemical systems which react with various wastes to
encapsulate, immobilize, or otherwise tie up wastes.  There are also several
silicate setting agents and soluble silicates that may be selected to obtain
the desired results.  For sludge produced in a lime or limestone FGD process,
sodium silicate is the soluble silicate and Portland cement is the silicate
setting agent.  The quantity of these two materials added to the untreated
sludge depends upon the time allowed for fixation, chemical and physical
properties of the sludge, and desired product physical, engineering, and
chemical properties (24).

     The desired product for this study is an earthlike material that can be
used for typical landfill.  The material's physical properties must allow
handling with belt conveyors, hauling by truck, and placement and compaction
                                     13

-------
in a landfill with common earthmoving equipment.  Tests conducted  on  lime and
limestone FGD sludges have indicated that the quantity of sodium silicate
and Portland cement to be added must be about 4 and  7% by wt,  respectively,
of the dry sludge quantity.  The soillike product of  this process  is  suitable
for landfill disposal and has fairly good bearing properties  following  initial
placement and compaction in the landfill.  The treated sludge tends to  degrade
structurally if the material is dug up and moved and a loss  of strength occurs.

     Stabilization is primarily a function of additive amounts and type.
Also, the rate of solidification is controlled with  amounts  of additives and
the reactions are not dependent upon the presence of  flyash  as in  the IUCS
process.  Analyses of leachates from disposal areas  in tests  conducted  by
Chemfix and preliminary test results of others show  that quality of the
leachate can be adjusted within acceptable standards  by varying the quantity
of additives mixed with the sludge.  The landfill area may also be reclaimed
and revegetated.

     The process has been successfully demonstrated  in full-scale  application
to wastes from metal finishing, electronics  fabrication, automotive assembly,
and municipal sewage treatment  (25).
                                    14

-------
                      DESIGN AND ECONOMIC PREMISES
     An accurate comparison of several sludge disposal processes can be
made only if a specific set of design and economic premises is established
and used as a basis for the design and economic calculations.  Through the
use of parameter studies (as compared to using only a single set of pre-
selected base case conditions) evaluations can be made without giving
advantage to a particular process.  The pertinent design and economic pre-
mises concerning the operation of power plant, the FGD system, and the
sludge disposal system are discussed in this section of the report.
DESIGN PREMISES

     A base case of design premises was established for each sludge disposal
alternative.  The premises for the power plant are the same for all disposal
alternatives, making this basis for comparison equal for the alternatives.

Power Plant

     Design premises for power plant stack gas emission control studies have
been established in 1976 by TVA and EPA in work conducted prior to this study
for use in general technical and economic evaluations of power plant emission
control technology.  These premises with appropriate additions and minor
adjustments are also used for this evaluation.

Fuel—
     A range of values for coal S and ash contents is considered in this
study.  The effects of S contents of 2.0, 3.5, and 5.0% (dry basis) and ash
contents of 12, 16, and 20% (wet basis) are evaluated.  The base case S and
ash contents of the coal are 3.5 and 16% respectively.  The complete compo-
sition for the base case coal and the amounts used for operation of a 500-MW
unit are as follows:
                                    15

-------
Component
C
H2
N2
02
S
Cl
Ash
H20
Composition
as fired,
wt %
57.56
4.14
1.29
7.00
3.12
0.15
16.00
10.74
500-MW unit
requirements }
Ib/hr
246,800
17,700
5,500
30,000
13,400
600
68,600
46,000
                    Total
100.00
428,600
This coal has a heating value of about 10,500 Btu/lb (as fired).

Plant Size—
     Three power station capacities are evaluated to determine the effect
of size on the economics of sludge disposal.   The base case is a 500-MW
unit.  Although most future stations will probably have capacities of 500-MW
or larger, 200-MW and smaller units will continue to be used.  Therefore,
power station capacities of 200-, 500-, and 1500-MW are considered in this
study.  The 1500-MW station is assumed to be three 500-MW units.

Power Unit Life, Operating Time, and Capacity—
     For each power station capacity used in the evaluation, a range of
values for operating life is considered.  The base case is a new 500-MW
plant.  New plants are estimated to have a 30-yr life, based on guidelines
suggested by the Federal Power Commission (FPC) (26).  Power unit operating
schedules that reflect TVA experience are shown below.
             Years    Capacity factor, %
            of life   (nameplate rating)
            Annual operating
           	time, hr
              1-10             80
              11-15            57
              16-20            40
              21-30            17
            Average for
            30-yr life       48.5
                 7,000
                 5,000
                 3,500
                 1,500

                 4,250
Existing units with remaining lives of 25 yr (92,500 hr), 20 yr  (57,500 hr)
and  15 yr  (32,500 hr) are also considered.  Table  4  lists the representative
heat values used in this study.

FGD  System

     The application of FGD systems in the U.S. is accelerating  and  a very
large percentage of these systems involve the lime and  limestone wet-scrubbing
process.  The premises used for this process are described in the following
discussion.
                                    16

-------
Lime and Limestone Scrubbers—
     Both of these processes remove S02 from power plant flue gas by contacting
the gas with a recirculating slurry stream that contains either slaked lime
or wet ground limestone.  The first stage of slurry circulation is for flue
gas cooling and particulate removal and the second stage is for SC>2 removal.
Overflow from this second stage reaction loop is fed to the first stage loop.

     The stoichiometric ratio of the CaO:S02 removal for the limestone process
is 1.5; in the lime process a ratio of 1.1 is used.

     Spent slurry, consisting of calcium compounds, unreacted lime or lime-
stone, and flyash, is pumped to a hold tank and subsequently to disposal.

Flue Gas Composition—
     Flue gas compositions are based on the combustion of coal with an excess
air amount of 20% of the stoichiometric requirement and air leakage into the
flue gas at the air preheater of 13% of the stoichiometric combustion require-
ment.  The total amount of air to the power plant system is 133% of the
stoichiometric amount.  These values reflect operating experience with TVA
horizontal, frontal-fired, coal-burning units.

               TABLE  4.  POWER UNIT INPUT HEAT REQUIREMENTS


Unit size, MW
500
500
200
200

Status
New
Existing
New
Existing
Heat rate,
Btu/kWh
9,000
9,200
9,200
9,500

     It is assumed that 80% of the ash present in the coal is emitted as
flyash and about 95% of the S in the coal is emitted as S02-  Table 5
includes information concerning coal composition and its corresponding flue
gas composition for 2.0, 3.5, and 5.0% S coals.  In each case the coal heating
value is 10,500 Btu/lb.

Emission Standards—
     The following are emission standards for new steam-generating facilities
set by EPA (27).

                                   Allowable emission,
                                   Ib/MBtu heat input

                    Particulates           0.1
                    S02                    1.2
                                     17

-------
TABLE 5.  COAL AND FLUE GAS COMPOSITIONS AND AMOUNTS FOR VARIOUS S CONTENTS IN COAL (500-MW UNIT)
S content in coal (dry
Coal
composition
C
H2
N2
02
S
Cl
Ash
H20

a,b








Total
Flue gas
composition
N2
°2
C02
S02
S03
NO
HC1
H20


Wt
58
4
1
1
1.
0,
16,
10.
100.

Vol %
73.
4.
12.
0.
0.
0.
0.
8.
Total 100.
Flyash
Dry
Wet
loading.


68
83
44
14
0014
06
01
84
00
gr/sft3


27,
basis)
3.57,
% Lb/hr
.03 248,
.17 17,
.30 5,
.81 33,
.80 7,
.15
.00 68,
.74 46,
,00 428,

Lb/hr
3,439,000
257,400
911,600
14,500
183
3,002
661
265,400
4,892,000

6.67
6.08
700
900
600
500
700
600
600
000
600
Aft3/min
(300°F)
1,134,000
74,350
191,400
2,092
21
924
168
136,100
1,539,000



Wt %
57.56
4.14
1.29
7.00
3.12
0.15
16.00
10.74
100.00
Lb/hr
246
17
5
30
13

68
46
428
,800
,700
,500
,000
,400
600
,600
,000
,600










5%
Wt % Lb/hr
56.89 244,000
4.09 17,500
1.27 5,400
6.40 27,400
4.46 19,100
0.15 600
16.00 68,600
10.74 46,000
100.00 4.28,600
Aft3/min
Vol % Lb/hr
73.76 3,450,
4.83 258,
12.31 904,
0.24 25,
0.0024
0.06 3,
0.01
8.79 264,
100.00 4,906,

6
6
000
200
200
130
317
009
661
500
000

.65
.06
1







1



(300°F)
,138,000
74,590
189,900
3,626
37
927
168
135,600
,543,000



Vol % Lb/hr
73.80 3,443,000
4.84 257,800
12.20 894,700
0.34 35,920
0.0034 454
0.06 3,000
0.01 661
8.75 262,400
100.00 4,898,000

6.66
6.08












Aft 3 /min
(300°F)
1,136,000
74,460
187,700
5,183
52
924
168
134,600
1,539,000




a. HHV = 10
b. As fired
,500 Btu/lb.
basis.










-------
The required amount of SC>2 to be removed varies with the S content of the
coal used.  Design provisions necessary to meet only the emission standards
have been provided; therefore, the degree of S02 removal ranges between 65
and 85% of the SC>2 entering the FGD system.

Sludge Disposal System

     The spent slurry from the limestone FGD scrubber is assumed to contain
15% solids and from the lime scrubber, 10% solids.  These solids contents
include the flyash removed.  The removal of flyash with the calcium solids
is assumed in all cases, except those schemes which remove dry flyash in
an ESP.  In the latter cases, the flyash is not included as a component of
the sludge.

     The sludge disposal system consists of all equipment used for the dis-
posal of spent slurry from the scrubber system.  The hold tank for spent
slurry from the scrubber system is the first item considered as part of the
disposal system area.

     Spent calcium solids slurry from the FGD system is assumed to be primarily
calcium sulfite hemihydrate.  The sulfite ion may be ultimately converted by
oxidation to gypsum or calcium sulfate dihydrate.  It is assumed that 15% of
the total SC>2 removed is ultimately converted to calcium sulfate dihydrate.
These two constituents of sludge are often referred to as sulfite and sulfate
sludge components.

Untreated Sludge Disposal—
     The base case for the disposal of untreated limestone sludge is direct
ponding of spent slurry (containing 15% solids) from the scrubber in a pond
lined with 12 in. of impervious clay.  Pond life is the same as the power
plant's remaining life.  Also, pond depth is determined such that excavation
and land costs are optimized.  The sludge is assumed to settle in the pond
as a material containing 50% solids.  Excess water is recycled back to the
scrubber system.  Pond evaporation and seepage is assumed to equal rainfall.
The distance from the disposal site to the pond is 1 mi and the average pond
depth is about 20 ft.

Dravo Process—
     The Dravo process base case is for disposing treated sludge containing
35% solids in a pond lined with 12 in. of impervious clay.  The pond life is
assumed to be the same as the power plant's remaining life.  Pond depth is
determined such that excavation and land costs are optimized.  Treated sludge
is assumed to settle as a material containing 50% solids and excess water is
recycled to the scrubber facility.  Fixation occurs in the settled slurry
and the final material has properties similar to typical soil.  The pond is
located 1 mi from the scrubber and the treated sludge is pumped to the pond.
The average pond depth is about 20 ft.

IUCS Process—
     The, base case IUCS process produces a stabilized sludge that is suitable
for handling with typical, earthmoving equipment and can be placed and compacted
                                    19

-------
in a natural landfill area.  It is assumed  that  the product  for  disposal has
properties similar to a claylike soil and contains about  60% solids.   The
disposal site is 1 mi from the scrubber and the  treated sludge is  hauled by
truck to the disposal area.  The landfill depth  is assumed  to average 30 ft.

Chemfix Process—
     Thickener underflow containing 35% solids is pumped  to  the  Chemfix
fixation facilities.  The Chemfix facilities are located  at  the  disposal
site 1 mi from the scrubber system facilities.   The product  for  disposal
has properties similar to typical soil and  can be handled with typical earth-
moving equipment for landfill disposal (average  depth  of  30  ft).   The water
content of the treated material is about 40%.

Raw Materials—
     All raw materials used in the three fixation properties are assumed to
be received by either truck or rail transportation.  Thirty-day  storage
facilities are provided for them.  Feed bins, intermediate process tanks,
etc. , are designed for 8 hr of storage capacity.

     Listed below are the raw materials along with their  assumed typical
characteristics used in the three fixation  processes.

    1.  Lime  (IUCS)
       Analysis:       CaO (95%), Si02 (1%), MgO (2%)
       Particle size:  Ground powder
       Bulk  density:   60 lb/ft3

    2.  Thiosorbic lime (Dravo)

       Analysis:       CaO (93-97%), Si02 (1%),  MgO (2-6%)
       Particle size:  Pebble, minus 1-1/4  in. to 3/4  in.
       Bulk  density:   55 lb/ft3

    3.  Calcilox  (Dravo)

       Analysis:       Si02 (30-40%), CaO (40-50%), MgO (3-10%), A1203 (10-20%)
       Particle size:  Finely ground powder
                       Elaine specific surface (1,800-5,000  sq cm/g)
       Bulk  density:   85 lb/ft3

    4.  Portland cement (Chemfix)

       Analysis:       CaO (60-64%), Si02 (20-24%), A1203 (5-6%),  Fe203 (2-5%)
       Particle size:  Finely ground powder
       Bulk  density:   95 lb/ft3

    5.  Sodium silicate (Chemfix)

       Analysis:       Ratio of 1 Na20:322  Si02  solution, 38.3%  sodium silicate,
                        61.7% water
       Specific grav-
        ity:           Minus 1.401 or 41.5° Baume
                                    20

-------
ECONOMIC PREMISES

     The criteria affecting the economic evaluation of the disposal systems
follow.

Plant Location

     A midwestern plant location was selected so that results of this study
will be based on similar assumptions made in earlier studies of this type.
Raw materials are readily available in this area.  Also, a large amount of
coal-fired power generating capacity exists in the area.

Capital Investment

     Capital investment estimates represent projects beginning mid-1977 and
ending mid-1980, with an average cost basis for scaling of mid-1979.  Direct
investments are prepared using the average annual Chemical Engineering cost
indexes and the projections shown in Table 6.  Capital investment estimates
are based on cost information obtained from engineering-contracting, processing,
and equipment companies.

     Other special provisions and assumptions needed to prepare uniform cost
estimates are as follows:

   1.  Spare pumps are provided to prevent operational shutdowns due to
       pump failure.  For all cases except IUCS, a spare pipeline is included
       for transport of sludge to the disposal area.  No other spare equip-
       ment is included.

   2.  Equipment, material, and construction labor shortages with accompanying
       overtime pay incentive are not included in the capital investments.

   3.  The cost of land will appear as a separate listing under capital
       requirements.

   4.  Costs for the generation facilities for electricity and the FGD system
       are not included in the capital investment.

Direct Investment—
     The cost of process equipment, piping and insulation, transport lines,
foundations and structural, excavation, site preparation, roads and railroads,
electrical, instrumentation, buildings, services, and pond construction are
included as the direct investment portion of the total capital investment.
The cost of both materials and labor for installation is included for each
equipment item.  Services are estimated at 1.5% of the total direct invest-
ment excluding the cost of pond construction.  This item of cost includes
allocated costs from the power plant for the use of maintenance shops, stores,
communications, security, and offices, using current TVA practice as a guide.
Parking lots, walkways, landscaping, fencing, and vehicles are also considered
in this estimate for service facilities.  Railroad facilities vary with each
process depending upon raw material usage.  Road requirements depend primarily


                                    21

-------
                               TABLE  6 .  COST INDEXES AND PROJECTIONS
Year         1970     1971     1972    1973    1974    1975    1976a   1977a   1978a    1979a    1980a   1981a
Plant

Material
Laborc
125.7

123.8
137.4
132.3

130.4
146.2
137.2

135.4
152.2
144.1

141.9
157.9
165.4

171.2
163.3
182.4

194.7
168.6
197.9

210.3
183.8
214.7

227.1
200.3
232.9

245.3
218.3
251.5

264.9
237.9
271.6

286.1
259.3
293.3

309.0
282.6

a.  Projections.
b.  Same as index in Chemical Engineering for "equipment, machinery, supports,
c.  Same as index in Chemical Engineering for "construction labor."

-------
upon the type process, i.e., ponding, landfill, and the distance to the
disposal area.  Other direct investment items are discussed in greater detail
in the Systems Estimated section of the report.

Indirect Investment—
     The indirect investment items include the following:

   ®  Engineering design and supervision
   0  Architect and engineering contractor expenses
      Construction expense
      Contractor fees
      Contingency
      Allowance for startup and modifications
      Interest during construction

     Engineering design and supervision—An estimate of this cost was made
using a technique that correlates the number of major equipment items with
drafting room man-hr and engineering design costs. A separate procedure was
used to determine this expense for the construction of disposal ponds.  For
pond engineering and design costs, a correlation between direct pond cost and
engineering and design expense was determined for a range of pond sizes.  From
this relationship each case was estimated.  A similar exception is made for
cases that use landfill disposal.  The engineering design and supervision cost
for these cases is based on major equipment items excluding earthmoving equip-
ment.

     Architect and engineering contractor expenses—This cost is based directly
upon the costs of engineering design and supervision.  Again, it is necessary
to differentiate between indirect costs for major equipment items and for
pond construction or landfill costs.  For the cases involving pond construc-
tion, 25% of the portion of the engineering design and supervision expense
associated with major equipment is estimated for architect and engineering
contractor (A&E) expense for major equipment and 10% of engineering design
and construction expense associated with the disposal pond construction is
estimated as an additional A&E expense.  For the cases involving landfill
systems, 25% of the total engineering design and supervision expense is used
as the A&E expenses.

     Contractor fees—A correlation between contractor fees and total direct
investment for the project was used to estimate the cost of contractor fees.
This relationship is as follows:

           contractor fees = 0.096 (a)

           where a = direct investment in M$

     Construction expense—A relationship, based on typical information
found in the literature, was found to exist between construction expense and
direct investment.  The following equation was used to estimate construction
expense.
                                     23

-------
           construction expense = 0.25 (b)0'83 + 0.13 (c)0'83

           where b = direct investment excluding pond or
                     landfill equipment costs in M$

                 c  =  direct pond cost  in  M$


     Contingency—The contingency is assumed to be 20% of the total of direct
investment, engineering design and supervision costs, architect and engineering
contractor expenses, contractor fees,  and construction expense.

     Allowance for startup and modification—This expense is 10% of direct
investment excluding pond construction plus all other indirect investment
costs except interest during construction.

     Interest during construction—This item was estimated to be 12% of
direct investment plus all other indirect investment costs.  This percentage
is calculated as the simple interest which would be accumulated at a 10%/yr
rate assuming an incremental capital structure of 60% debt-40% equity and a
3-yr project expenditure schedule as indicated in Table 7.

                 TABLE  7.  PROJECT EXPENDITURE SCHEDULE


                                       	Year	
                                          123     Total
       Fraction of total expenditure
        as borrowed funds              0.15   0.30   0.15    0.60
       Simple interest at 10%/yr as
        % of total expenditure
         Year 1 debt                   1.5    1.5    1.5     4.5
         Year 2 debt                    -     3.0    3.0     6.0
         Year 3 debt                    -     _-	   1.5     1.5

       Accumulated interest as % of
        total expenditure              1.5    4.5    6.0     12.0
 Other Capital Charges—
     The final two items that are estimated for each system  evaluated  are
 land and working capital.

     Land—The cost of land is estimated at $3500/acre.

     Working capital—Working capital consists of:   (1) money  invested in
 raw materials, supplies and finished products carried  in  stock,  and semi-
 finished products in the process of being manufactured;  (2)  accounts receiv-
 able; (3) cash retained for payment of operating expenses, such  as  salaries,
 wages, and raw material purchases;  (4) accounts payable;  and (5)  taxes payable.,

                                    24

-------
For these premises, working capital is defined as the equivalent cost of 3
wk of raw material costs, 7 wk of direct costs, and 7 wk of overhead costs.

Revenue Requirements

     The calculations relating to annual revenue requirements are based on
7000 hr of operation/yr.  Process operation schedules are assumed to be the
same as the power plant operating profiles and remaining life assumptions
given in the power plant design premises.

Direct Costs—
     Raw material, labor, utility, and maintenance costs considered are
direct costs.  These are projected to 1980 for this study.

     Raw materials—Table  8 shows projected  (1980) costs for the raw mater-
ials used in the three disposal systems involving sludge treatment.
         TABLE   8 .  PROJECTED 1980 UNIT COSTS FOR RAW MATERIALS


            	Raw material	Cost, $/ton

            Lime
              Pebble (IUCS process)                    48.00
              Ground (Thiosorbic, Dravo process)       51.00
            Calcilox (Dravo process)                   58.00
            Portland cement (Chemfix process)          52.00
            Sodium silicate (Chemfix process)          98.00
     Labor—Table  9  shows the cost of labor for 1980.


             TABLE   9.  PROJECTED 1980 UNIT COSTS FOR LABOR


          	Type	Unit cost, $/man-hr

          Plant operation and supervision          12.50
          Analyses                                 17.00
          Landfill equipment and truck
           operators                               17.00
     Land preparation—Another direct cost is the land preparation cost for
those cases with landfill disposal.  This cost covers the annual expense for
preparing the disposal site for landfill (clearing, excavation, drainage,
reclamation).  This cost, based on the annual quantity of land used, is
assumed to be $1700/acre.
                                    25

-------
     Other direct costs—The cost of operating trucks and landfill  equipment
(fuel and maintenance) was estimated and projected to 1980.   Truck  operating
costs vary depending upon distance traveled.  The following  are  the rates
tabulated for those cases requiring trucks for sludge transport.

                    Distance     Sludge transport cost,
                  traveled, mi    $/ton of wet sludge

                       1                 0.06
                       5                 0.20
                      10                 0.39

     The  cost of fuel and maintenance is also estimated  for  the  earthmoving
equipment used in the landfill operation.  These projected estimates are as
follows:

                                         Fuel and maintenance
                                             expense,  $/ton
            	Disposal system	of wet  sludge

             IUCS  (no  haul)                       0.16
             Chemfix  (short haul, 1 mi)           0.30

      The only utility item used by the estimated disposal system is electri-
 city.   The  electricity rate varies with the  size of  the  power plant-sludge
 disposal facility.   For  a  200-MW plant the unit cost is  $0.031/kWh.  The rate
 for a 500-MW plant  is $0.029/kWh and for a  1500-MW plant, $0.027/kWh.  Main-
 tenance costs are  estimated on the basis of  direct investment and are varied
 for each process  as  a function of disposal method.   For  those disposal options
 requiring a pond, maintenance is estimated  to be 4%  of the direct investment
 (excluding  pond  construction) and 3% of the  pond construction cost.  The
 maintenance rate  is  4%  of  total investment  for all other cases (landfill dis-
 posal).  Although maintenance costs  increase with  the age of a unit, they
 decrease as annual operating hr decline;  therefore,  maintenance costs are
 assumed to  be  constant  over the entire life  of the plant.

 Indirect Costs—
      The indirect costs  include capital charges and  overhead projected to  1980,

      Capital charges—Tables  10 and  11 show  a breakdown  of  capital charges
 for the sludge  disposal systems evaluated  in this  study.  The rate is dif-
 ferent because  of the considerable difference  in interim replacement require-
 ments for those  processes  requiring  trucks  and earthmoving  equipment.  This
 equipment is assumed to have  a  6-yr  life,  and  therefore, is  replaced much
 more often than  typical process equipment.   In estimating the regulated
 capital charges  associated with scrubber  sludge  disposal, the conventional
 method of considering the overall life of  the  power  plant is used.  The
 conclusion of  the National Power  Survey  that a  30-yr service life  is reason-
 able for steam-electric plants  is recognized by  FPC.  FPC has designated
 interim replacements as  an allowance factor in estimating annual revenue
                                     26

-------
requirements for replacement of items with less than a 30-yr life.  Use of
this allowance, following FPC-recommended practice, provides for financing
the cost of replacing such short-lived units.  An average allowance of about
0.35% of the total investment is normally provided for steam-electric plants
(26).  However, to provide for the unknown life span of S02 scrubber sludge
disposal facilities, a value of 0.7 is used for new units.  These values are
shown in Tables 10 and 11.  An insurance and property tax allowance is also
included in the capital charges based on FPC practice (2.0%).  The deprecia-
tion rate is straight line based on the remaining life of the power plant
after pollution control systems are installed.
     TABLE 10.  ANNUAL CAPITAL CHARGES FOR POWER INDUSTRY FINANCING

                   (LANDFILL DISPOSAL OF FIXED SLUDGE)
      Years remaining life

      Depreciation-straight line (based on
       years remaining life of power unit)
      Interim replacements (equipment having
       less than 30-yr life)
      Insurance and property taxes

           Total rate applied to original
           investment
   Percentage of
 total depreciable
 capital investment
 30   25   20   15
3.3  4.0  5.0   6.7

2.5  2.4  2.3   2.1
2.0  2.0  2.0   2.0
7.8  8.8  9.3  10.8
      Cost of capital (capital structure
       assumed to be 60% debt and 40% equity)
        Bonds at 10% interest
        Equity^ at 14% return to stockholder
      Income taxes (Federal and State)c
                                                    Percentage of
                                                     unrecovered
                                                 capital investment'
         6.0
         5.6
         5.6
           Total rate applied to depreciation base
        17.2d
     a.  Original investment yet to be recovered or "written off."
     b.  Contains retained earnings and dividends.
     c.  Since income taxes are approximately 50% of gross return,
         the amount of taxes is the same as the return on equity.
     d.  Applied on an average basis, the total annual percentage of
         original fixed investment for new (30-yr) plants would be
         7.8% + 1/2 (17.2%) = 16.4%.
                                    27

-------
TABLE 11.  ANNUAL CAPITAL CHARGES FOR POWER INDUSTRY FINANCING

                 (POND DISPOSAL OF FGD SLUDGE)
   Years remaining life

   Depreciation-straight line  (based on
    years remaining life of power unit)
   Interim replacements (equipment having
    less than 30-yr life)
   Insurance and property taxes

        Total rate applied to  original
        investment
                                          Percentage of
                                        total depreciable
                                        capital investment
                                         30   25   20   15
                                        3.3  4.0  5.0  6.7

                                        0.7  0.4
                                        2.0  2.0  2.0  2.0
                                        i.O  6.4  7.0  8.7
    Cost  of  capital  (capital structure
     assumed to  be 60%  debt and 40%  equity)
      Bonds  at  10% interest
      Equity^ at 14%  return to stockholder
    Income taxes (Federal  and State)0

         Total  rate  applied to depreciation
         base
                                                Percentage  of
                                                 unrecovered
                                             capital  investment'
                                                6.0
                                                5.6
                                                5.6
                                               17.2"
 a.
 b.
 c.

 d.
Original investment yet to be recovered or "written off."
Contains retained earnings and dividends.
Since income taxes are approximately 50% of gross return,
the amount of taxes is the same as the return on equity.
Applied on an average basis,  the total annual percentage of
original fixed investment for new (30-yr)  plants would be
6.0% + 1/2 (17.2%) = 14.6%.
                               28

-------
     Another component of the capital charges for which variations may be
expected is debt to equity ratio.  FPC data indicate that the long-term debt
for privately owned electric utilities varied only from 51.5 to 54.8% of
total capitalization during the period 1965-73.  However, recent economic
upheavals have changed the incremental debt to equity ratio, as utilities
are forced to depend more and more on bonds and bank loans for project fund-
ing.  The capital structure for this study is assumed to be 60% debt and 40%
equity.  The interest rate for bonds is assumed to be 10% and the return to
stockholders on equity, 14%.  Cost of capital and income tax charges are
applied to the uncovered portion of capital investment.  Income taxes are
50% of the gross return, and the return on equity is 50% of gross return.
Since return on equity is 5.6% (see Tables 10 and 11) of total capital
investment, then income taxes are also 5.6% of total capital investment.
Since most regulatory commissions base the annual permissible return on
investment on the remaining depreciation base  (that portion of original
investment yet to be recovered or "written off"), a portion of the annual
capital charge included in the lifetime operating cost declines uniformly
over the life of the power plant.

     Overhead—The cost of plant, administrative, and marketing overheads
vary from company to company.  Based on the various methods used by industry
and suggested by cost estimating sources, the plant and administrative over-
all costs were assumed to be as follows (28, 29, 30):  plant overhead—50%
of  the subtotal conversion costs less utilities (conversion costs include
all direct costs except raw material costs); administrative overhead—10% of
operating labor and supervision.
                                    29

-------
                            SYSTEMS ESTIMATED
     This section of the report covers the estimates of systems for the
four primary disposal alternatives—untreated sludge and the three treated
sludge processes (Dravo, IUCS, and Chemfix).   For each primary disposal
alternative, 24-41 case variations have been estimated.

     In evaluating these disposal alternatives, the following must be con-
sidered (31, 32).

      Material balances
      Flow diagrams
      Equipment lists and descriptions
      Instrumentation diagrams
      Layout drawings

     The method for estimating costs for piping, electrical, instrumentation,
pond feed, return lines, services, pond construction, foundation and struc-
tural, excavation, site preparation, roads and railroads, buildings, and
services is discussed in this section of the report.  Unless otherwise spec-
ified, the system is designed to handle both flyash and S02 sludge.  Table
12 lists all cases for the disposal alternatives and the quantity of sludge
for disposal (13).
UNTREATED SLUDGE

     The ponding of FGD system spent slurry without chemical treatment or
dewatering is the least complicated of the disposal alternatives considered
in this study.  Since this system involves only a few items of equipment the
layout drawings, flow diagrams, and instrumentation diagrams are not presented
in this report.

     Underflow containing 15% solids from the scrubber system is pumped to
an agitated pond feed tank.  The slurry is then pumped 1 mi to a disposal
pond where the slurry is allowed to settle to form a material containing
50% solids.  Excess water is returned to the scrubber system for reuse.
Carbon steel, rubber-lined pipelines are used to transport the sludge to
the disposal pond, which is clay-lined to prevent leachate from the wastes
from entering ground water.  A material balance for the base untreated case
is shown in Table 13 and provides information concerning each process stream.
                                    31

-------
 TABLE  12.    QUANTITIES  OF  SLUDGE  FOR  DISPOSAL  -  ALL  PROCESSES  AND  CASE  VARIATIONS

Case
Base case
200 MW new
200 MW existing
200 MW existing
200 MW existing
500 MW existing
500 MW existing
500 MW existing
1500 MW nev
1500 MW exls ing
1500 MW exis ing
1500 MW exis ing
12% ash in c al
20% ash in c al
2% S in coal
5% S in coal
200 MU, no flyash
500 MW, no flyash
1500 MW, no flyash
5 ml to disposal
10 ml to disposal
fixation additive amount - variation 1
Fixation additive amount - variation 2
Intermediate ponding and truck to landfill
Lime scrubbing process
Clarify (35% solids) and pump 1 mi
Clarify (35% solids) and pump 5 mi
Clarify (35% solids) and pump 10 mi
Clarify, filter (60% solids) and truck 1 mi
Clarify, filter (60% solids) and truck 5 mi
Clarify, filter (60% solids) and truck 10 mi
200 MW, constrained pond acreage (50% of optimum)
200 MW, constrained pond acreage (75% of optimum)
Constrained pond acreage (50% of optimum)
Constrained pond acreage (75% of optimum)
1500 MW, constrained pond acreage (75% of optimum)
Pond settled density (40% solids)
Pond settled density (60% solids)
Unlined pond
Synthetic pond lining (S1.50/yd2)
Synthetic pond lining ($2.50/yd2)
Synthetic pond lining ($3.50/yd2)
Synthetic pond lining ($4.50/yd2)
Yr
life
30
30
25
20
15
25
20
15
30
25
20
15
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
Untreated disposal3
Dry, Ib/hr
116,000
48,000
50,000
50,000
50,000
119,000
119,000
119,000
348,000
355,000
355,000
355,000
96,000
139,000
81,000
151,000
25,000
62,000
185,000
116,000
116,000



101,000
116,000
116,000
116,000
116,000
116,000
116,000
48,000
48,000
116.! 000
166,000
347,000
347,000
93,000
139,000
116,000
116,000
116,000
116,000
116,000
wet , J.D/ ill.
232,000
95,000
99 , 000
99,000
99,000
237,000
237,000
237,000
695,000
710,000
710,000
710,000
191,000
277,000
161,000
301,000
50,000
123,000
369,000
232,000
232,000
_


202,000
232,000
232,000
232,000
193,000
193,000
193,000
95,000
95,000
232,000
232,000
695,000
695,000
232,000
232,000
232,000
232,000
232,000
232,000
232,000
b
Dravo process
Dry, Ib/hr
125,000
51,000
53,000
53,000
53 000
1281000
128,000
128,000
375,000
384,000
384,000
384,000
103,000
136,000
87,000
163,000
34,000
83,000
249,500
125,000
125,000
123,000
129,000
125,000
109,000
_




_
51,000
51 ,000
125,000
125,000
375,000
375,000







250,000
102,000
106,000
106.000
106 QOQ
235! 885
256,000
256,000
750,000
767,000
767,000
767,000
206,000
272,700
174,000
325,000
68,000
166,000
497,000
250,000
250,000
246,500
257,000
250,000
218,000
_




_
102,000
102 ,000
250 ! 000
250,000
750,000
750,000







IOCS, process0
Dry Ib/hr Wet Ib/hr
120,000 198,000
49,000
51,000
51,000
51,000
123,000
123,000
123,000
361,000
369,000
369,000
369,000
99,000
144,000
85,000
157,000
26,000
64,000
192,000
120,000
120,000
119,000
122,000

105,000
















81,000
83,000
83,000
83,000
202,000
202,000
202,000
593,000
606,000
606,000
606,000
163,000
236,000
137,000
257,000
59,000
144,000
430,000
198,000
198,000
196,000
199,000
-
172,000
-















Chemfix
Dry Ib/hi
121,000
50,000
51,000
51,000
51,000
123,000
123,000
123,000
363,000
371,000
371,000
371,000
100,000
145,000
84,000
157,000
26,000
64,000
192,000
120,000
120,000
136,00
137,000
121 000
105,000
















processd
Wet , Ib/hr
198,000
83,000
86,000
86,000
86,000
207,000
207,000
207,000
609,000
623,000
623,000
623,000
167,000
243,000
141,000
264,000
44,000
107,000
323,000
198,000
198,000
267,000
232,000
-
198,000
177,000
-















«*,   Base untreated case:  direct ponding in clay-lined pond, pump  1 mi from scrubber  facilities, slurry to pond - 15% solids;  settled slurry in pond -
    50% solids.

b.   Base Dravo case:  ponding  in clay-lined pond; pump 1 mi from scrubber facilities;  50% solids settled density in pond; treated with Calcllox
    (72 of dry aludge) and Thiosorbic  lime (1%  of dry sludge),

L.   Base IUCS case:   landfill  disposal of 60% solids material;  1 mi to landfill from  scrubber facilities; trucks used for transport of treated sludge;
    treated with lime (4% of dry sludge).

d.   Base Chemfix case:  landfill disposal of 602 solids material;  1 mi to landfill from scrubber facilities; pipeline used for transport  of thickener

    underflow to disposal and  treatment area, treated with Portland cement (7% of dry  sludge) and sodium silicate (2% of dry sludge).

e.   New 500-MW plant; 30-yr life; coal analysis (by wt) :  3.5Z  S (dry basis), 16% ash; S02 and flyash removed together to meet NSPS; limestone process
    with 1.5 stoichiometry based on S02 removed.
                                                                   32

-------
             TABLE 13.   MATERIAL BALANCE - UNTREATED PROCESS

Description of stream


Rate, Ib/hr
Rate, gpm
Specific gravity
% solids (undissolved)
Spent slurry
to pond feed tank
772,000
1,404
1.10
15
Spent slurry
to pond
772,000
1,404
1.10
15
Settled
slurry
232,000
320
1.45
50
Recycle
water
540,000
1,081
1.00
0

Major Equipment

     As stated earlier, very few items of equipment are needed for this dis-
posal option.  Table 14 lists the equipment used for direct ponding of sludge
produced by the base 500-MW plant.
                TABLE 14.  UNTREATED DISPOSAL - BASE CASE

                             EQUIPMENT LIST
           Item
No.
Description
    Tank, pond feed
    Agitator
    Pump, pond feed

    Pump, recycle pond
    water
 1    63,000 gal, field erected, 21 ft dia,
       26 ft high, vertical with open top,
       carbon steel, 1/4 in. neoprene lined
 1    15 hp, neoprene lined
 3    1,404 gpm, 1.28 sp. gr.,  300-ft head,
       neoprene lined, with 125-hp motor
 2    1,081 gpm, 200-ft head, multistage tur-
      bine, cast iron bowl, stainless steel
      impellers with 100-hp motor
Field Equipment

     The additional items of cost other than major process equipment are
piping, electrical equipment, instrumentation, excavation and site prepara-
tion, transport lines, buildings, services, pond construction, landfill, and
roads and railroads.  The methods of estimation of their costs are described
below.

Piping—
     Carbon steel pipe and gate valves are used for all water lines.  For
slurry lines, stainless steel pipe is used for lines less than 3-in. diameter,
                                     33

-------
whereas for all larger size lines, rubber-lined  carbon  steel  piping is used.
Stainless steel strainers are used for pipes less  than  4-in.  diameter and
rubber-lined strainers are used for 4-in.-diameter and  larger pipes.

Foundations and Structural—
     Concrete foundations for each equipment item  are fixed according to
equipment sizes.  Foundations for the structure  are estimated on the basis
of the weight and size of the structure.

     Structural estimates are based on the arrangement  and types of equip-
ment.  The quantity of structure for each disposal process depends upon
raw material usage, tank volumes, dewatering requirements, etc.

Electrical—
     The electrical cost is divided into four  sections:   (1)  cost of feeder
cables from the power plant transformer yard to  the sludge disposal system,
 (2)  transformer costs for each area,  (3) costs of  power supply from area
field modules to individual motors, and  (4) motor  control  costs  between
remote control center, field equipment location, and individual  motors.
Total  connected motor horsepower is calculated for use  in  establishing
costs  for  feeder cables and transformers.  Costs for power supplies and
motor  controls are based on individual motor sizes and  the number of connected
motors.  A typical layout is assumed for the disposal system in  reference
to  the power plant transformer yard, remote control center, and  other areas.
Pumps  for  return of supernate from disposal ponds  5 and 10 mi from the power
plants are not controlled from the power plant-sludge disposal system. Addi-
 tional labor is needed to monitor these pumps.

 Instrumentation—
      Instrumentation  costs are based on  (1) fixed  costs for instruments
which  do not change in size and cost with equipment and size variations and
 (2)  variable costs for instruments which increase  in size  and cost as equip-
ment and pipe sizes increase.  Each of these costs may  be  dependent upon  the
number of  pumps, feeders, mixers, conveyors, dryers, thickeners, etc.  Costs
are included for control valves, graphic and panelboards,  annunciators, air
dryers and piping, and instrument cable and wiring systems.

Excavation and  Site Preparation—
      The excavation and site preparation requirements depend upon the number
 of  items and the type and size of equipment.   Estimates are based on the
number of  cubic yd of material that is moved in  each case.  The cost of exca-
vation for underground pipelines for  transport of  sludge to the disposal
 area represents a major portion of excavation  cost for  those cases requiring
pipeline.

Transport  Lines—
      The pipelines used for transporting slurry  to a disposal pond and for
returning  water to the scrubber facility are called transport lines.  For
 the base case a 1-mi, carbon steel, rubber-lined,  12-in. line is used.  These
lines  are  underground (2 ft) and a spare line  is included.  The recycle water
                                     34

-------
line for the base case is a 10-in., carbon steel unlined pipe, and no spare
line is costed.   The size of the lines for the variations of untreated cases
varies from 8 to 18 in. for the pond feed lines and from 6 to 16 in. for the
recycle water lines.

Buildings—
     Additional buildings are not needed for the direct ponding untreated
cases.  All pumps are controlled from the scrubber facility.  A building is
needed for the untreated cases that require dewatering of sludge to 60%
solids for landfill disposal.  Rotary drum filters which are used for dewa-
tering are located inside a building.  The controls for this equipment are
housed near the equipment and a control building is included in costs.

Services—
     The cost of services for each case was estimated to be 1-1/2% of direct
investment cost.  This cost includes vehicles, maintenance and instrument
shop equipment, laboratories, lockers, offices, restrooms, storage area,
parking area, walkways, landscaping, fencing, and security allocated to the
sludge disposal area by the power plant.

Pond Construction—
     A computer program was used to calculate optimum pond dimensions and
costs for each case.  The total pond depth for the base case pond is 21.2 ft,
with an excavation depth of 3.0 ft.  The pond covers 407 acres, is assumed to
be built on relatively level land, and is square.  All ponds are lined with
1 ft of clay except those variations where another liner type is specified
so that the effect of liner cost on overall pond cost can be estimated.
Figure 1  shows typical construction diagrams for the perimeter and diverter
dikes of the disposal pond.  The length of the diverter dike is assumed to
be three-fourths of the length of one side of the perimeter.

Roads and Railroads—
     Railroads are not needed for untreated sludge disposal systems.  All
untreated cases are estimated to require 6600 ft of roadway.  This require-
ment is for access to the disposal area, to pumps, and to other required
equipment with a service vehicle.  In the case of landfill disposal, roads
are needed for trucks used in the transport of sludge to the disposal area.
The cost of roads is held constant for all cases including disposal at a
site of 5 or 10 mi from the scrubber facility.  For these cases it is assumed
that public roads can be used, with a minimum requirement of plant access
roads  (6600 ft).

Case Variations

     The base case premises discussed in Design and Economic Premises of
this report apply to all untreated sludge disposal cases.  The following
variations from the base case are considered in this evaluation.

   1.  The distance to the disposal pond is 1 mi for the base case.  Five-
       and 10-mi distances are also considered.  The items changing are the
       sludge transport lines, pond feed pumps, and pond recycle water pumps.


                                     35

-------
                    OUTER BOUNDARY
                     OF POND AREA
                      '9
         GROUND LEVEL
                                                                                                     10% FREE BOARD
                                                                                 DEPTH OF SLUDGE
                                                   POND PERIMETER DIKE
                                                                           TOPSOL EXCAVATION'
                                                                                (I FT)
                                                                                J_    TOTAL
                                                                                   EXCAVATION DEPTH

                                                                                1
                                                                                               SUBSOIL EXCAVATION
TOPSOL EXCAVATION
    (I FT.)
      ORGINAL GROUND LEVEL

SUBSOIL EXCAVATION
                                                   POND DIVERTER DIKE
                                                                                                      10% FREE BOARD
                                                                                                                      (TYR OTHER SIDE)
                                                                                                      DEPTH OF SLUDGE


                                                                                                   i      TOTAL
                                                                                                       EXCAVATION DEPTH
                            Figure 1.   Limestone slurry  process dike construction diagram.

-------
 2.   The base  case disposal  pond is  lined  with 12  in.  of  clay.   Special
     cases  are considered  for  an unlined pond and  four types  of  synthetic
     linings.   The pond cost is  significantly affected by the type  of
     liner  used.

 3.   The settled  density of  the  ponded sludge is 50%  solids  for  the base
     case.   Cases for 40 and 60% solids settled density are  considered.
     This variation affects  the  pond construction  cost, recycle  water  pump
     size,  and land requirement.

 4.   The gravity  thickener can be used to  dewater  sludge  to  35%  solids.
     Special cases are considered for the  pumping  of  this partially dewa-
     tered  sludge to disposal  ponds  located 1, 5,  and 10  mi  from the
     scrubber  facility.  By  dewatering before transporting,  the  cost of
     pipelines and pond feed pumps is reduced.

 5.   If gravity thickeners and rotary drum filters are used,  the 15% solids
     slurry can be dewatered to  form materials containing 35  and 60% solids
     respectively.  The latter material can be handled by truck  for land-
     fill disposal.  Those variations include cases for landfill disposal
     of dewatered sludge at  disposal sites located 1,  5,  and  10  mi  from
     the scrubber facility.

 6.   The base  case is a 500-MW power plant.   Two variations—new 200-  and
     1500-MW plants—are also  considered.

 7.   Disposal  systems are  evaluated  for 5-,  10-, and  15-yr-old existing
     200-,  500-,  and 1500-MW power plants.

 8.   The coal  analysis was varied as follows:

                           Base  case   Variations  from
               Component   condition	base case

                S, %          3.5            2, 5
               Ash, %         16           12, 20

 9.   Three  cases  were considered for 200-, 500-, and  1500-MW power  plants
     equipped  with an ESP  upstream of the  scrubber system.   The  sludge
     disposal  system was evaluated for handling only  the  calcium solids
     sludge.

10.   One case  was evaluated  for  the  direct ponding of a 10%  slurry  taken
     from a lime  scrubber  system with 1.1  stoichiometry.   The total amount
     of S02 removed was the  same as  the base case; however,  the  amount of
     excess lime  is less than  that of excess limestone in the base  case.
     Although  the amount of  S02  removed is the same as the base  case,  the
     size of equipment needed  for handling and transport  of  sludge  is
     larger than  that used in  the base case (10% slurry vs 15% slurry).
                                  37

-------
TREATED SLUDGE

     Sludge generated by FGD systems that use lime or limestone  as  the
primary sorbent for S02 is usually a thixotropic, fluid material containing
85-90% water.   The material can be dewatered by using gravity  thickeners and
various types of filters to yield a more stable product for  disposal  (19).
However, the sludge can easily become fluid again if subjected to vibration
or stress or if water is added.  The dewatered sludge also lacks, in many
instances, the desirable chemical and physical properties which  would prevent
the contamination of surface and ground water.

     The treatment of sludge with fixation additives, such as  lime, cement,
flyash, etc. , can result in the formation of a claylike or an  earthlike
material which is structurally and environmentally more acceptable  than
untreated sludge.  In all stabilization-fixation processes the sludge is
solidified by adding materials that result in pozzolanic or  other cementitious
reactions.  These reactions take place between various components of the
sludge  (alumina and silica in the flyash, lime, limestone, sulfates, and
sulfites) and the additives.  Chemical fixation of the FGD sludge produces
a material that may ultimately be more desirable because of  the  following
improvements in structural properties (2).

      Lower permeability, porosity, and leachability
      Improved mechanical properties that enable easier handling
      Decreased tendency for softening or reslurry with addition of water
      Higher bulk density
      Increased structural strength

     The chemical properties of sludges are also improved by fixation.
Pozzolanic or cementitious reactions result in the formation of  complex
and less soluble compounds that tie up water and trace elements.  The poten-
tial for ground or surface water pollution is thereby reduced.   A number of
fixation processes are available for utility use and among those are the
Dravo,  IUCS, and Chemfix processes which are evaluated in this report.  These
three processes in which different chemical reactions and mechanisms occur
produce stable and more environmentally acceptable materials than untreated
sludge.
DRAVO PROCESS

     The product for disposal from the Dravo fixation process  is  a slurry
containing 35% solids which is pumped to a disposal pond  for curing.   This
slurry settles to form a material containing about 50%  solids  in  the  disposal
pond and begins to solidify.  The curing-solidification step requires 15-30
days depending upon the sludge composition and additive rates.   Slurry under-
flow from the scrubber facility is pumped to an agitated  tank  which has a
capacity of about 8 hr of underflow.  The slurry  (15% solids)  from this tank
is fed to a thickener where the solids content is increased to 35%.  Thickener
overflow water is returned to the scrubber loop for use in slurry makeup.
                                    38

-------
Underflow material is pumped to a tank for mixing with Dravo process addi-
tives, Thiosorbic lime, and Calcilox.  The mix tank is agitated and has an
8-hr capacity.

     Lime is received at the waste disposal facility in a covered rail car,
unloaded, and conveyed to a bucket elevator for transfer to storage silos
(30 days' capacity).  The lime is in pebble form when received and must be
slaked before use.  Lime is transferred from the storage silos via weigh
feeders to an 8-hr storage hopper that feeds a lime slaker.  The lime slurry
from the slaker is pumped to an agitated storage tank (8-hr capacity).  The
slurry is pumped to the mix tank for blending with sludge.

     Calcilox is received by either rail or truck and pneumatically conveyed
to 30-day storage silos.  Calcilox is transferred from the storage silos via
weigh feeders to feed hoppers (8-hr capacity) for the mix tank.

     The treated sludge is pumped from the mix tank to the disposal pond.
The reactions between the sludge and additives begin immediately after
mixing, but the sludge properties are not significantly changed for several
days.  Supernatant water from the disposal pond is returned to the scrubber
facility for reuse.  The flow diagram and material balance for this process
are shown in Figure 2 .

Major Equipment (33)

     Table 15 lists all items of process equipment included in the Dravo
system, with a brief description of each equipment item for the base case.
A control diagram and layout drawings for the base case of the Dravo process
are shown in Figures  3-5.

Field Equipment

     The discussion that follows is similar to that of the untreated system.
Each area of cost other than process equipment is discussed here.

Piping—
     See piping description for the untreated system.

Foundations and Structural—
     See foundations and structural description for the untreated system.
                                    39

-------
                                                                                                                         SETTLING POND
STREAM NO.
     SLbs. %
          THICKENER
          FEED TANK
            140
                    NER
                          OVERFLOW
                          Z33BIZ
                          	883
                             UNDERFLOW
                                   TO
                                 MIX TA
                               331k
CALCILOX
  TO
MIX TANK
                                     BIOS
FROM
LAK
                                                      SLURRY TO SLURRY TO
                   MIX TANK

                    ^
                                                        ±flt
                                                            STL£7?*D
                                                                 3t
Notes:
   Calculations based on
   1.   150%  limestone stoichiometry based  on  SC>2  removed
   2.   90% of S in  coal evolved as SO2
   3.   3.5%  S and  16% ash  coal
   4.   T^l-yasVi -removed, -witti SO;?
   5 .    SO2.  TC
                                                                          Ji:
                                                                                 Figure 2.   Dravo  Process.   Flow diagram and
                                                                                         material balance — base case.

-------
SOj ABSORPTION
   AREA
                            (TYP FOR
                            SLURRY PUMPS)
                                 Figure 3.   Dravo  process.   Control  diagram - base case.

-------
CALCILOX
  FEED
HOPPER
                                  CALCILOX
                                  STORAGE
                                    SILOS
                                                        LIME
                                                      STORAGE
                                                        SILOS
           LIME SLURRY	\
           FEED  TANK
 HOPPER

LIME SLAKER
   LIME
UNLOADING
    PIT
                    Figure 4. Dravo process. Elevation - base case.

-------
                                                         J
                                                                         ROADWAY
    THICKENER
      FEED
      TANK
THICKENER
OVERFLOW
  TANK
21' DIA
                           CALCILOX  CALCILO.X
                          v—FEED    STORAGE
                          \ HOPPER     SILOS
   LIME
UNLOADING
 HOPPER
                                                                                                       S3 CAR PULLER
                                                              LIME
                                                               FEED TANK
                                                                  i
                                                                  I
                                                           LIME
                                                          TORAGE
                                                          SILOS
                                                                                   LIME
                                                                  i        i        SLAKER
                                                                  i        I CONTROL
                                                                  i	i BUILDING
                                                                         ROADWAY
                                     Figure 5,   Dravo process.  Overall plot plan - base  case.

-------
            TABLE 15.  DRAVO PROCESS  -  BASE CASE EQUIPMENT LIST
           Item
                            No.
                      Description
 1.   Lime unloading hopper     1
 2.   Lime unloading feeder     1
 3.   Lime  unloading  con-
     veyor

 4.   Sump  pump,  tunnel
     under unloading
     conveyor

 5.   Bucket elevator,
     lime  storage  silo

 6.   Silo, lime  storage
 7-   Dust collecting
     system,  lime  silo
     and unloading system

 8.   Feeder discharge,
     lime storage  silo

 9.   Vibrator,  lime
     storage silo

10.   Conveyor
11.   Bucket elevator
12.   Feed bin,  lime to
     slaker

13.   Vibrator,  lime feed
     bin

14.   Feeder discharge,
     lime feed  bin
     8 ft 4 in. side, 2 ft 4 in. bottom, 3 ft
     deep, carbon steel

     24 in. wide x 42 in. long pan, 2-1/2-hp
     vibrator, carbon steel

     100 ft/min, 24~in. belt, 20 ft long,
     1-hp motor, carbon steel

     5 gpm, 10-ft head, neoprene lined, carbon
     steel, 1/2-hp motor
1    45 tons/hr, 80 ft high, carbon steel,
     7-1/2-hp motor

1    21 ft dia, 42 ft high, with top and 60-degree
     cone bottom, carbon steel, 30-day  storage
     capacity
              o
1    12,000 ft /min inertial separator; dust
     hopper, fan, and 60-hp motor, carbon steel
     Rotary air lock, 8 in. dia x 8 in. long,
     carbon steel

     Electromechanical rotary vibrators,  1-hp
     motor

     10 tons/hr, 30 ft long, 14 in.-belt,  100
     ft/min, carbon steel, 1/2-hp motor

     10 tons/hr, 30 ft high, 1-hp motor,  carbon
     steel

     5 ft dia, 10 ft high, with top and 60-degree
     cone bottom, carbon steel

     Electromechanical rotary vibrators,  1-hp
     motor

     Rotary air lock, 8 in. dia x 8 in. long,
     carbon steel
                                 (continued)

                                      44

-------
                           TABLE 15 (continued)
        Item
No.
                 Description
15.   Weigh feeder,  lime
     to slaker

16.   Lime slaker
17-  Pump, slaked lime
     to storage

18.  Tank, lime slurry
19.  Agitator, lime
     slurry tank

20.  Pump, lime slurry
     to mix tank

21.  Pneumatic conveying
     system, Calcilox

22.  Car puller

23.  Storage silo,
     Calcilox
24.  Vibrator, Calcilox
     silos

25.  Discharge feeder,
     Calcilox storage
     silos

26.  Feed bin, Calcilox
     to mix tank

27.  Discharge feeder,
     Calcilox feed bin

28.  Vibrator, Calcilox
     feed bin
  1

  3



 24
      5 ft long,  14-in. belt, carbon steel, 3/4-
      hp motor

      20 ft x 5-1/2 ft x 9 ft,  7,720 Ib/hr, 15%
      solids slurry rate, neoprene lined, carbon
      steel, 10-hp agitator motor

      14 gpm, 50  ft head, centrifugal, neoprene
      lined,carbon steel, 3/4~hp motor

      8-hr storage, 11 ft high, 11 ft dia, verti-
      cal, cylindrical, open top, neoprene lined,
      carbon steel

      Neoprene coated, 7-1/2-hp motor
14 gpm, 60-ft head, centrifugal, neoprene-
lined, carbon steel, 3/4-hp motor

Complete system with blower, cyclone
receiver, receiver filter, pump, motor

15,000 Ib, 500 ft, 15-hp motor

25 ft dia, 49 ft high, with top, 60-degree
cone bottom, carbon steel, 30-day storage
capacity

Electromechanical rotary vibrators, 1-hp
motor

Rotary air lock, 8 in. dia, 8 in. long,
carbon steel
       8  ft  dia,  16  ft  high, with  top,  60-degree
       cone  bottom,  carbon  steel,  8-hr  storage

       Rotary  air lock,  8 in.  dia,  8  in.  long,
       carbon  steel

       Electromechanical rotary  vibrators,  1-hp
       motor
                                (continued)

                                    45

-------
                           TABLE 15 (continued)
         Item
                           No.
                      Description
29.   Weigh feeder,           1
     Calcilox to mix
     tank

30.   Tank, thickener feed   1
31.   Agitator,  thickener
     feed tank

32.   Pump,  sludge to
     thickener

33.   Thickener
34.  Pump, thickener
     overflow water

35.  Tank, thickener
     overflow water

36.  Pump, thickener
     underflow

37.  Sump pump, thickener
     pit

38.  Mix tank
39.  Agitator,  mix tank     1

40.  Pump,  pond feed        3


41.  Pump,  recycle water    2
     7 ft long, 26-in. belt, 4 tons/hr, 3/4-hp
     motor
     21 ft dia, 26 ft high, neoprene lined,
     carbon steel
1    Neoprene coated, 15-hp motor
     75-ft head, 1,404 gpm, centrifugal, neoprene
     lined, 60-hp motor

     219 ft dia, 10 ft high, stainless steel or
     rubber-coated concrete basin, rake, and
     drive motor with spare

     881 gpm, 75-ft head, centrifugal, neoprene
     lined, 30-hp motor, carbon steel

     10 ft high, 18 ft dia, neoprene lined,
     carbon steel

     517 gpm, 75-ft head, centrifugal, neoprene
     lined, 25~hp motor

     5 gpm, 10-ft head, centrifugal, neoprene
     lined, l/2~hp motor
     14 ft dia, 14 ft high, neoprene lined,
     carbon steel

     Neoprene coated, 15-hp motor

     533 gpm, 300-ft head, centrifugal, neoprene
     lined, 75-hp motor

     195 gpm, 200-ft head, multistage turbine,
     75~hp motor
                                    46

-------
Electrical—
     See electrical description for the untreated system.

Instrumentation—
     See instrumentation description for the untreated system.

Excavation and Site Preparation—
     See excavation and site preparation description for the untreated system.

Transport Lines—
     The base Dravo case (500-MW plant) requires an 8-in.-diameter, neoprene-
lined, carbon steel pipe for transport of sludge to the disposal pond.  The
recycle water line is 4 in. in diameter and made of carbon steel.  A spare
line for slurry feed to the pond is included in the system design.

     For the case variations pond feed line sizes vary from 6 to 16 in. in
diameter and recycle water line sizes vary from 2 to 6 in. in diameter.  All
pipes are underground (2-ft depth).

Buildings—
     A control building is needed for all Dravo cases.  The same size building
(40-ft wide x 40-ft long) is estimated for all cases.  No buildings are needed
for equipment housing.

Services—
     The cost of services for the Dravo cases is estimated to be 1-1/2% of
direct investment costs.  The cost for services is discussed in more detail
in the services discussion of the untreated disposal process.

Pond Construction—
     The pond sizes were estimated using a computer program as in the cases
for untreated ponding.  The Dravo base case pond is 21.4 ft total depth and
the excavation depth is 3.0 ft.  The area covered by the pond is 414 acres.
All ponds are clay lined, square, and have a divider dike.

Roads and Railroads—
     Calcilox and Thiosorbic lime are received at the plant by rail.  All
Dravo cases are estimated to require 750 ft of track with turnouts and
bumper stops for unloading raw materials received in railroad cars.  A car
puller for moving cars in and out of unloading area is included in equipment
costs.  Roads, estimated to be 8000 ft, are required for access to the dis-
posal pond, to pumps, and to other equipment.

Case Variations

     Case variations for the Dravo process are described below.  All process
conditions other than these variable parameters are the same as for the base
case as described above.
                                     47

-------
1.   The base case is a new 500-MW station with a 30-yr  life.   Two  cases
    also evaluated are new 200- and 1500-MW stations with  a  30-yr  life.

2.   Disposal systems are evaluated for existing 200-, 500-,  and  1500-MW
    plants having remaining lives of 25, 20, and 15 yr.

3.   The coal analysis variations are the same as for the untreated cases.

4.   Sludge disposal systems are evaluated for 200-, 500-,  and  1500-MW
    plants that have ESP for flyash removal.  The resulting  sludge for
    disposal contains very little flyash and therefore  the total quantity
    of material for disposal is less than for the base  cases  (200-, 500-,
    and 1500-MW new plants) .   Flyash collection and disposal is not con-
    sidered for these cases.

5.   Two cases are considered for disposal ponds located 5  and  10 mi from
    the scrubber facility.  Equipment requirements for  these cases are
    identical to the base case except for pumps for transport  of sludge
    to the disposal pond.  The added distance to the disposal  pond, as
    compared to a 1-mi location, increases the pumping  requirement such
    that centrifugal neoprene-lined pumps cannot be used as  in other
    cases.  Large positive displacement plunger pumps are  used to meet
    this requirement.

6.   The amount of Calcilox addition for all cases, except  two  variations,
    is 7% by wt of the dry sludge solids.  Two cases are evaluated for
    Calcilox additions of 5 and 10% of dry solids.  The rate of  curing
    is directly affected by the concentration of additive  in the product
    mixture.

7.   One Dravo case is evaluated for sludge from a new 500-MW plant
    (base premises) using a lime scrubber operating at  a 1.1 stoichio-
    metric mol ratio of CaO:S02 removed.  The scrubber  slurry  contains
    10% solids (15% is used for limestone cases), therefore, additional
    dewatering capacity is needed due to the reduced scrubber  system
    stoichiometry; the total amount of sludge for disposal is  less than
    that in the base case.

8.   Dravo offers a design variation that yields a fixed sludge that can
    be landfilled.  The system is very similar to the system for ponding
    except the material is pumped from the mix tank to  a series  of small
    curing ponds near the scrubber facility, instead of to a permanent
    disposal pond.  The material is allowed to cure in  a small pond for
    2-4 wk and is then dug out with a clamshell or front-end loader for
    transport by truck to a landfill.  The material has physical properties
    similar to a silty-clay soil.
                                 48

-------
IUCS PROCESS

     An earthlike material that can be used for landfill disposal is produced
using the IUCS sludge fixation process.  This material has physical and struc-
tural properties that make it suitable for handling with belt conveyors,
trucks, and typical earthmoving equipment.

     Spent slurry containing 15% solids from the FGD system is pumped to an
agitated storage tank (8-hr capacity).  The slurry is fed to a thickener in
which the solids content in the slurry is increased from 15 to 35%.  Thick-
ener overflow water is returned to the scrubber facility for reuse.  Under-
flow is pumped to a rotary drum filter and the sludge is dewatered to form
a material containing 60% solids.  Filtrate is also returned to the scrubber
system for reuse.  The filter cake is transferred by belt conveyor to a
blade-type mixer for blending with the fixation additives.  The fixed material
is conveyed to a small disposal pile where it is loaded with a front-end
loader into a truck and subsequently hauled to a disposal site.  Lime is used
as the additive and is received by truck or rail at the sludge fixation fac-
ilities.  Pneumatic conveyors are used for transporting the lime to storage
silos  (30-day storage capacity) and for transferring the additive to feed
bins (8-hr capacity) above the mixers.  Weigh feeders are used to meter the
lime to the mixers and the standard amount of additive is 4% by wt of the
dry sludge solids.  A flow diagram and material balance for the IUCS base
case are shown in Figure  6 .

Major Equipment

     All items of major equipment for the IUCS base case are included in
Table  16.  A control diagram for the IUCS process and layout drawings for
the base case are shown in Figures  7-9.

Field Equipment

     A definition of field equipment is given in the discussion of the
untreated disposal systems.
                                    49

-------
                                                        Notes:
                                                          See Figure 2.   Same basis
                                                          for calculations.
DESCRIPTION
LB/HR
Qf*ft|
Ip ap
KbsLvnsLDS. %
SLURRY TO
THICKENER
FEED TAW
772k
1404
MO
15
SLURRY
TO
THICKENER
772*
1404
MO
15
THICKENER
OVERFLOW
• 441k
883


UNDERFLOW
TO
FILTER
331k
517
128
35
RECYCLE
FILTRATE
276


CAKE
TO MIXER
193k
241
1.60
60
LIME
TO MIXER
4633



TREATED
SLUDGE TO
DISPOSAL
198k



RECYCLE
WATER TO
SYSTEM
579k
1159


Figure 6.  IUCS process.  Flow diagram and material balance - base case.

-------
   TO
 LIMESTONE
 GRINDING
 AND SO.
ABSORPTION
  AREAS
 FROM SOt
ABSORPTION
  AREAS
                                     Figure  7,   I'UCS process.   Control diagram -  base case.

-------
-MIXERS
    Figure 8,   IUCS process.   Elevation -. base case.

-------
                                                                  ROADWAY
21' DIA.-
                                   THICKENER
                                   OVERFLOW
                                     TANK
                        Figure 9.   TUGS process.   Overall plot  plan - base  case.

-------
            TABLE 16.  IUCS PROCESS - BASE  CASE EQUIPMENT LIST
          Item
                           No.
                 Description
 1.  Pneumatic  conveying
    system, lime

 2.  Storage silo, lime
 3.   Feeder,  discharge
 4.   Vibrator,  lime          24
     storage  silo

 5.   Feed bin,  lime           1
 6.   Feeder,  bin  discharge    1
 7.   Vibrator,  lime feed
     bin

 8.   Weigh feeder,  lime
 9.   Car puller

10.   Sump pump
11.   Tank,  thickener feed     1
12.   Agitator,  thickener      1
     feed tank

13.   Pump,  thickener  feed     2
14.   Thickener
Complete system with blower,  cyclone  receiver,
receiver filter, motor

18,532 ft3, 510 tons, field erected,  22.8 ft
dia, 45.6 ft high, carbon  steel, with top,
60-degree cone bottom

Rotary air lock type, 4,633 Ib/hr,  8  in. dia,
8 in. long, carbon steel

Electromechanical, rotary  vibrators,  1-hp
motor

618 ft3, 7 ft dia, 15 ft high, with top, 60-
degree cone bottom, carbon steel

Rotary air lock type, 8 in. dia, 8  in. long,
carbon steel

Electromechanical, rotary  vibrators,  1-hp
motor

5 ft long, 14-in. belt, 3/4-hp B.C. motor,
carbon steel

15,000 Ib, 500 ft, 15-hp motor

5 gpm, 10-ft head, carbon  steel, 1/4-hp
motor

63,000 gal, field erected, 21 ft dia, 26 ft
high, open top, four 1 ft  9 in. x 26  ft
baffles offset 3-1/2 in. from wall, neoprene
lined, carbon steel

15 hp, 72-in.-dia blade, neoprene coated


1,500 gpm, 75-ft head, neoprene lined, 60-
hp motor

219 ft dia, stainless steel or neoprene-
lined concrete basin with  rake and  motor
with 1 spare
                                 (continued)


                                      54

-------
                           TABLE  16  (continued)
         Item
No.
Description
15.   Tank,  thickener        1
     overflow

16.   Pump,  thickener        2
     overflow recycle

17.   Pump,  thickener        2
     underflow to  filter

18.   Sump pump,  thickener   1
     tunnel

19.   Rotary drum filter     3
      26,500 gal, 16-1/2 ft dia, 16-1/2 ft high,
      neoprene lined, carbon steel

      881 gpm, 75-ft head, neoprene lined, 30-hp
      motor

      517 gpm, 75-ft head, neoprene lined, 25~hp
      motor

      5 gpm, 10-ft head, carbon steel, 1/4-hp
      motor

      464 ft, 10 ft dia x 16 ft long drum, stain-
      less steel (wetted parts), vacuum and fil-
      trate pumps
20. Pump, filtrate
recycle
21. Conveyor, hori-
zontal filter
22. Conveyor, sloping
filter cake
23. Mixer
24. Conveyor, horizontal
fixed cake
25. Conveyor, sloping
fixed cake
2 276 gpm, 75-ft head, neoprene lined, 10-hp
motor
3 18 ft long, 48 tons/hr, 1/2-hp motor
3 30 ft long, 24-in. belt, 48 tons/hr, 10-hp
motor
1 Carbon steel, 75~hp motor
1 30- in. belt, 30 ft long, 99 tons/hr, 3/4-
hp motor
1 30- In. belt, 150 ft long, 99 tons/hr, 15-hp
motor

 Piping-
      See piping description for the untreated system.

 Foundations and Structural—
      See foundations and structural description for the untreated system.

 Electrical—
      See electrical description for the untreated system.

 Instrumentation—
      See instrumentation description for the untreated system.
                                     55

-------
Excavation and Site Preparation--
     See excavation and site preparation description  for  the untreated system.

Transport Lines—
     There are no pipeline requirements for any of  the IUCS cases.

Buildings—
     Two buildings, one for a control room and another for process  equipment,
are needed for the IUCS facilities.  The control building is 12 ft  high by
40 ft by 40 ft.  The equipment building is 40 ft high by  75 ft by 100 ft for
the 200- and 500-MW plants and 40 ft high by  150 ft by 100 ft for the 1500-MW
plants.

Services—
     The cost of services is estimated to be  1-1/2% of the direct capital
investment requirement.  A more detailed discussion of this item is included
in the discussion of the untreated process system.

Landfill-
     Treated sludge is transported to a disposal site where it is placed and
compacted as landfill.  Land requirements for the landfill are based on the
quantity of material for disposal  (yd3) , assuming an  average depth  of 30 ft
over the entire disposal site.  The disposal  area is  cleared of vegetation
and topsoil before the sludge is deposited.  The clearing operation is grad-
ual, based on  the  current land usage rate and eventually  the entire site is
covered.  The  landfill is covered with topsoil and  can be recovered with
vegetation after the filling operation is complete.  The  filled area is
designed so that runoff rainwater or streams  are diverted around the site
as much as possible.  The site is also contoured and  sloped to prevent as
much seepage as possible from rainfall.  Drainage from the site is  captured
in a small holding pond for analysis and treatment  (if needed) before release
to local streams.

Earthmoving Equipment—
     Fixed sludge  is moved by belt conveyor from the  IUCS facility to a
product pile.  Wheeled loaders are used to transfer the fixed sludge from
the pile to a  dump truck that hauls the sludge to the landfill disposal site.
The fixed material is placed and compacted in the landfill using typical
landfill equipment  (motor grader, bulldozer,  and towed roller).  The base
case is estimated  to require two wheeled-loaders, three dump trucks, one
grader, one bulldozer, and one towed roller.  The number  of pieces  of equip-
ment and their sizes depend on the sludge production  rate and varies for  the
disposal alternatives considered.

Roads  and Railroads—
     The requirements are the same as  for all treated process cases and are
discussed in the Roads and Railroads section  for  the  Dravo systems.

Case Variations

     Variations from the base case are as follows:
                                    56

-------
   1.   Two cases for new 200- and 1500-MW power stations are considered.

   2.   Disposal systems are evaluated for existing 200-, 500-, and 1500-MW
       plants having remaining lives of 25, 20, and 15 yr.

   3.   Coal analysis variations are the same as for the untreated cases.

   4.   An IUCS system was evaluated for 200-, 500-, and 1500-MW plants that
       are equipped with ESP for flyash removal.  In all other cases flyash
       is removed in the scrubber system and is part of the slurry underflow
       from the scrubber facility for disposal.  The IUCS process requires
       flyash for fixation.  For these cases where flyash is not included
       in the scrubber underflow to the IUCS facility, a provision is made
       for adding flyash to the sludge prior to disposal.  Dry flyash from
       the ESP is pneumatically conveyed to storage silos near the IUCS fac-
       ility.  After dewatering with the thickener and rotary drum filters,
       as in all cases, the sludge is conveyed to a mixer for mixing with
       the dry flyash as well as the IUCS additive.  The amount of flyash
       to be added is 4% by wt of the total dry solids in the sludge.  The
       size of dewatering equipment is reduced for this system, but the fac-
       ilities for flyash handling are extra requirements as compared to
       other processes.

   5.   The rate and extent of fixation can be varied by varying the amount
       of fixation additive used.  Cases for an additive amount of 3% (base
       is 4%) and 5% by wt of the total dry solids in the sludge are evaluated.

   6.   The evaluation is made of one IUCS disposal system for sludge from a
       new 500-MW plant using a lime slurry scrubber operating at a stoich-
       iometry of 10% excess CaO.  The scrubber underflow to the fixation
       facility contains 10% solids.
CHEMFIX PROCESS

     The system for sludge fixation with the Chemfix process is very similar
to the IUCS process.  The product of stabilization is a soillike material
that is suitable for landfill.  Physical and structural properties are similar
to typical soil and the fixed sludge is suitable for handling with belt con-
veyors, loaders, and earthmoving equipment.

     A flow diagram and material balance for the Chemfix base cas.e are shown
in Figure 10.  Scrubber system underflow slurry (15% solids) is pumped to an
8-hr-capacity thickener feed tank.  The solids content of the sludge is
increased in the thickener from 15 to 35%.  Overflow water from the thickener
is recycled to the scrubber system for reuse.  The thickener underflow is
pumped to rotary drum filters for dewatering to form a cake containing 60%
solids.  The dewatered sludge is transferred by belt conveyor to a blade-type
mixer where Chemfix additives are blended with the sludge.  Product from the
mixer is transferred by belt conveyor to an earthmoving vehicle (scraper) for
transport' to the landfill area.


                                   57

-------
                                                             Notes:
                                                               See Figure 2.  Same basis for
                                                               calculations.
Figure 10.  Chemfix process.  Flow diagram and material balance - base case.

-------
      The fixation additives are Portland cement and sodium silicate.  These
 materials are received in either truck or rail cars and transferred  to 30-day
 storage facilities.  Portland cement is transferred with a pneumatic conveying
 system to storage silos and subsequently to a feed bin  (8-hr capacity) for
 the mixing equipment.  Sodium silicate (liquid) is pumped from the unloading
 area to a storage tank and is metered from this tank into the sludge during
 mixing.  The base case amount of Portland cement and sodium silicate to be
 added is 7% and 2% by wt, respectively, of dry solids in sludge.

      The thickener is located near  the scrubber facility, but the remainder
 of the Chemfix facilities are located at the disposal site.  Pipelines are
 used to transport the underflow from the thickener to the remaining  treat-
 ment facilities 1 mi from the scrubber area.  Trucks are not required for
 sludge transport; however, earthmoving equipment is needed to carry  the
 treated material to the landfill from the fixation facility.

 Major Equipment

      Major process equipment items  are listed in Table  17.  A brief  descrip-
 tion of each item is given.  A control diagram and base case layout  drawings
 for the Chemfix system are shown in Figures 11-13.

 Field Equipment

      A definition of field equipment is given in the discussion of the
 untreated disposal system.

 Piping—
      See piping description for the untreated system.


           TABLE 17.  CHEMFIX PROCESS - BASE CASE EQUIPMENT LIST


	Item	No.	  Description	

 1.  Pump, sodium silicate   2    50  gpm, 75~ft head, rubber lined, 3~hp motor
    unloading

 2.  Tank, sodium silicate   1    129,600 gal, 28 ft dia, 28 ft high,  carbon
    storage                      steel, rubber lined with top and flat bottom

 3.  Pump, sodium silicate   2    3 gpm, 75-ft head, rubber lined, 1/2-hp motor
    to mixer

 4.  Pneumatic conveying     1    49  tons/hr, 150 ft long, 8 in. carbon steel
    system, concrete             lined

 5.  Silo, cement storage    4    22,154 ft3/silo, 242 ft dia, 48.4 ft high,
                                 carbon steel with top and cone bottom
                                     59

-------
                            TABLE 17 (continued)
         Item
                              No.
              Description
 6.   Feeder,  cement storage    4
     silo discharge

 7.   Vibrator,  cement         32
     storage  silo

 8.   Feed bin,  cement          1
 9.   Feeder,  cement feed
     bin discharge

10.   Weigh feeder, cement
     bin to mixer

11.   Vibrator,  cement bin
12.  Car puller                1

13.  Sump pump                 1


14.  Tank, thickener feed      1
15.  Agitator,  thickener
     feed tank

16.  Pump, thickener feed
17.  Thickener
18.   Tank,  thickener
     overflow

19.   Pump,  thickener
     overflow recycle

20.   Pump,  thickener
     underflow
Rotary air lock type,  9  in.  dia  x  9 in.
long, carbon steel

Electromechanical,  rotary  vibrators,
1-hp motor

985 ft3, 8.6 ft dia,  17.2  ft high, carbon
steel with top and  cone  bottom

Rotary air lock type,  9  in.  dia  x  9 in.
long, carbon steel

4 tons/hr, 14-in. belt,  5.6  ft long,
carbon steel

Electromechanical,  rotary  vibrators, 1-
hp motor

15,000 Ib, 500 ft,  15-hp motor

5 gpm, 10-ft head,  1/4-hp  motor, carbon
steel

63,000 gal, 21 ft dia, 26  ft high, open
top, carbon steel,  field erected,  rubber
lined with four 1 ft  9 in. x 26  ft
baffles offset 3-1/2  in. from  wall

15 hp, rubber lined
1,500 gpm, 75-ft head, rubber lined,
60~hp motor

219 ft dia, stainless steel or rubber
coated, concrete basin with rake and
motor (1 spare)

26,500 gal, 16-1/2 ft dia, 16-1/2  ft
high carbon steel with flat bottom

881 gpm, 75-ft head, rubber lined,  30~hp
motor

517 gpm, 300-ft head, rubber lined,  125-
hp motor
                                    60

-------
                           TABLE 17 (continued)
         Item
No.
Description
21.   Rotary drum filter
22.   Pump,  filtrate
     recycle

23.   Conveyor,  horizontal
     cake

24.   Conveyor,  sloping
     cake

25.   Mixer

26.   Conveyor,  sloping
     to disposal
      464 ft2 surface area, 10 ft dia, 16~ft long
      drum, stainless steel wetted parts, vacuum
      and receiver pumps included

      276 gpm, 200-ft head, rubber lined, 30~hp
      motor

      48 tons/hr, 30~in. belt, 18 ft long, 100
      ft/min, l/2~hp motor

      48 tons/hr, 30~in. belt, 30 ft long, 100
      ft/min, 3-hp motor

      36 ft dia, 40-hp motor, 102 tons/hr

      500 ft long, 30-in. belt, 98 tons/hr, 100
      ft/min, 20-hp motor
Foundations and Structural—
     See foundations and structural description for the untreated system.

Electrical—
     See electrical description for the untreated system.

Instrumentation—
     See instrumentation description for the untreated system.

Excavation and Site Preparation—
     See excavation and site preparation description for the untreated system.

Transport Lines—
     Pipelines are needed to transport sludge from the thickener to the
remainder of the Chemfix treatment facilities at the disposal site.  Carbon
steel, neoprene-lined, 8-in.-dia, 1-mi-long pipes are used.  One line is
required for routine use and a second line is included as a spare.  A 6-in.
carbon steel line is needed for returning filtrate from the rotary drum
filters to the scrubber facility.  All lines are underground.

Buildings—
     The building requirements are the same for Chemfix as for IUCS.  All
cases are estimated to require a control building and an equipment building.
The sizes of these buildings are given in the discussion of the IUCS building
requirements.
                                     61

-------
(TYP FOR
SLURRY PUMPS)
      Figure 11.   Chemfix process.   Control diagram -  base case.

-------
CEMENT
STORAGE
 SILOS
                                         SODIUM
                                         SILICATE
                                         STORAGE
                                          TANK
                      -MIXERS
                       Figure 12.  Chemfix process;  Elevation - base case.

-------
                                                                         DISPOSAL PILE-
Figure  13.   Chemflx process.   Overall plot  plan - base case.

-------
Services—
     The  estimate of capital needed for services is 1-1/2% of direct capital
investment.   A description of this requirement is included in the untreated
process system estimate.

Landfill-
     See  landfill for IUCS case.

Earthmoving Equipment—
     The  Chemfix fixation facilities are located on the disposal site.   There-
fore, trucks are not required to transport fixed sludge from the treatment
facility  to a disposal site a mile away.  The landfill for the 500-MW base
Chemfix case is estimated to cover 198 acres.  Earthmoving equipment is needed
for placement of fixed sludge.  Scrapers are used for transferring sludge from
the treatment facility to the landfill area.  Graders, bulldozers, and rollers
are needed  for placement of the material.  The base case is estimated to
require two scrapers, one bulldozer, one grader, and one towed roller.

Roads and Railroads—
     The  requirements are the same for all treated process cases and are dis-
cussed in the Roads and Railroads section for the Dravo systems.

Case Variations

     The  variations from the base case are as follows:

   1.  The  first variation from the base is the method for transfer of
       material to the disposal area.  The facilities for sludge treatment
       are  adjacent to the scrubber system facilities and 1-mi sludge trans-
       port lines are not required.  After the untreated dewatered sludge is
       mixed with fixation additives, it is transferred by belt conveyor to a
       small disposal pile.  Wheeled loaders are used to fill trucks from this
       small disposal pile and the sludge is hauled 1 mi to a landfill for
       placement and compaction.

   2.  Systems for new 200- and 1500-MW plants are evaluated.

   3.  Evaluations are made for 200-, 500-, and 1500-MW plants having remaining
       lives of 25, 20, and 15 yr.

   4.  Coal analysis variations are the same as for the untreated system.

   5.  Three disposal systems are estimated for 200-, 500-, and 1500-MW power
       plants equipped with ESP for flyash removal.  The cost of flyash
       collection and disposal is not considered for these variations.

   6.  Two  cases are evaluated for disposal systems that use additive amounts
       other than the amount for the base case.  Portland cement and sodium
       silicate rates are increased and percent solids in the dewatered sludge
       is increased in the systems evaluated for these case variations.  In
       both cases large facilities are required for handling fixation additives
                                     65

-------
    and the requirement for dewatering equipment  (rotary  drum filters) is
    reduced.   Estimates are made for sludge containing  50 and 55%  solids.
    Sodium silicate amounts are increased to 9 and 6% of  the  sludge solids
    amount respectively.   Portland cement rates are also  increased to 22
    and 12%,  respectively, for these two case variations.   Curing-fixation
    time requirements and final product characteristics are assumed to be
    unchanged.

7.   One Chemfix disposal  system is estimated for treatment  of sludge from
    lime scrubber operating at a stoichiometry of 10% excess  CaO.  Scrubber
    underflow to the Chemfix facility contains 10% solids.
                                 66

-------
                    ECONOMIC EVALUATION AND COMPARISON
     Capital investment and revenue requirements were estimated for 121 cases
of the four primary sludge disposal alternatives.  Detailed estimates for each
are included in Appendix A.  These cases and the bases for the cost estimates
have been described in previous sections of this report (Design and Economic
Premises, Systems Estimated, and Process Background and Description).

     The capital investment estimates are based on:  (1) cost information
obtained from engineering contracting, processing, and equipment companies;
(2) information and data already available within TVA; and (3) specific cost-
equipment-size relationships used for calculating indirect capital costs
obtained from reliable literature sources (28-32).  All capital cost estimates
are projected to 1979.

     The revenue requirement estimates are based on:  (1) raw material costs
obtained from companies currently marketing these materials;  (2) current labor
and supervison rates; (3) purchased power costs, and (4) currently acceptable
indirect costs from reliable literature sources and current industry practice.
All revenue requirement estimates are projected to 1980.
CAPITAL INVESTMENT

     The capital investment of 121 cases estimated for the four primary dis-
posal alternatives are discussed in this section.  To produce results that
are comparable and suitable for economic evaluation, a standard format and
procedure for estimating each process was used.

     Results are presented in summary tables and graphs so that comparisons
between processes can be readily made.

Estimating Procedure

     For each of the case variations estimated, a material balance and flow-
sheet were prepared.  This information served as a basis for compiling an
equipment list.  Equipment lists for base cases are included in the Systems
Estimated.  Flow rates, residence times, and storage capacities were used to
estimate the size of each item of process equipment.  Major process equipment
costs were derived from either budgetary estimates obtained from vendors or
actual cost for similar equipment purchased by TVA.  The costs of minor
equipment were estimated using authoritative publications on equipment esti-
mating.
                                     67

-------
     As explained earlier in the section Design and Economic  Premises,  the
projected capital investment estimates correspond to a midwestern plant loca-
tion and a 3-yr construction schedule beginning mid-1977,  ending mid-1980.
The expected midpoint of project expenditures is mid-1979.  Chemical Engineering
indices are used to project current cost estimates to 1979.   These indices are
shown in Table 6 of the Design and Economic Premises section.

     Other direct investment costs include piping, foundations  and structural,
electrical, excavation, roads, railroads, instrumentation  buildings, services,
transport lines, earthmoving equipment, and services.  The details of these
items are discussed in the section Systems Estimated.

     The sum of costs for these items and cost of process  equipment represents
the direct investment requirement.  Each item in the direct investment  includes
the combined cost of labor for fabrication and installation and the cost of
materials.

     Indirect investment costs are added to direct investment costs to  yield
the total fixed investment cost.  Indirect cost items are:  (1)  engineering
design and supervision, (2) A&E contractor expense, (3)  construction expense,
(4) contractor fees, (5) contingency, (6) allowance for  startup and modifica-
tion, and (7) interest during construction.  Each of these is described in the
section Design and Economic Premises.

     Two other capital expense items are combined with the subtotals for
direct and indirect investment to obtain the total capital investment for
each case.  These items are land cost and working capital.

Results

Capital Investment for Declining-Load Operating Profile—
     Breakdowns of the capital investment for each of the  121 cases are pre-
sented in Appendix A.  Each cost summary includes direct,  indirect, and other
capital items that make up the total capital investment.   Tables 18-21  are
summaries of total capital investments for the case variations  of each dis-
posal process.  The projected total investments for the  base  cases (500-MW
new plant) range from $24,114,000 for disposal in a lined  pond  following Dravo
process treatment to $10,717,000 for landfill disposal using  the IUCS fixa-
tion process.

     Tables 22-25 show breakdown analyses of capital investment for the four
disposal alternatives for the 200-, 500-, and 1500-MW plant cases (new units
with 30-yr life).

Capital Investment for Constant-Load Operating Profile—
     The total capital investment for disposal systems that serve a power
plant operating at a constant load over a 30-yr life is  included.  All other
capital estimates are for plants with a declining operating profile over a
30-yr life, resulting in a total lifetime operating time of  127,500 hr.
Estimates are made for 200-, 500-, and 1500-MW plants which operate at con-
stant annual loads of 5000 and 7000 hr/yr.  The total operating time for the


                                     68

-------
30-yr life of these plants is 150,000 hr and 210,000 hr, respectively, for
5,000 and 7,000 hr/yr annual operation.  The pond construction and land
requirements for a disposal pond or for a landfill are, therefore, much
greater;  hence, both direct and indirect investment requirements are affected.
Table 26  summarizes these case variations for each disposal alternative.

Land Requirements—
     A significant portion of the total capital investment for each of the
estimates was for the purchase of land.  Land costs are estimated at $3500/acre
and additional expenditures ($1700/acre) are necessary for those cases involving
landfill  disposal.  The latter expenditures are included in the revenue require-
ments and are the costs associated with the use of earthmoving equipment for
preparing a landfill site (excavation of topsoil and vegetation), the cost
of covering the compacted sludge product with sufficient soil to prevent wind
and water erosion, the cost of contouring the filled area to provide maximum
runoff, minimum seepage, and the cost of constructing small collection basins
for runoff and seepage water before analysis (treatment if needed) and release
to local  streams.  Table 27 is a summary of land requirements for the four
disposal  alternatives.
REVENUE REQUIREMENTS

     Total annual, lifetime, and constant-load revenue requirements are esti-
mated for case variations of the four disposal methods.  These estimates are
based on raw material costs, labor rates, capital charges, power costs, etc.
A detailed explanation of these items is given in the section Economic Premises.

     Cost estimates are made on the basis of regulated economics which allow
the power company to earn a specified return on investment.  Regulation is
usually the responsibility of state or local agencies with FPC responsible
for setting guidelines for accounting and rates on interstate transactions
(6).  The sludge disposal system cost is combined with the total power plant
investment and, therefore, increases the "rate base" on which the utility is
allowed to earn at the rate set by the regulatory commission.  Thus, a return
on equity must be included in any process evaluation under regulated economics.
This "cost-of-investment money" is added to the disposal system's revenue
requirements as part of capital charges.

Estimating Procedure

Annual Revenue Requirements—
     Total annual revenue requirements were estimated for the 121 case varia-
tions and are presented in tabular form in Appendix A.
                                    69

-------
TABLE 18.   TOTAL CAPITAL INVESTMENT SUMMARY - UNTREATED  SLUDGE DISPOSAL*
Remaining life
Case of system, yr
b
Base case
Variation from base
200 MW
200 MW existing
200 MW existing
200 MW existing
Existing plant
Existing plant
Existing plant
1500 MW
1500 MW existing
1500 MW existing
1500 MW existing
12% ash in coal
20% ash in coal
2% S in coal
5% S in coal
200 MW, no flyash in sludge
No flyash in sludge
1500 MW, no flyash in sludge
5 mi to disposal
10 mi to disposal
Pond settled density, 40% solids
Pond settled density, 60% solids
Lime scrubbing process, 1.1 stoich-
iometry
Clarify (35% solids) and pump 1 mi
to pond
Clarify (35% solids) and pump 5 mi
to pond
Clarify (35% solids) and pump 10 mi
to pond
Clarify, filter (60% solids) and
truck to disposal (1 mi)
Clarify, filter (60% solids) and
truck to disposal (5 mi)
Clarify, filter (60% solids) and
truck to disposal (10 mi)
200 MW constrained pond acreage
(50% of optimum)
200 MW constrained pond acreage
(75% of optimum)
Constrained pond acreage (50% of
optimum)
(continued)
70
30

30
25
20
15
25
20
15
30
25
20
15
30
30
30
30
30
30
30
30
30
30
30

30

30

30

30

30

30

30

30

30

30


Total capital
investment, k$ $/kW
17,211

9,800
8,480
6,844
5,511
14,578
11,399
8,822
36,455
30,212
22,904
16,999
15,031
19,055
13,390
20,655
6,716
11,397
23,595
26,836
37,420
20,070
15,194

16,226

18,490

24,881

31,458

8,294

8,825

9,249

12,774

10,203

22,676


34.4

49.0
42.4
34.2
27.6
29.2
22.8
17.6
24.3
20.1
15.3
11.3
30.1
38.1
26.8
41.3
33.6
22.8
15.7
53.7
74.8
40.1
30.4

32.5

37.0

49.8

63.0

16.6

17.6

18.5

63.9

51.0

45.3



-------
                          TABLE  18 (continued)
                                      Remaining  life    Total  capital
                Case	of  system, yr     investment,  k$    $/kW
Constrained pond acreage (75% of
optimum)
1500 MW constrained pond acreage
(50% of optimum)
1500 MW constrained pond acreage
(75% of optimum)
Pond settled density, 40% solids
Pond settled density, 60% solids
Unlined pond
Synthetic pond lining ($1.50 /yd2)
Synthetic pond lining ($2.50/yd2)
Synthetic pond lining ($3.50/yd2)
Synthetic pond lining ($4.50/yd2)

30

30

30
30
30
30
30
30
30
30

17,985

48,917

38,228
20,070
15,194
14,391
20,994
23,070
24,959
26,707

36.0

32.6

25.5
'40.1
30.4
28.8
42.0
46.1
50.0
53.4

a.   Basis
      Midwest plant location;  average basis for cost scaling,  mid-1979.
      S0£ and flyash removed to meet New Source Performance  Standards  (NSPS)
b.   Base case
      New 500-MW plant with 30-yr life;  direct ponding of 15%  solids  slurry
       in a clay-lined pond 1  mi from scrubber facilities;  settled density
       in pond,  50% solids.
                                    71

-------
      TABLE 19.   TOTAL CAPITAL INVESTMENT SUMMARY - DRAVOC
Remaining life
Case of system, yr
b
Base case
Variation from base
200 MW
200 MW existing
200 MW existing
200 MW existing
Existing plant
Existing plant
Existing plant
1500 MW
1500 MW existing
1500 MW existing
1500 MW existing
12% ash
20% ash
2% S
5% S
200 MW, no fly ash
No flyash
1500 MW no flyash
5 mi to disposal
10 mi to disposal
5% Calcilox added
10% Calcilox added
Lime scrubbing process, 1.1 stoich-
iometry
Intermediate ponding and truck to
landfill
200 MW constrained pond acreage
(50% of optimum)
200 MW constrained pond acreage
(75% of optimum)
Constrained pond acreage (50% of
optimum)
Constrained pond acreage (75% of
optimum)
1500-MW constrained pond acreage
(50% of optimum)
1500-MW constrained pond acreage
(75% of optimum)
30

30
25
20
15
25
20
15
30
25
20
15
30
30
30
30
30
30
30
30
30
30
30

30

30

30

30

30

30

30

30
Total capital
investment, k$ $/kW
24,114

13,942
13,258
11,597
10,239
21,416
18,281
15,553
48,235
41,382
33,924
27,905
21,446
26,028
19,251
28,523
12,242
19,745
38,722
30,994
37,765
23,120
25,209

21,318

12,670

20,701

17,305

37,697

31,061

80,098

64,503
48.2

69.7
66.3
58.0
51.2
42.8
36.6
31.1
32.2
27.6
22.6
18.6
42.9
52.1
38.5
57.0
61.2
39.5
25.8
62.0
75.5
46.2
50.4

42.6

25.3

103.5

86.5

75.4

62.1

53.4

43.0

Basis
  Midwest plant location;  average basis for cost scaling, mid-1979.
  S02 and flyash removed to meet NSPS.
Base case
  New 500-MW plant with 30-yr life; ponding of 35% solids slurry in a
   clay-lined pond 1 mi from scrubber facilities; settled density in pond,
   50% solids; pipeline transport to disposal area; Calcilox for stabili-
   zation (7% of dry sludge).
                                 72

-------
         TABLE  20.   TOTAL  CAPITAL INVESTMENT SUMMARY - IUCS'

Remaining life
Case of system, yr
b
Base case
Variation from base
200 MW
200 MW existing
200 MW existing
200 MW existing
Existing plant
Existing plant
Existing plant
1500 MW
1500 MW existing
1500 MW existing
1500 MW existing
12% ash
20% ash
2% S
5% S
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
3% lime for stabilization
5% lime for stabilization
Lime scrubbing process, 1.1
stoichiometry

30

30
25
20
15
25
20
15
30
25
20
15
30
30
30
30
30
30
30
30
30
30
30

30
Total capital
investment, k$ $/kW

10,717

7,193
7,428
7,351
7,295
10,591
10,402
10,269
20,105
19,952
19,382
18,976
9,345
11,957
9,025
12,283
7,301
9,839
18,103
11,377
11,891
10,302
10,748

10,383

21.4

36.0
37.1
36.8
36.5
21.2
20.8
20.5
13.4
13.3
12.9
12.7
18.7
23.9
18.1
24.6
36.5
19.7
12.1
22.8
23.8
20.6
21.5

20.8

a.  Basis
      Midwest plant location; average basis for cost scaling, mid-1979.
      S02 and flyash removed to meet NSPS.
b.  Base case
      New 500-MW plant with 30-yr life; landfill disposal of 60% solids
       material 1 mi from scrubber facilities; truck transport of treated
       sludge to disposal area; lime for stabilization (4% of dry sludge).
                                   73

-------
       TABLE 21.  TOTAL CAPITAL INVESTMENT SUMMARY  -  CHEMFIXC
                               Remaining life    Total  capital
Case of system, yr
b
Base case
Variation from base
200 MW
200 MW existing
200 MW existing
200 MW existing
Existing plant
Existing plant
Existing plant
1500 MW
1500 MW existing
1500 MW existing
1500 MW existing
12% ash
20% ash
2% S
5% S
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate No. 1
Fixation additive rate No. 2
Lime scrubbing process, 1.1
stoichiometry
Transport by truck to disposal
area
30

30
25
20
15
25
20
15
30
25
20
15
30
30
30
30
30
30
30
30
30
30
30

30

30
investment, k$ $/kW
13,531

9,259
9,448
9,367
9,311
13,400
13,204
13,077
24,104
23,922
23,337
22,915
11,879
14,192
11,123
14,854
7,767
10,124
18,313
20,227
26,988
16,270
14,757

12,431

11,740
27.1

46.3
47,2
46,8
46.5
26.8
26,4
26.2
16.1
15,9
15.6
15.3
23,8
28.4
22.2
29.7
38.8
20.2
12.2
40.5
54.0
32.5
29,5

24.9

23.5

a.  Basis
      Midwest plant location;  average  basis  for cost scaling, mid-1979.
      S02 and flyash removed to  meet NSPS.
b.  Base case
      New 500-MW plant with 30-yr life;  landfill disposal of 60% solids
       material 1 mi from scrubber facilities;  pipeline transport to
       treatment and disposal area;  fixation additives - Portland cement
       (7% of dry sludge) and sodium silicate (2% of dry sludge).
                                   74

-------
      TABLE 22.   CAPITAL  INVESTMENT ANALYSIS - UNTREATED PROCESS

Investment
200 MWa

Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation;
roads and railroads
Electrical
Instrumentation
Buildings
Subtotal
Services and miscellaneous
Subtotal excluding pond
Pond construction
Subtotal direct investment
Engineering design and
supervision
Architect -engineering
contractor expense
Construction expense
Contractor fees
Subtotal
Contingency
Subtotal fixed investment
Allowance for startup and
modification
Interest during construction
Subtotal capital investment
Land
Working capital
Total capital investment
k$
78
96
746
6

66
354
41
-
1,387
21
1,408
3,652
5,060

262

38
713
329
6,402
1,280
7,682

403
922
9,007
708
85
9,800
of total
0.8
1.0
7.5
0.1

0.7
3.6
0.4
-
14.1
0.2
14.3
37.3
51.6

2.7

0.4
7.3
3.3
65.3
13.1
78.4

4.1
9.4
91.9
7.2
0.9
100.0
500 MWa
k$
128
121
1,109
7

73
395
53
-
1,886
28
1,914
7,251
9,165

367

49
1,102
517
11,200
2,240
13,440

619
1,613
15,672
1,423
116
17,211
of total
0.7
0.7
6.4
0.1

0.4
2.3
0.3
-
10.9
0.2
11.1
42.2
53.3

2.1

0.3
6.4
3.0
65.1
13.0
78.1

3.6
9.3
91.0
8.3
0.7
100.0
1500 MWa
k$
237
207
1,922
14

77
522
53
-
3,032
45
3,077
16,946
20,023

587

71
1,997
936
23,614
4,723
28,337

1,139
3,400
32,876
3,359
220
36,455
of total
0.6
0.5
5.3
0.1

0.2
1.4
0.1
-
8.3
0.1
8.4
46.5
54.9

1.6

0.2
5.5
2.6
64.8
12.9
77.7

3.1
9.4
90.2
9.2
0.6
100.0
Basis
  New  plant  (30-yr life), Midwest  plant location, mid-1979  costs.
  Coal analysis (by wt):  3.5% S  (dry basis), 16% ash.
  Flyash removed with S02  to meet  NSPS.
  Limestone  process with 1.5 stoichiometry based on SC>2 removed.
  Pond disposal, 15% solids slurry,  settled density - 50% solids, clay-lined, 1 mi from
  scrubber facilities.
                                       75

-------
        TABLE 23.   CAPITAL INVESTMENT ANALYSIS -  DRAVO  PROCESS
Investment

Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation;
roads and railroads
Electrical
Ins t r umentat ion
Buildings
Subtotal
Services and miscellaneous
Subtotal excluding pond
Pond construction
Subtotal direct investment
Engineering design and
supervision
Architect- engineering
contractor expense
Construction expense
Contractor fees
Subtotal
Contingency
Subtotal fixed investment
Allowance for startup and
modification
Interest during construction
Subtotal capital investment
Land
Working capital
Total capital investment
200
k$
1,405
179
451
116

141
795
100
115
3,302
50
3,352
3,479
6,831

682

144
1,048
414
9,119
1,824
10,943

746
1,313
13,002
676
264
13,942
MWa
%
of total
10.2
1.3
3.2
0.8

1.0
5.7
0.7
0.8
23.7
0.3
24.0
25.0
49.0

4.9

1.0
7.5
3.0
65.4
13.1
78.5

5.4
9.4
93.3
4.8
1.9
100.0
500
k$
2,272
262
657
313

164
974
113
115
4,870
73
4,943
7,410
12,353

821

162
1,627
649
15,612
3,122
18,734

1,132
2,249
22,114
1,450
550
24,114
MWa
%
of total
9.4
1.1
2.7
1.3

0.7
4.0
0.5
0.5
20.2
0.3
20.5
30.7
51.2

3.4

0.7
6.7
2.3
64.7
13.0
77.7

4.7
9.3
91.7
6.0
2.3
100.0
1500
k$
4,363
424
978
540

240
1,301
119
115
8,081
121
8,202
17,358
26,560

1,136

207
2,823
1,127
30,853
6,171
37,024

1,967
4,443
43,434
3,414
1,387
48,235
MWa
I
of total
9.1
0.9
2.0
1.1

0.5
2.7
0.3
0.2
16.8
0.2
17.0
36,0
53,0

2,4

0.4
5.9
2.3
64.0
12,8
76,8

4.1
9.2
90.1
7.0
2.9
100.0
Basis
  New plant  (30-yr life),  Midwest plant location,  mid-1979  costs.
  Coal analysis (by wt):   3.5% S (dry basis),  16%  ash.
  Flyash  removed with S02  to meet NSPS.
  Limestone  process with  1.5 stoichiometry based on S02  removed.
  Pond disposal of treated 35% solids slurry in a  clay-lined  pond  located 1 mi from
  scrubber  facilities, slurry  settled density   50% solids.
                                         76

-------
             TABLE  24.   CAPITAL  INVESTMENT ANALYSIS  - IUCS  PROCESS
Investment

Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation;
roads and railroads
Electrical
Instrumentation
Buildings
Subtotal
Services and miscellaneous
Subtotal excluding trucks
and equipment
Trucks and earthmoving
equipment
Subtotal direct investment
Engineering design and
supervision
Architect-engineering
contractor expense
Construction expense
Contractor fees
Subtotal
Contingency
Subtotal fixed investment
Allowance for startup and
modification
Interest during construction
Subtotal capital investment
Land
Working capital
Total capital investment
200
k$
1,520
126
-
65

94
430
56
550
2,841
43

2,884

400
3,284

311

78
602
237
4,512
902
5,414

501
650
6,565
280
348
7,193
MWa
%
of total
21.1
1.8
-
0.9

1.3
6.0
0.8
7.6
39.5
0.6

40.1

5.6
45.7

4.3

1.1
8.3
3.3
62.7
12.6
75.3

7.0
9.0
91.3
3.9
4.8
100.0
500
k$
2,551
176
-
136

115
639
70
550
4,237
64

4,301

581
4,882

392

98
839
320
6,531
1,306
7,837

726
940
9,503
676
538
10,717
MWa
%
of total
23.7
1.6
-
1.3

1.1
6.0
0.7
5.1
39.5
0.6

40.1

5.4
45.5

3.7

0.9
7.8
3.0
60.9
12.2
73.1

6.8
8.8
88.7
6.3
5.0
100.0
1500
k$
5,050
287
-
314

180
1,012
74
1,004
7,921
119

8,040

1,057
9,097

495

124
1,410
514
11,640
2,328
13,968

1,291
1,676
16,935
2,030
1,140
20,105
MWa
%
of total
25.1
1.4
-
1.6

0.9
5.0
0.4
5.0
39.4
0.6

40.0

5.2
45.2

2.5

0.6
7.0
2.6
57.9
11.6
69.5

6.4
8.3
84.2
10.1
5.7
100.0

Basis
  New  plant  (30-yr life), Midwest plant location, mid-1979 costs.
  Coal analysis  (by wt):   3.5% S (dry basis), 16% ash.
  Flyash  removed with S02 to meet NSPS.
  Limestone  process with 1.5 stoichiometry based on SC>2 removed.
  Landfill disposal of 60% solids material 1 mi from  scrubber facilities, trucks used for
  transport  of treated material to disposal site.

                                        77

-------
     TABLE 25.   CAPITAL  INVESTMENT ANALYSIS  - CHEMFIX  PROCESS
Investment

Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation;
roads and railroads
Electrical
In s t r ument at ion
Buildings
Subtotal
Services and miscellaneous
Subtotal excluding trucks
and equipment
Trucks and earthmoving
equipment
Subtotal direct investment
Engineering design and
supervision
Architect -engineering
contractor expense
Construction expense
Contractor fees
Subtotal
Contingency
Subtotal fixed investment
Allowance for startup and
modification
Interest during construction
Subtotal capital investment
Land
Working capital
Total capital investment
200
k$
1,709
173
487
77

138
587
87
550
3,808
57

3,865

423
4,288

392

98
768
290
5,836
1,167
7,003

658
840
8,501
284
464
9,249
MWa
of total
18.6
1.9
5.3
0.8

1.5
6.3
0.9
5.9
41.2
0.6

41.8

4.6
46.4

4.2

1.1
8.3
3.1
63.1
12.6
75.7

7.1
9.1
91.9
3.1
5.0
100.0
500
k$
2,885
227
697
207

162
853
107
550
5,690
85

5,775

442
6,217

472

118
1,072
385
8,264
1,653
9,917

948
1,190
12,055
693
783
13,531
MWa
of total
21.3
1.7
5.2
1.5

1.2
6.3
0.8
4.1
42.1
0.6

42.7

3.2
45.9

3.5

0.9
8.0
2.8
61.1
12.2
73.3

7.0
8.8
89.1
5.1
5.8
100.0
1500
k$
5,499
367
1,027
394

239
1,274
119
1,004
9,923
149

10,072

789
10,861

564

141
1,700
588
13,854
2,771
16,625

1,584
1,995
20,204
2,083
1,817
24,104
MWa
I
of total
22.8
1.5
4.3
1.6

1.0
5.3
0.5
4.2
41.2
0.6

41.8

3.3
45.1

2.3

0.6
7.1
2.4
57.5
11.5
69.0

6.6
8.2
83.8
8.6
7.6
100.0
Basis
  New plant  (30-yr life), Midwest  plant  location, mid-1979 costs.
  Coal analysis  (by wt):   3.5% S (dry  basis), 16% ash.
  Flyash  removed with S02 to meet  NSPS.
  Limestone  process with 1.5 stoichiometry based on S02 removed.
  Landfill disposal of 60% solids  material 1 mi from scrubber facilities, pipelines  used
  for  transport of 35% solids  thickener underflow to treatment and disposal  area.
                                          78

-------
        TABLE  26.   CAPITAL  INVESTMENTS  FOR SYSTEMS OPERATING

                   AT  CONSTANT LOAD  DURING 30-YR LIFE
  Annual  operating
Capital investment, M$
time, hr
5,000


7,000


Case
200 MW
500 MW
1500 MW
200 MW
500 MW
1500 MW
Untreated
10,682
18,937
40,438
12,882
23,272
50,462
Dravo
14,739
24,771
51,998
16,875
30,293
62,551
IUCS
7,214
10,779
20,282
7,369
11,159
21,415
Chemf ix
9,274
13,515
24,066
9,432
13,984
24,453

a.   New plants  operating 30 yr;  Midwest plant location;  mid-1979
     costs;  coal analysis (wt %) :   3.5% S (dry),  16% ash;  flyash
     removed with S02 to meet NSPS; limestone scrubbing  FGD process
     with 1.5 stoichiometry based  on S02 removed.
                                   79

-------
          TABLE  27.   SUMMARY  OF LAND REQUIREMENTS - ALL PROCESSES
Land required
	 Case 	 	 	 	 	

Base case
Variation from base case

200 MW new
200 MW existing, 25 -yr remaining life
200 MW existing, 20 -yr remaining life
200 MW existing, 15 -yr remaining life
Existing, 25 -yr remaining life
Existing, 20-yr remaining life
Existing, 15 -yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20_yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S in coal
200 MW, no fly ash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate - variation 1
Fixation additive rate - variation 2
Lime scrubbing process
Intermediate ponding and truck to landfill
Transport by truck to disposal area
Clarify (35% solids) and pump 1 mi
Clarify (35% solids) and pump 5 mi
Clarify (35% solids) and pump 10 mi
Clarify, filter (60% solids) and truck 1 mi
Clarify, filter (60% solids) and truck 5 mi
Clarify, filter (60% solids) and truck 10 mi
200 MW, constrained pond acreage (50% of optimum)
200 MW, constrained pond acreage (75% of optimum)
Constrained pond acreage (50% of optimum)
Constrained pond acreage (75% of optimum)
1500 MW, constrained pond acreage (50% of optimum)
1500 MW, constrained pond acreage (75% of optimum)
Pond settled density (40% solids)
Pond settled density (60% solids)
Unlined pond
Synthetic pond lining ($1.50/yd )
Synthetic pond lining ($2.50/yd2)
Synthetic pond lining ($3.50/yd2)
Synthetic pond lining ($4.50/yd )
200 MW, constant-load operating profile (5,000 hr/yr)
Constant-load operating profile (5,000 hr/yr)
1500 MW, constant-load operating profile (5,000 hr/yr)
200 MW, constant-load operating profile (7,000 hr/yr)
Constant-load operating profile (7,000 hr/yr)
1500 MW, constant-load operating profile (7,000 hr/yr)
Untreated
407


202

162
112
72
322
222
143
960
761
519
335
347
461
301
497
124
250
591
407
407
-
-
407
-
-
407
407
407
188
188
188
101
152
204
305
480
720
496
342
486
-
_
-
-
229
461
1,091
299
601
1,419
for sludge disposal, acre'
Dravo
414


193

165
110
74
328
235
145
975
770
535
343
358
445
313
511
172
345
814
414
414
406
424
373
189
-
-
-
-
-
-
-
97
145
207
311
488
731
-
-
-
-
_
-
-
237
473
1,118
304
608
1,454
IUCS
193


80

59
37
21
143
89
51
580
430
267
151
159
231
134
251
58
141
404
193
193
192
194
168
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
_
-
-
93
228
681
130
314
953
Ghemfix
198


81

61
38
22
147
91
52
595
442
275
155
163
237
138
258
43
105
316
198
198
261
227
173
-
198
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
96
233
699
133
327
979
Ponds are  designed for optimum costs unless otherwise specified.  Total pond depth is
variable.  Land requirements  for landfill cases  are calculated for a 30-ft  depth of
compacted  sludge.  The land cost for all cases is  $3,500/acre.
                                         80

-------
     Direct costs—There are two categories of direct costs.  The first,
covering raw materials,  is projected 1980 delivered costs to a midwestern
power plant location.   Estimates of the cost for each raw material are
obtained from appropriate suppliers for the Chicago area.  The second cate-
gory of direct cost is conversion costs, which include operating labor and
supervision, maintenance labor and materials, electricity, analyses, fuel
and maintenance for trucks and landfill equipment, and land preparation costs
for landfill disposal operations.

     Labor costs are projected for 1980 midwestern rates.  Electricity rates
depend upon the quantity purchased.  Also, the values used are fully allo-
cated costs, as if purchased from an independent source with full capital
recovery provided.  The quantity of required electricity is estimated on the
basis of operating motor horsepower.

     Operating labor and supervision for each process is estimated consid-
ering the number, size,  and complexity of operation of major process equip-
ment.  Analyses labor estimates are based on the number of analyses that
must be made to maintain process control.

     Maintenance costs are derived from percentages of the direct investment
for the sludge handling and treatment facilities and the direct investment
for pond construction.  The percentage values are based on information con-
erning actual maintenance requirements for similar equipment and processing
systems.  Fuel and maintenance costs for trucks and landfill equipment are
estimated from information obtained from companies operating similar dis-
posal systems or involved in similar transport operations.  Land preparation
costs for the landfills are based on annual land usage and associated equip-
ment operation costs.

     Indirect costs—The two primary indirect cost items are capital charges
and overheads.  These items are estimated based on current utility practice,
interest rates, and authoritative literature sources.  Capital charges are
applied as average capital charges including depreciation, interim replace-
ments, insurance, taxes, and the cost of capital.  The total rate applied
depends on the power plant's remaining life and the particular type of dis-
posal system used, since the cost of interim replacements is much higher for
systems using trucks and landfill equipment than those using a disposal pond.

     Plant overhead is estimated at 50% of conversion costs less utilities.
Administrative overhead is 10% of operating labor costs.

Lifetime Revenue Requirements—
     Annual revenue requirements are estimated on the assumption that annual
operating time for the disposal system is 7000 hr.  These estimates are
suitable for comparing processes and measuring the effect of process variable
changes.  Also, they may represent operating profiles similar to those during
the early years of a plant's life.  However, most power units have a declining
load over their life and seldom operate in later years at the 7000-hr level
assumed for the annual revenue requirement calculations.  Since revenue
                                   81

-------
requirement estimates are needed which reflect the operating  profiles  of
older plants, lifetime revenue requirement estimates are  included  in this
evaluation.  These estimates consider the variations in capital  charges and
operating profile with plant age.

     Capital charges—The portion of indirect costs that  reflects  the  cost
of capital and taxes is based on undepreciated capital investment.   A  computer
program was used to calculate the revenue requirements for each  year over the
plant life.  Straight-line depreciation is used and capital charges  decrease
uniformly with depreciation over the life of the disposal system.

     Operating profile—The actual quantities affecting direct costs (raw
materials, electricity, operating labor and supervision, maintenance,  and
analyses) were estimated in order to calculate annual revenue requirements
for each disposal system based on 7000 hr annual operating time.   As the
plant's remaining life decreases, the operating profile of the plant and the
quantities of raw materials, analyses, and electricity also decrease.  The
projected costs for these items were modified to show the effect of  decreased
operating load on total revenue requirements.  The annual quantities of each
item are scaled proportional to the annual operating hr for the  plant.  Annual
quantities for operating labor and supervision are scaled proportional to
the annual operating hr raised to the 0.5 power.  The overhead charges (10%
of operating labor and supervision) included in the indirect  costs are also
scaled proportional to annual operating hr raised to the  0.5  power.

     The direct charges for maintenance are scaled proportional  to the annual
operating hr raised to the 0.6 power.  These adjustments  to total  annual
revenue requirements to yield lifetime revenue requirements provide  informa-
tion for more accurately estimating revenue requirements  for  later years in
the disposal system's life.

Constant-Load Revenue Requirements—
     The capacity of a power plant is often held constant or  increased with
time by adding new generating units as the capacity of older  units is  reduced
by age.  When this occurs, the capacity of the sludge disposal system must
be held constant or increased to meet the power plant's demands.

     In this study two types of constant-load revenue requirements,  annual
and lifetime, are considered.  The annual values are based on average  capital
charges over a 30-yr plant life and a revised capital investment using an
adjusted disposal pond or landfill area as compared to a  declining profile-
type operation.  The lifetime values are based on declining capital  charges
and the same revised capital investment.  Estimates are included to  show
the annual and lifetime revenue requirements for plants with  constant  annual
operating loads of 5000 and 7000 hr over a 30-yr life.  Estimates  are  made
for 200-, 500-, and 1500-MW plants with the untreated ponding, Dravo,  IUCS,
and Chemfix systems for sludge disposal.
                                    82

-------
Results

Annual Revenue Requirements—
     The total annual revenue requirements for the disposal systems evaluated
for the  base case 500-MW power plant are as follows:

                     Untreated ponding   $3,280,000
                     IUCS process        $5,291,000
                     Dravo process       $6,701,000
                     Chemfix process     $6,988,000


     The revenue requirement summary tables for the 121 case variations of
the four primary disposal methods are given in Appendix A.  Each summary
table includes the cost of direct and indirect revenue requirement items.
Tables 28-31 summarize the total annual revenue requirements for the case
variations of the four disposal alternatives.  The unit revenue requirements
(mills/kWh, $/ton dry solids, $/ton wet solids) for the 121 case variations
are summarized in Table 32.

Lifetime Revenue Requirements—
     Twelve summary tables (computer projections) are included in Appendix
B to show detailed year-to-year revenue requirement estimates for 200-, 500-,
and 1500-MW plants using the four sludge disposal processes.  For these plants
the revenue requirements are estimated for each year of the 30-yr operating
life.

     Table 33 shows summarized results of the lifetime revenue requirement
estimates for the four disposal systems.  The cumulative  (30 yr) net revenue
requirements are shown for the 12 case variations.  These projections are
prepared on a regulated economic basis, as mentioned earlier on revenue
requirements, and correspond to the 30-yr operating profile of the plant
established in the power plant design premises.  The overall net increase or
decrease in power cost is shown for each year on tables in Appendix B.

Constant-Load Revenue Requirements—
     Constant-load annual revenue requirements are shown  in Table 34 for
systems  operating at 5000 and 7000 hr/yr for plants having 30-yr lives.

     Appendix C includes a summary of the constant-load lifetime revenue
requirements, showing the detailed year-to-year variations and the net change
for each of the 24 case variations of systems operating for 30 yr.  Tables
35 and 36 summarize the cumulative (30 yr) net revenue requirements for these
case variations (four disposal systems for 200-, 500-, and 1500-MW plants)-
Constant operating loads of 5000 and 7000 operating hr/yr are considered.
                                    83

-------
      TABLE 28.   SUMMARY  OF TOTAL ANNUAL  REVENUE REQUIREMENTS  -

                             UNTREATED PROCESS3
Total
annual
Case amount, k$
b
Base case
Variation from base case

200 MW new
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
27, S in coal
5% S in coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate - variation 1
Fixation additive rate - variation 2
Lime scrubbing process
Intermediate ponding and truck to landfill
Transport by truck to disposal area
Clarify (35% solids) and pump 1 mi
Clarify (35% solids) and pump 5 mi
Clarify (35% solids) and pump 10 mi
Clarify, filter (60% solids) and truck 1 mi
Clarify, filter (60% solids) and truck 5 mi
Clarify, filter (60% solids) and truck 10 mi
200 MW, constrained pond acreage (50% of optimum)
200 MW, constrained pond acreage (75% of optimum)
Constrained pond acreage (50% of optimum)
Constrained pond acreage (75% of optimum)
1500 MW, constrained pond acreage (50% of optimum)
1500 MW, constrained pond acreage (75% of optimum)
Pond settled density (40% solids)
Pond settled density (60% solids)
Unlined pond
Synthetic pond lining ($1.50/yd )
Synthetic pond lining ($2.50/yd2)
Synthetic pond lining ($3.50/yd2)
Synthetic pond lining ($4.50/yd2)
3,280

2,014

1,814
1,605
1,433
2,906
2,435
2,130
6,746
5,827
4,726
3,969
2,902
3,609
2,639
3,869
1,495
2,289
4,546
5,527
7,504
-
-
3,136
-
-
3,694
5,195
6,450
3,809
4,925
5,818
2,462
2,033
4,119
3,365
8,985
7,037
3,747
2,949
2,765
3,882
4,253
4,590
4,900
Unit revenue requirements
Mills /kWh
0.94

1.44

1.32
1.15
1.02
0.83
0.70
0.61
0.64
0.55
0.45
0.38
0.83
1.03
0.75
1.10
1.07
0.65
0.43
1.58
2.14
-
-
0.9
-
-
1.06
1.48
1.84
1.09
1.41
1.66
1.76
1.45
1.18
0.96
0.86
0.67
1.07
0.84
0.79
1.11
1.21
1.31
1.40
$/ton
dry sludge
8.08

12.12

10.62
9.26
8.27
7.01
5.87
5.13
5.55
4.69
3.80
3.19
8.68
7.44
9.37
7.35
17.08
10.63
7.04
13.61
18.48
-
-
8.87


9.10
12.79
15.89
9.38
12.13
14.40
14.81
12.23
10.15
8.29
7.40
5.79
11.54
6.05
6.91
9.50
10.47
11.30
12.07
$/ton
wet sludge
4.04

6.06

5.31
4.63
4.14
3.51
2.94
2.57
2.77
2.35
1.90
1.60
4.34
3.72
4.69
3.68
8.50
5.32
3.52
6.81
9.24


4.44

-
4.55
6.40
7.95
4.69
6.07
7.20
7.41
6.12
5.08
4.15
3.70
2.90
5.77
3.03
3.41
4.75
5.24
5.65
6.04
Basis
  Midwest plant location, mid-1980 costs; 7,000 hr/yr plant on-stream time; S0? and  flyash removed
  to meet NSPS.
Base case
  New  500-MW plant with 30-yr life; direct ponding of 15% solids  slurry in a clay-lined pond 1 mi
  from scrubber facilities; settled density in pond   50% solids.
                                           84

-------
         TABLE  29.   SUMMARY OF TOTAL  ANNUAL  REVENUE  REQUIREMENTS  -
                                  DRAVO PROCESS^

Case
Base case
Variation from base case
200 MW new
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S in coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate - variation 1
Fixation additive rate - variation 2
Lime scrubbing process
Intermediate ponding and truck to landfill
200 MW, constrained pond acreage (50% of optimum)
200 MW, constrained pond acreage (75% of optimum)
Constrained pond acreage (50% of optimum)
Constrained pond acreage (75% of optimum)
1500 MW, constrained pond acreage (50% of optimum)
1500 MW, constrained pond acreage (75% of optimum)
Total
annual
amount, k$
6,701

3,643
3,672
3,461
3,390
6,377
5,941
5,728
14,264
13,821
12,749
12,138
5,924
7,406
5,314
8,007
3,063
5,073
10,448
8,124
9,360
6,052
7,577
6,168
6,620
4,423
4,134
9,109
7,901
20,366
17,290
Unit revenue requirements
Mills/kWh
1.91

2.60
2.62
2.47
2.42
1.82
1.70
1.64
1.36
1.32
1.21
1.16
1.69
2.12
1.52
2.29
2.19
1.45
1.00
2.32
2.67
1.73
2.16
1.76
1.89
3.16
2.95
2.60
2.25
1.94
1.65
$/ton
dry sludge
15.32

20.41
19.87
18.73
18.35
14.23
13.26
12.78
10.87
10.30
9.50
9.04
16.43
15.58
17.45
14.08
25.74
17.48
12.01
18.57
21.39
14.09
16.85
8.10
15.13
24.78
23.16
20.82
18.06
15.52
13.17
$/ton
wet sludge
7.66

10.21
9.94
9.37
9.18
7.12
6.63
6.39
5.44
5.15
4.75
4.52
8.22
7.79
8.73
7.04
12.84
8.74
6.01
9.29
10.70
7.05
8.43
4.05
7.57
12.39
11.58
10.41
9.03
7.76
6.59
Basis
  Midwest plant  location, mid-1980 costs; 7,000 hr/yr plant on-stream time;  SC>2 and flyash removed
  to meet NSPS.
Base case
  New 500-MW plant with 30-yr  life; ponding of 35% solids slurry in a clay-lined pond 1  mi from
  scrubber facilities; settled density in pond - 50% solids; pipeline transport to the disposal
  area; Calcilox for stabilization (7% of dry sludge).
                                             85

-------
         TABLE  30.   SUMMARY OF  TOTAL  ANNUAL  REVENUE REQUIREMENTS  -

                                  IUCS  PROCESS3
               Case
                                                   Total
                                                  annual
                                                amount, k$
Unit revenue requirements
         T~r~          $/ton
             $/tOn        y/ Lull
Mills/kWh   dry sludge   wet sludge
Base case
Variation from base case
200 MW new
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S In coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate variation 1
Fixation additive rate variation 2
Lime scrubbing process
3,zyi

3,567
3,699
3,725
3,822
5,402
5,430
5,559
10,411
10,656
10,684
10,900
4,533
5,971
4,654
6,188
3,396
4,650
8,162
6,490
7,475
4,994
5,511
5,093
1 .31

2.55
2.64
2.66
2.73
1.54
1.55
1.59
0.99
1.01
1.02
1.04
1.30
1.71
1.33
1.77
2.43
1.33
0.78
1.85
2.14
1.43
1.57
1.46
i£ . jj

20.68
20.66
20.80
21.35
12.55
12.62
12.92
8.23
8.24
8.26
8.43
13.05
11.84
15.57
11.29
37.03
20.87
12.17
15.40
17.73
11.96
12.95
13.88
/ .DJ

12.59
12.73
12.82
13.16
7.63
7.68
7.86
5.02
5.02
5.04
5.14
7.94
7.23
9.71
6.88
16.45
9.23
5.42
9.37
10.78
7.28
7.91
8.46

Basis
  Midwest plant location, mid-1980 costs; 7,000 hr/yr plant on-stream  time; S02 and flyash removed to
  meet NSPS.
Base case
  New 500-MW plant with 30-yr life; landfill disposal of 60% solids  material 1 mi from scrubber
  facilities; truck  transport of  treated sludge to disposal area;  lime for stabilization  (4% of dry
  sludge).
                                             86

-------
           TABLE 31.   SUMMARY  OF  TOTAL  ANNUAL REVENUE REQUIREMENTS  -

                                     CHEMFIX PROCESS3
                    Case
   Total
  annual
amount, k$.
                                                                          Unit  revenue  requirements
Mllls/kWh
            $/ton
          dry  sludge
                                         _
                                      $/ton
                                    wet sludge
Base case
Variation from base case
  200 MW new
  200 MH existing, 25-yr remaining life
  200 MW existing, 20-yr remaining life
  200 MW existing, 15-yr remaining life
  Existing, 25-yr remaining life
  Existing, 20-yr remaining life
  Existing, 15-yr remaining life
  1500 MW new
  1500 MW existing, 25-yr remaining life
  1500 MW existing, 20-yr remaining life
  1500 MW existing, 15-yr remaining life
  12% ash in coal
  20% ash in coal
  27. S  in  coal
  5% S  in  coal
  200 MW, no flyash
  No flyash
  1500 MW, no flyash
  5 mi to disposal
  10 mi to disposal
  Fixation additive rate    variation 1
  Fixation additive rate    variation 2
  Lime scrubbing process
  Intermediate ponding and truck to landfill
  Transport by truck to disposal area
 6,988

 4,529
 4,695
 4,730
 4,856
 7,152
 7,191
 7,329
14,362
14,749
14,791
15,053
 6,229
 7,600
 5,935
 8,263
 3,766
 5,184
 9,771
 8,675
10,003
13,651
10,099
 6,200

 6,698
2.00

3.24
3.35
3.38
3.47
2.04
 .05
 .10
 .37
 .40
 .41
 .43
 .78
 .17
 .70
 .36
 .69
 .48
0.93
2.48
 .86
 .90
 .89
  2.
  3.
  2.
  1.77
1.91
                            16.51

                            26.14
                            26.11
                            26.31
                            27.01
                            16.55
                            16.64
                            17.03
                            11.31
                            11.36
                            11.39
                            11.59
                            17.86
                            15.00
                            20.19
                            15.01
                            40.89
                            23.17
                            14.30
                            20.49
                            23.63
                            28.71
                            20.99
                            16.83

                            15.82
                           10.08

                           15.59
                           15.60
                           15.72
                           16.13
                            9.87
                            9.92
                           10.16
                            6.74
                             .76
                             .78
                             .90
 6.
 6.
 6.
10.66
 8.93
12.02
 8.94
24.45
13.84
 8.52
12.52
14.43
14.61
12.42
10.01

 9.66
a.  Basis
     Midwest plant location, mid-1980 costs; S02 and flyash removed to meet  NSPS.
b.  Base case
     New 500-MW plant with 30-yr life; landfill disposal of 607. solids material  1 mi  from scrubber
     facilities; pipeline transport to treatment and disposal area; fixation additives:  Portland
     cement (7% of dry sludge) and sodium silicate (27, of dry sludge) .
                                                  87

-------
                                       TABLE  32.    SUMMARY  -  UNIT  REVENUE  REQUIREMENTS  -  ALL  PROCESSES
oo
CO
Untreated dlaoosal*
Case
Base case«
200 HW new
200 HW existing, 25-yr remaining life
200 HW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing , 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 HW new
15.00 HW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
122 ash in coal
202 ash in coal
22 S in coal
52 S in coal
200 HW, no flyash
No flyash
1500 HW, no flyash
5 ml to disposal
10 mi to disposal
Lime scrubbing process
Intermediate ponding and truck to landfill
Transport by truck to disposal area
Clarify (352 solids) and pump 1 mi
Clarify (35% solids) and pump 5 mi
Clarify (352 solids) and pump 10 mi
Clarify, filter (60% solids) and truck 1 mi
Clarify, filter (60X solids) and truck 5 mi
Clarify, filter (602 solids) and truck 10 mi
200 HW, constrained pond acreage (SOX of optimum)
200 HW, constrained pond acreage (752 of optimum)
Constrained pond acreage (752 of optimum)
1500 MW, constrained pond acreage (502 of optimum)
1500 HW, constrained pond acreage (752 of optimum)
Pond settled density (40% solids)
Unlined pond
Synthetic pond lining (S1.50/yd2)
Synthetic pond lining (S2.50/yd2)
Synthetic pond linina ($3.50/yd2)
Synthetic pond lining ($4.50/yd'i)
a. Direct ponding of 157. solids slurry; clay-lined
b. Ponding of 357. solids slurry; clay-lined pond;
c. Landfill disposal of 607. solids material; 1 mi
d. Landfill disposal of 607. solids material; 1 mi
$/ton $/ton
Milla/kVh drv sludee* vet sluda.* Mllla/kUh
0.94
1.44
1.32
1.15
1.02
0.83
0.70
0.61
0.64
0.55
0.45
0.38
0.83
1.03
0.75
1.10
1.07
0.65
0.43
1.58
2.14
0.90
_
-
1.06
1.48
1.84
1.09
1.41
1.66
1.76
1 18
0,96
0.86
0.67
1.07
0 84
0.79
1.11
1.21
1.31
1.40
pond; pump 1 ml
pump 1 ml from at
to landfill from
to landfill from
8.08 4.04
12.12 6.06
10.62 5.31
9.26 4.63
8.27 4.14
7.01 3.51
5.87 2.94
5.13 2.57
5.55 2.77
4.69 2.35
3 . 80 1.90
3.19 1.60
8.68 4.34
7.44 3.72
9.37 4.69
7.35 3.68
17.08 8.50
10.63 5.32
7.04 3.52
13.61 6.81
18.48 9.24
8.87 4.44
_
-
9.10 4.55
12.79 6.40
15.89 7.95
9.38 4.69
12.13 6.07
14.40 7.20
14.81 7.41
10 15 5 08
8.29 4.15
7.40 3.70
5.79 2.90
11.54 5.77
6.05 3.03
6.81 3.41
9.50 4.75
10.47 5.24
11.30 5.65
12.07 6.04
1.91
2.60
2.62
2.47
2.42
1.82
1.70
1.64
1.36
1.32
1.21
1.16
1.69
2.12
1.52
2.29
2.19
1.45
1.00
2.32
2.67
1.73
2.16
1.76
1.89
-
-
-
-
-
-
-
3.16
2 60
2.25
1.94
1.65
-
-
-
-
-
-
from scrubber facllltlea; 5CX aolids
:rubber facilities; 5<
scrubber facilities;
scrubber facilitlea;
77. aollda aettled
trucks used for
Dravob
$/ton
drv sludge i
15.32
20.41
19.87
18.73
18.35
14.23
13.26
12.78
10.87
10.30
9.50
9.04
16.43
15.58
17.45
14.08
25.74
17.48
12.01
18.57
21.39
14.09
16.85
8.10
15.13
-
-
-
-
-
-
-
24.78
20 82
is!o6
15.52
13.17
-
.
-
-
-
"
settled sludge
sludge in pond
transport of tr
pipeline used for transport of

$/ton
7.66
10.21
9.94
9.37
9.18
7.12
6.63
6.39
5.44
5.15
4.75
4.53
8.22
7.79
8.73
7.04
12.87
8.74
6.01
9.29
10.70
7.05
8.43
4.05
7.57
-
-
-
-
-
-

12.39
11.58
10.41
9.03
7.76
6.59
-
-
-
-
-
"
in pond.
; treated
eated alu«
thickener


1.51
2.55
2.64
2.66
2.73
1.54
1.55
1.59
0.99
1.01
1.02
1.04
1.30
1.71
1.33
1.77
2.43
1.33
0.78
1.85
2.14
1.43
1.57
1.46
-
-
-
-
-
-
-
-
-

-
-
-
-
-
-
-
-
"

with Calcilox
ige; treated V
underflow to
IUCSC
S/ton
12.55
20.68
20.66
20.80
21.35
12.55
12.62
12.92
8.23
8.24
8.26
8.43
13.05
11.84
15.57
11.29
37.03
20.87
12.17
15.40
17.73
11.96
12.95
13.88
-
-
-
-
-
-
-
-
-

-
-
-
-
-
-
-
-
"

(7* of dry a
ith lime (41
disposal and


Oiemftxd

$/ton $/ton $/ton
7.63
12.59
12.73
12.82
13.16
7.63
7.68
7.86
5.02
5.02
5.04
5.14
7.94
7.23
9.71
6.88
16.45
9.23
5.42
9.37
10.78
7.28
7.91
8.46
-
-
-
-
-
-
-
-
-

-
-
-
-
-
-
-
-
"

ludge) an
of dry so
treatment
2.00
3.24
3.35
3.38
3.47
2.04
2.05
2.10
1.37
1.40
1.41
1.43
1.78
2.17
1.70
2.36
2.69
1.48
0.93
2.48
2.86
3.90
2.89
1.77
-
1.91
-
-
-
-
-
-
-

-
-
-
-
-
-
-
-
-

d Thioaorblc 11
lids).
area; treated
16.51
26.14
26.11
26.31
27.01
16.55
16.64
17.03
11.31
11.36
11.39
11.59
17.86
15.00
20.19
15.01
40.89
23.17
11.30
20.49
23.63
28.71
20.99
16.83
-
15.82
-
-
-
-
-
-
-

-
-
-
-
-
-
-
-
-

me (U of dry

with Portland
10.08
15.59
15.60
15.72
16.13
9.87
9.92
10.16
6.74
6.76
6.78
6.90
10.66
8.93
12.02
8.94
24.45
13.84
8.52
12.52
14.43
14.61
12.42
10.01
-
9.66
-
-
-
-
-
-
-

_
-
-
-
_
-
-
-
-

sludge).

cement
         (77, of dry solids) and sodium silicate (2% of dry solids).
         The amount of dry solids in the scrubber effluent for disposal.
         The amount of wet material that is actually ponded or landfllled, i.e., 50£ solids sludge for untreated baae case and material placed in landfill in IUCS caaea.
         New 500-MH plant (30-yr life); 7,000 hr/yr on-stream time; Midwest plant location; mid-1980 costs; limestone process with 1.5 stoichiometry based on S02 removed; coal analysis (by wt):  3.57. S (dry basis),
         167. ash; S02 and flyash removed to meet NSPS.

-------
 TABLE 33.   SUMMARY - LIFETIME REVENUE REQUIREMENTS FOR ALL  PROCESSES

      (ACTUAL AND DISCOUNTED  CUMULATIVE TOTAL AND UNIT VALUES3)
Cumulative
actual
net
increase.
Lifetime average increase
in unit revenue
requirements

in revenue
Caseb
Untreated
200 MW
500 MW
1500 MW
Dravo
200 MW
500 MW
1500 MW
IUCS
200 MW
500 MW
1500 MW
Chemfix
200 MW
500 MW
1500 MW
requirements , $

58,750
97,757
203,309

94,392
175,764
375,002

89,013
131,224
254,498

111,241
167,942
333,190

,000
,800
,200

,200
,900
,700

,000
,200
,000

,300
,300
,900
Mills/kWh

2.30
1.53
1.06

3.70
2.76
1.96

3.49
2.06
1.33

3.36
2.63
1.74
$/ton
dry
solids

19.40
13.22
9.18

29.03
22.06
15.69

28.33
17.09
11.05

35.25
21.78
14.41
$/ton
wet
solids

9.70
6.61
4.59

14.52
11.03
7.84

17.24
10.40
6.73

21.02
13.30
8.58
Cumulative present
worth net
increase
in
Levelized increase
in unit
revenue requirements

revenue
requirements, $

20
33
69

33
62
133

30
45
88

38
59
119

,204
,612
,819

,368
,052
,456

,584
,381
,798

,655
,099
,154

,800
,100
,400

,200
,600
,200

,100
,700
,600

,100
,300
,500
Mills/kWh

2.03
1.35
0.94

3.36
2.50
1.79

3.08
1.83
1.19

3.89
2.38
1.60
$/ton
dry
solids

6.67
4.55
3.15

10.26
7.79
5.58

9.73
5.89
4.33

12.25
7.67
5.15
$/ton
wet
solids

3.34
2.27
1.58

5.13
3.89
2.79

5.92
3.58
2.64

7.31
4.68
3.07
Basis
  Over previously defined power plant operating  profile;  30-yr life;  7,000 hr   10 yr, 5,000 hr   5
  yr, 3,500 hr - 5 yr,  1,500 hr - 10 yr; Midwest plant location, 1980 revenue requirements;  constant
  labor cost assumed over life of project.
New plants, coal analysis (wt %) :  3.5%S  (dry),  16%  ash; flyash  removed with S02 to meet NSPS.
Discounted at 10% to initial year.
Equivalent to discounted process cost over life  of power plant.
                                           89

-------
        TABLE 34.   ANNUAL REVENUE REQUIREMENTS FOR SYSTEMS OPERATING

                     AT CONSTANT LOAD DURING 30-YR LIFE
Annual operating
                                 Annual revenue requirements, $
t ime , hr
5,000
5,000
5,000
7,000
7,000
7,000
Case
200 MW
500 MW
1500 MW
200 MW
500 MW
1500 MW
Untreated
2,156,300
3,552,600
7,361,700
2,519,700
4,276,500
9,052,500
Dravo
3,562,100
6,421,300
13,692,300
4,124,700
7,718,200
17,049,900
IUCS
3,423,600
4,958,200
9,427,200
3,586,900
5,340,200
10,555,200
Chemfix
4,391,400
6,247,000
12,166,100
4,548,700
7,037,800
14,511,100

a.
New plants operating 30 yr,  Midwest plant location, mid-1979 costs; coal
analysis (wt %):   3.5% S (dry),  16% ash;  flyash removed with S02 to meet
NSPS; limestone  scrubbing FGD process.
                                     90

-------
         TABLE  35.   SUMMARY - LIFETIME REVENUE  REQUIREMENTS  FOR

  SYSTEMS OPERATING AT CONSTANT LOAD OF  5,000  HR/YR  DURING  30-YR LIFE

          (ACTUAL AND DISCOUNTED CUMULATIVE TOTAL AND UNIT VALUES3)
Cumulative
actual
net
Lifetime average increase
in unit revenue
requirements
increase

Caseb
Untreated
200 MW
500 MH
1500 MW
Dravo
200 MW
500 MW
1500 MW
IUCS
200 MW
500 MW
1500 MW
Chemfix
200 MW
500 MW
1500 MW
in revenue
requirements , $

68,635
113,972
238,074

111,652
202,043
432,232

105,897
154,682
297,631

135,579
194,309
382,117

,900
,700
,400

,500
,900
,700

,500
,700
,200

,800
,700
,300
Mills /kWh

2.29
1.52
1.06

3.72
2.69
1.92

3.53
2.06
1.32

4.52
2.59
1.70
$/ton
dry
solids

19.57
13.10
9.13

29.19
21.55
15.37

28.64
17.13
10.98

36.52
21.42
14.04
$/ton
wet
solids

9.63
6.55
4.57

14.60
10.78
7.68

17.42
10.42
6.68

21.78
13.08
8.37
Levelized increase
Cumulative present in unit
worth net revenue requirements'1
increase in
revenue
requirements, $°

22
37
78

35
63
135

31
45
88

40
57
112

,269,300
,296,900
,056,500

,498,100
,826,800
,328,300

,497,700
,980,100
,019,300

,359,100
,798,000
,489,900
Mills /kWh

2
1
1

4
3
2

3
2
1

4
2
1

.68
.80
.25

.28
.08
.17

.79
.22
.41

.86
.79
.81
$/ton
dry
solids

6.25
4.29
2.99

9.28
6.81
4.81

8.52
5.09
3.25

10.87
6.37
4.13
$/ton
wet
solids

3.13
2.14
1.50

4.64
3.40
2.41

5.18
3.10
1.98

6.48
3.89
2.46
a.  Basis
     Midwest plant location, 1980 revenue requirements;  30-yr life; 5,000 hr/yr; 150,000 hr  total
     operating time.
b.  New plants, coal analysis (wt %); 3.5% S  (dry),  16% ash; flyash removed with S02 to meet  NSPS.
c.  Discounted at 10% to initial year.
d.  Equivalent to discounted process cost over life  of power plant.
                                           91

-------
            TABLE 36.   SUMMARY - LIFETIME REVENUE REQUIREMENTS  FOR

     SYSTEMS OPERATING AT CONSTANT LOAD  OF 7,000 HR/YR DURING  30-YR  LIFE

           (ACTUAL AND  DISCOUNTED  CUMULATIVE TOTAL AND UNIT VALUES3)




Caseb
Untreated
200 MH
500 MW
1500 MW
Dravo
200 MW
500 MW
1500 MW
IUCS
200 MW
500 MW
1500 MW
Chemflx
200 MW
500 MW
1500 MW
Cumulative
actual
net
increase
in revenue
requirements, $

80,584,600
137,899,200
293,677,800

129,537,700
243,352,900
538,992,900

111,398,500
167,635,400
335,937,400

140,934,100
219,892,700
457,926,200
Lifetime average increase
in unit revenue
requirements


Mills /kWh

1.92
1.31
0.93

3.08
2.32
1.71

2.65
1.60
1.07

3.36
2.09

$/ton
dry
solids

16.16
11.32
8.05

24.19
18.54
13.69

21.52
13.26
8.85

27.12
17.32
12.02
$/ton
wet
solids

8.08
5.66
4.02

12.10
9.27
6.84

13.10
8.06
5.38

16.17
10.58
7.16
Cumulative present
worth net
increase in
revenue
requirement, $

26,228,200
45,197,300
96,399,600

41,066,500
76,570,300
167,889,600

33,019,700
49,563,800
98,617,900

41,840,600
64,876,200
133,464,500
Levelized increase
in unit v
revenue


Mills/kWh

2.26
1.56
1.11

3.53
2.64
1.93

2.84
1.80
1.25

3.60
2.23

requirements
$/ton
dry
solids

5.26
3.71
2.64

7.67
5.83
4.26

6.38
3.92
2.60

8.04
5.11
3.50
$/ton
wet
solids

2.63
1.86
1.32

3.83
2.92
2.13

3.88
2.38
1.58

4.80
3.12
2.09
a.   Basis
     Midwest plant location, 1980 revenue requirements;  30-yr life; 7,000 hr/yr;  210,000 hr total
     operating time.
b.   New plants, coal analysis (wt 7,) ;  3.5% S (dry), 16% ash; flyash removed with SO, to meet NSPS.
c.   Discounted at  10% to initial year.
d.   Equivalent to  discounted process cost over life of power plant.
                                            92

-------
SENSITIVITY  ANALYSES

     The sensitivities of variations of several process and plant parameters
were studied.   The effects of these variables on total capital investment and
revenue requirements are discussed in the following paragraphs.

Power Plant  Size

     Figures 14 and 15 show the relationships between power plant size and
total capital investment and total annual revenue requirements for new plants.
Figures 16-21 show the effect of plant age and power plant size on total
capital investment and total annual revenue requirements.  The untreated pond
disposal alternative becomes the most favorable alternative (capital invest-
ment) as the remaining life of the plant is decreased.  Total annual revenue
requirements are the least for the untreated disposal alternative in every
case (new,  existing, etc.).  Dravo ponding becomes more desirable (not most
desirable) with respect to other processes as the remaining life of the plant
is decreased.   Figure 22 shows the effects of plant size on unit capital
investment  and for a new plant.  For the same cases the annual unit revenue
requirements for new plants are shown in Figures 23-26.  The effect of plant
size on levelized unit revenue requirements (mills/kWh) is shown in Figure 27.

     The total capital and annual revenue requirements are increased for
plants operating at constant annual loads over their 30-yr life.  Figures 28-
31 show the  effects of these variations on total capital investment and annual
revenue requirements for 200-, 500-, and 1500-MW new plants.

Sludge Rate

     Several of the case variations considered in this study involved primarily
a change in the sludge rate from the FGD system.  The unit revenue require-
ment ($/ton  of dry solids for disposal) was calculated for a range of sludge
production  rates.  Figures 32 and 33 show these values.  The economics of
scale is known to be significant up to about 200 tons dry solids/hr.

S Content in Coal

     The effect of S content in coal on total capital investment is shown
in Figure 34.   Figure 35 shows relationship between S in coal and annual
revenue requirements.

Ash in Coal

     Figures 36 and 37 show the relationship between the percent ash in
coal and total capital investment and annual revenue requirement.

Independent  Flyash Removal

     Disposal systems were estimated for new 200-, 500-, and 1500-MW plants
that removed only S02 in the FGD system (flyash was removed with an ESP and
handled separately from S02 sludge for disposal)-  The total capital invest-
ment and annual revenue requirements for these systems are shown in Figures
38 and 39 as functions of power plant size.  Ash handling and  disposal costs
are not included for these cases.

                                    93

-------
  50
 :30
UJ
z:
h-
to
 ,20
Q.
<
        O  UNTREATED
        •  DRAVO
        A  IUCS
        X  CHEMFIX
                              I
                            I
            250     500      750       1000
                         POWER PLANT SIZE, f,
                                  1250
               1500
    Figure 14.  All processes.   Effect  of power  plant size  on
               total capital  investment.   New plants.
  15
  12
 z
 UJ
 ce

 i 9
 UJ
 CXI
   6-
   3}-
        O
        •
  I        I
UNTREATED
DRAVO
IUCS
CHEMFIX
                     I
                   I
I
            250       500      750     1000
                        POWER PLANT SIZE,  M
                                   1250
                1500
        Figure 15.   All processes.  Effect of power plant
      size on total  annual  revenue requirements.   New plants,
                               94

-------
  50
  30
_l
<
^20
<
(-
o
  10
             I
        ° UNTREATED
        • DRAVO
        A IUCS
        x CHEMFIX
                              I
                 I
            250      500      750      1000
                       POWER PLANT SIZE, MW
                        1250
 1500
    Figure 16,  All processes,   Effect of  power plant  size on
        total capital investment.  Existing plant with
                       with  25-yr remaining life.
  50
LU
£
I-
C/>
_i
<
  30
  20
_i
i-
o
  10
             I
        O UNTREATED
        • DRAVO
        A IUCS
        x CHEMFIX
I
                     I
        I
            250      500      750      1000
                       POWER PLANT SIZE, MW
                        1250
1500
 Figure  17.   All processes.  Effect of power  plant size  on
       total capital  investment.   Existing plant with
                  20-yr remaining  life.
                                  95

-------
  50
  30
  20
i-
o
  10
       	1	
       O UNTREATED
       • DRAVO
       £ IUCS
       * CHEMFIX
                     I
                      I
                                      I
           250      500      750       1000
                      POWER PLANT SIZE, MW
                                      1250
1500
 Figure  18.   All processes.   Effect  of power plant size on
       total capital  investment.   Existing plant with
                  15-yr  remaining  life.
 15
5£L2
 - 9
 o
 LU
cc
 LU
 OJ r
 > 6
 UJ
 <
 z

-------
  15
  12
LU
UJ
o:

i
LU
111


I
     I        \
O  UNTREATED
•  DRAVO
A  IUCS
x  CHEMFIX
                                       J_
             250      50Q       750      1000
                         POWER  PLANT SIZE,  MW
                                      1250
       1500
      Figure  20.   All processes.  Effect  of power plant  size
       on total annual revenue requirements.   Existing plant
                     with  20-yr remaining  life.
           °  UNTREATED
           *  DRAVO
              IUCS
           x  CHEMFIX
              250
              500      750      1000
                POWER  PLANT SIZE, MW
1250
1500
       Figure 21.   All processes.   Effect of  power plant  size
        on total  annual revenue  requirements.   Existing plant
                      with 15-yr  remaining life.
                                   97

-------
  100
1  80
•*/»•
   60
 <
 £ 40
   20
    0
             1
    	1
     O UNTREATED
     • DRAVO
     £ 1UCS
     x CHEMFIX
         1
                 1
      0
250
500
                                               1250
                                           1500
                         750      1000
                      POWER PLANT SIZE, MW
Figure  22.   All processes.   Effect of power plant  size
     on unit capital investment.   New plants.
  LU
  S 3
  LU

  LU
    0
              I
          O UNTREATED
          • DRAVO
          A IUCS
          * CHEMFIX
              I
          I
         I
                                  I
                                           I
I
      0
250
                        1250
                                                  1500
                500       750     1000
                   POWER  PLANT SIZE, MW

Figure  23.   All processes.   Effects of  power plant size
  on annual unit revenue requirements.   New plants.
                             98

-------
 o
 H-
 ^.
 *»

  ^
 
  20
  E12
 tu
 ce
  ai
  >
  LU
                      I

                  ° UNTREATED
                  • DRAVO
                  A 1UCS
                  x CHEMFIX
                               i.
     0       250      500       750     1000     1250      1500

                         POWER PLANT SIZE, MW


     Figure  24.  All  processes.   Effect of  power plant size

        on annual unit  revenue  requirements.   New plants.
 o
00



I  32
   ...

   16
OL


3
<3
LU
ex:
«t


I   o
    I

0 UNTREATED
• DRAVO
           CHEMFIX
                       I
                      I
J_
            250      500       750      1000
                        POWER PLANT SIZE, MW
                                      1250
                1500
    Figure  25.  All  processes,   Effect  of power plant size

       on annual unit revenue  requirements.  New  plants.

                                  99

-------
2 20
_j
o


I—
LLJ


"z 16
O
  12
a
UJ
UJ
>
                °  UNTREATED

                *  DRAVO

                *  IUCS

                x  CHEMFIX
            250      500      750      1000

                        POWER PLANT SIZE, MW
                                               1250
                1500
    Figure  26,   All processes,  Effect  of power  plant size

   on annual  unit revenue  requirements.   Existing plant with

                   25-yr  remaining life.
  z
  LLJ
  c
  UJ
  I
  UJ
    i
  Q
  UJ
  SI
    0
             T
             J_
                 	1—
                  O UNTREATED
                  % DRAVO
                  A IUCS
                  X CHEMFIX
                 T
                               _L
_L
_L
                                                    J_
     0
             250
        1250
        1500
                 500      750      1000

                     POWER PLANT SIZE, fill

Figure  27.   All processes.  Effect of power plant  size

 on  levelized unit revenue requirements.   New plants,

                             100

-------
  60
i-
z
UJ
UJ
_l
<
   36
z  24
<
   12
   0
     0
             1
         ° UNTREATED
         • DRAVO
         A IUCS
         x CHEMFIX
              I
         I
I
I
                                                    I
250
      1250
       1500
                 500      750      1000
                    POWER PLANT SHE, MW
Figure  28.   All processes.  Effect of  power plant size  on
     total  capital investment.  New plant,  operating
    constant 5,000 hr/yr  throughout its  30-yr life.
    15
  UJ
  111
  a:
  a
  UJ
 Qi

  _l
  <
  t-
  o
    o1
         ° UNTREATED
         • DRAVO
         A IUCS
         x CHEMFIX
                      I
                  I
             250      500      750     1000
                        POWER PLANT SIZE, Ml'
                                 1250
               1500
    Figure 29.   All processes.   Effect of  power plant size  on
     total annual revenue  requirements.   New plant operating
       constant 5,000 hr/yr throughout its 30-yr life.
                               101

-------
  75
  60
 ^J
>
z

<
!E3oi_
<
»—
o
  15
     O UNTREATED
     • DRAVO
     A IUCS
     x CHEMFIX
                    1
           150      500      750      1000
                       POWER PLANT SIZE, f!W
                                          1250
1500
  Figure 30.   All processes.   Effect  of  power plant  size on
       total capital investment.  New  plant operating
       constant 7,000 hr/yr throughout  its  30-yr life.
  25
  20
  ._
  15
3 10
01
cc:
_i
<

I  5
          I        I
     ° UNTREATED
     * DRAVO
     A IUCS
     x CHEMFIX
                                     1
                                                     1500
 0      250       500      750      1000     1250
                     POWER PLANT SIZE,  MW
Figure  31.   All processes.   Effect of  power plant size on
 total  annual revenue requirements.  New  plant, operating
     constant 7,000 hr/yr  throughout its  30-yr life.
                             102

-------
  30
U)
a
z
o
            DRAVO
   18
 .
01
E:
in
a:
 S
a:
 z
 LU
                      1
1
 I
1
             25      50        75       100       125     150

                   DRY SLUDGE (100% SOLIDS) FOR DISPOSAL, TONS/HR
                                   175
                          200
            Figure 32.   Untreated  disposal  and Dravo processes.

         Effect of sludge rate on  annual unit revenue  requirements.
  330,.
  Q
 00


  c:



  a
  h-
 —
 *<>

  •%
  
-------
  50
  30
Iz 20
  10
	1	
 o UNTREATED
 • DRAVO
 A IUCS
 x CHEMFIX
                             I
                               I
    01234         56
                 S IN COAL,  I BY WT (DRY BASIS)

    Figure 34.  All  processes.  Effect of  S  content
 of  coal on total  capital investment.  New 500-MW plant.
  15,
 39
 o
 LU
ce
 LU
 ID
 O
 •
            I         I
          UNTREATED
          DRAVO
          IUCS
          CHEMFIX
                    _L
                      _L
o
 0       1        2        3        4        5
              S IN COAL,  I BY WT  (DRY BASIS)
Figure  35.   All  processes.  Effect of S content
 of coal  on total annual revenue requirements.
                New  500-MW plant.
                            104

-------
    50
    30
  <
  I-

  £20
    10
- 1 —

 o UNTREATED
 • DRAVO
           CHEMFIX
               I
                       I
              12       14       16       18

                ASH IN COAL, % BY WT (WET BASIS)
                                       20
     Figure 36.   All processes.  Effect  of ash in  coal

      on total  capital investment.  New  500-MW plant.
  UI


  36

  a
  UJ
  a:

  UJ

  z


  >  4
  UI  4
  a:
  Z
  «=C
  £
               I

          O  UNTREATED

          *  DRAVO

          A  IUCS

          x  CHEMFIX
               I
                               I
1
             12       14       16       18       20

                ASH  IN COAL, % BY WT (WET BASIS)


    Figure 37.  All processes.   Effect  of ash in  coal

on total annual revenue requirements.   New 500-MW plant.
                             105

-------
  50
  39
  10
        o UNTREATED
        • DRAVO
        A IUCS
        * CHEMFIX
                    _L
                                     _L
     0
   250
      1250
1500
                 500      750      1000
                    POWER PLANT SIZE, HW
Figure 38.   All  processes.  Effect of size  of  power plant
 having a  separate ash disposal  system on total capital
  investment for sludge disposal systems.   New plants.
  15
  12
C£.

LU
O
Z   3
O UNTREATED
• DRAVO
A IUCS
X CHEMFIX
                      I
                      I
I
     0       250      500      750      1000
                        POWER PLANT SIZE, MW
                                      1250
                1500
  Figure  39.   All processes.   Effect of size of power plant
       having  a separate ash  disposal system on total
    annual  revenue requirements for sludge  disposal systems,
                          New  plants.
                                 106

-------
Distance to Disposal Site

     Estimates were made for case variations in which the distance from the
scrubber facilities was increased over the basic premise of 1 mi.  Figures
40 and 41 show the variation with distance on total capital investment and
annual revenue requirements.  Transport lines (rubber-lined piping) are used
for sludge transport in the untreated, Dravo, and Chemfix cases.  Trucks are
used for transport of material for landfill using the IUCS process.  Figures
42 and 43 show the effects of sludge transport mode on total capital invest-
ment and annual revenue requirements (untreated sludge) for the range of
disposal distances.  Transport by truck is the least expensive capital invest-
ment method of transporting sludge at all distances (Figure 42).  The distance
to the disposal site determines if the solids content of the sludge should be
increased in a thickener before pumping to the pond.  Above a distance of
about 3 mi, the capital investment of a system for pumping a 15% solids slurry
is less than that of a system for pumping a 35% solids slurry (Figure 42) .

Plant Remaining Life

     The remaining life of a power plant when the FGD and sludge disposal
system is installed has an effect on total capital investment and annual
revenue requirements.  An older plant that operates a shorter period of
time will require a smaller acreage for the disposal pond or landfill.
Capital charges are higher than that of a new plant due to depreciation.
Figures 44-49 show the relationship between plant remaining life and the
total capital investment and annual revenue requirements.

Optimum Pond Cost

    A computer program was used for calculating optimum pond construction
cost with respect to depth and area.  For each sludge disposal rate, the
optimum pond was estimated based on 1979 costs.  Also, the amount of excava-
tion and total depth and acreage of the pond were calculated.  Since land
availability may limit the acreage on which a pond can be constructed,
estimates were made for the two systems (untreated ponding and Dravo process)
that use ponds for disposal, with pond acreage held at 50 and 75% of optimum.
These results are shown in Figures 50-53 as functions of new plant sizes.
Pond construction cost is greatly increased (122% for Dravo 500-MW plant)
when the acreage is limited (50% of optimum), thereby increasing the excava-
tion depth over optimum.

Settled Sludge Density

     The base case assumption for settled sludge density in the disposal
pond is 50% solids.  There may be cases in which settled sludge density is
more or less than 50% solids.  Two case variations are included for untreated
pond disposal for settled densities of 40% solids and 60% solids.  Figures
54 and 55 show the effect of settled density on total capital investment and
annual revenue requirements for disposal of untreated sludge from a new 500-
MW power plant.
                                   107

-------
  50
<" 30
UJ J{J
<
»—
o
  10
        O UNTREATED
        • DRAVO
        A IUCS
        X CHEMFIX
                                      _L
                                      _L
                      3579
                      DISTANCE TO DISPOSAL SITE, Mi
                                               11
       Figure  40.   All processes.  Effect  of distance to
        disposal site on  total capital  investment.   New
                        500-MW plant.
   15
  = 12
 UJ

 I 9
 o>
 UJ
     I
o UNTREATED
• DRAVO
4 IUCS
X CHEMFIX
             13579
                         DISTANCE TO DISPOSAL SITE, Mi
                                               11
       Figure  41.   All processes.  Effect of distance to
      disposal site on  total annual  tevenue requirements,
                           New 500-MW plant.
                                  108

-------
  50
LU
>
  20
  10
             I         I
        ° TRUCK
        • PUMP, 35% SOLIDS
        A PUMP, 15% SOLIDS
                      I
         I
I
     0       2        4        6        8       10
                     DISTANCE TO  DISPOSAL  SITE, Mi

    Figure 42.   Untreated process.  Effect  of  distance
      to disposal site and mode of transport on total
          capital investment.   New 500-MW plant.
  10
 cs
 LJJ
 DC.
 LU
 >
cc:

 =c
             I         I        |
         O PUMP, 35% SOLIDS SLURRY
         • TRUCK
         A PUMP, 15% SOLIDS SLURRY
                      I
         I
I
46         8
DISTANCE TO DISPOSAL SITE,
                                               10
                12
   Figure 43.  Untreated process.   Effect of  distance
      to disposal  site and mode  of  transport on total
      annual revenue requirements.   New 500-MW plant.
                               109

-------
 50
  30
  20
  10
   0
       	1	
       O UNTREATED
       • DRAVO
       A IUCS
       X CHEMFIX
                                      I
I
           25               20                 15
                    REMAINING PLANT LIFE, YR
 Figure 44.   All processes.   Effect of  remaining plant
   life on  total capital  investment.  200-MW plant.
  50
  30
UJ
>
<
s: 20
  10
            1
        o UNTREATED
        • DRAVO
        A IUCS.
        x CHEMFIX
            25               20
                    REMAINING PLANT  LIFE,  YR
15
 Figure  45.   All processes.  Effect of remaining plant
   life  on total capital investment.   500-MW  plant.
                             110

-------
  50
   30
 <

 I 20
 CJ
   10
 o UNTREATED
 • DRAVO
 A IUCS
 X CHEMFIX
             25               20
                    REMAINING PLANT LIFE,  YR
                                      15
Figure 46.  All  processes.   Effect of  remaining plant
  life on total capital investment.  1500  MW-plant.
   15
    12
  UJ
  oc.
  <
  =)
  z
  z
  «=c
O  UNTREATED
•  DRAVO
A  IUCS
x  CHEMFIX
             25
                     20
              REMAINING PLANT LIFE, YR
15
  Figure  47.   All processes.  Effect of remaining plant
life on total annual  revenue requirement.   200-MW plant.
                             Ill

-------
 a:

 = 9
 <3
 UJ
 en

 LU
 >
 LLJ
 ct:
       	1	

        ° UNTREATED
        * DRAVO
        A IUCS
        x CHEMFIX
             25                20
                    REMAINING PLANT LIFE, YR
                                      15
   Figure  48.   All processes.  Effect of remaining

   plant life on total  annual revenue requirements.

                    500-MW plant.
  30
LJJ
£
UJ

£ 18
n
a
LJ
  12
        	1	
        o UNTREATED

        * DRAVO

          IUCS

          CHEMFIX
             T
T
T
T
A

X
             25              20

                     REMAINING PLANT LIFE, YR
                                      15
   Figure 49.  All  processes.   Effect of  remaining

   plant  life on  total annual  revenue requirement.

                   1500-MW plant.
                            112

-------
 100
  30
•z.
UJ
UJ
>
  60
_l
<
H
<
I—
O
   20
              I         I

            50Z OPTIMUM ACREAGE

            OPTIMUM ACREAGE
            75% OPTIMUM ACREAGE
                                I
             250       500       750       1000

                         POWER  PLANT SIZE, MW
1250
 1500
     Figure 50.  Untreated process.  Effect of available pond

     acreage and power plant  size on total capital  investment.
   10
 a
 UJ
 UJ  i)

 UJ


 _l
 <



 I  2
          O 50% OPTIMUM ACREAGE

          • OPTIMUM ACREAGE
          ^ 75% OPTIMUM ACREAGE
             250       500       750     1000

                          POWER PLANT SIZE, Mk
1250
1500
        Figure 51.   Untreated disposal.   Effect  of available

               pond acreage  and power  plant size on

                total annual revenue requirements.

                                   113

-------
  100
   60
>
z
<
I—
CL
   20
         O 50% OPTIMUM ACREAGE
         • OPTIMUM ACREAGE
         A 75% OPTIMUM ACREAGE
                      _L
          I
                               I
             250      500      750       1000
                           POWER PLANT SIZE, P
                          1250
                                               1500
        Figure 52.  Dravo process.   Effect  of available pond
     acreage  and power plant size  on total  capital  investment,
   20
LU

I  15
a
LU
   10
Z
Z
•=c
              I        I
         O  50% OPTIMUM ACREAGE
         •  OPTIMUM ACREAGE
         A  75% OPTIMUM ACREAGE
                      -L
        _L
                              1
1
J_
             250
500
                                               1250
                                  1500
                     750      1000
                 POWER  PLANT SIZE, Ml
Figure  53.   Dravo  process.   Effect  of available pond
    acreage and power plant  size on total annual
             revenue requirements.

                         114

-------
  50
   40
 CO
 LU
   30
 1= 20
 O-
   10
                              I
I
             40               50              60
                     SETTLED DENSITY, % SOLIDS

    Figure 54.  Untreated process.  Effect of  settled
  density in disposal pond on total capital investment,
                     New 500-MW plant.
  50
g 40

CO
I-
z
LU

I 30

a
UJ
oz
LU

1 20
 <

I 10
                                              T
            40               50
                    SETTLED DENSITY, % SOLIDS
       60
    Figure 55.  Untreated process.  Effect of settled
    density in disposal pond on total  annual revenue
            requirements.  New 500-MW  plant.
                         115

-------
 Pond Liners

      The cost of constructing a disposal pond is partially dependent upon
 the type of  liner used.   Figures 56 and 57 show the relationship between
 cost of pond lining and  total capital investment and total annual  revenue
 requirements.  The estimates are for direct ponding of untreated  (15% solids
 slurry) sludge from a new 500-MW (base case) plant.  The liner  costs used in
 these estimates represent a range of costs obtained from vendors for synthetic
 lining materials (Hypalon, polyethylene, etc.).

 Stabilization Additive Rate

      A standard rate for stabilization additive was specified by each of
 the three process companies (Dravo, IUCS, Chemfix).  One set of case varia-
 tions considered was for additive rates above and below the standard rates.
 The effect of these variations on the total capital requirements and annual
 revenue requirements is  shown in Table 37.  The rate deviations considered
 were based on changes that have equivalent effects on the stabilization proc-
 ess (time for stabilization, required dewatering, handling properties, etc.).

 Ponding versus Landfill  - Dravo Process

      Estimates were made for a variation of the Dravo process that involves
 intermediate ponding of  treated sludge in a small 2-wk-capacity holding pond
 for curing (15-30 days)  before transport by truck to a landfill for disposal.
 Three small ponds located near the scrubber facilities are used for a con-
 tinuous, cyclic operation:  filling, curing, and emptying.  A comparison of
 this disposal alternative with the base Dravo process of ponding is shown
 below.  (The quantity—new 500-MW plant—of sludge being treated is the
 same for both alternatives.)

                                    Total capital   Annual revenue
                                     investment,     requirements,
             Case variation	k$	k$	

         Intermediate ponding and
          trucking to landfill         12,670          6,620
         Standard Dravo ponding        24,114          6,701


Truck versus  Pipeline Transport - Chemfix

     All cases for the Chemfix process involve the pipeline transport of 35%
solids slurry from a thickener near the scrubber facilities to the  disposal
area where the final stages of treatment by the Chemfix process  are applied.
The 35% solids slurry is  filtered to form a material containing  60% solids
and mixed with fixation additives before placement and compaction in a land-
fill with earthmoving equipment.
                                    116

-------
  80
  60
<
H
o_
 |20
  10
            1        2        3       /:        5
                     POND LINER COST, $/Yo2

   Figure  56.   Untreated process.   Effect of unit cost
    of  pond liners on total  capital investment.  New
                     500-MW plant.
 a
 LU
 >
 LU ,
 Cd '
 _J
 <
 ^
 z
 5
 i-
 o
            T
T
T
T
                    1
                1
            12345
                     POND LINER COST, $/Yo2

   Figure  57-   Untreated process.   Effect of unit cost
   of pond liners on total annual  revenue requirements.
                   New 500-MW plant.
                            117

-------
            TABLE 37.   EFFECT OF STABILIZATION ADDITIVE RATE

       ON TOTAL CAPITAL INVESTMENT AND ANNUAL REVENUE REQUIREMENTS


                        Additive         Capital         Revenue
       Treated           amount,       investment,    requirement,
    sludge process   % of dry solids	k$	k$
	 , 	 J^ 	 1- 	
Dravo
Dravo
Dravo
IUCS
IUCS
IUCS
Chemfix
Chemfix
Chemfix
\
T
10
3b
4D
5,
7b,c
12
22
23,120
24,114
25,209
10,302
10,717
10,748
13,531
14,757
16,270
6,052
6,701
7,577
4,994
5,291
5,511
6,988
10,089
13,651

    a.   Base case with additive amount variations.
    b.   Base case additive amount.
    c.   Fixation will not occur below this amount of additive.
     An alternative of treating the filter cake at the scrubber facilities
and trucking the treated sludge to the disposal area was also considered  as
a case variation.   The following costs are for the Chemfix base case and  the
truck transport variation.

                                Total capital   Annual revenue
                                 investment,      requirements,
             Case  variation	jc$	k$	

           Truck transport          11,740           6,698
           Pipeline transport       13,531           6,988
                                   118

-------
                    CONCLUSIONS AND  RECOMMENDATIONS
     The conclusions derived  from data  generated  in this  study  are divided
into  three categories.  One category  is  for  conclusions concerning the
economic comparisons of disposal  process alternatives.  The second category
deals with the effects of  case variations for  each  of  the disposal process
alternatives.  The  third category summarizes the  recommendations  for  future
studies needed to provide  a complete  evaluation of  sludge disposal options.
The three categories are discussed in this section  of  the report.
ECONOMIC COMPARISONS OF PROCESS ALTERNATIVES

     Economic  comparisons.are  significant  among  both  capital  investments
and revenue requirements  for the  four  disposal process  alternatives.   The
following is a listing of  conclusions  that can be  derived  from the comparison
of costs.

Capital Investments

   1.  The disposal alternative for  a  new  500-MW plant  (base  case) requiring
      the lowest  capital  investment is  the IUCS process  for  fixation and
      landfill disposal.   The Dravo process  for treatment and pond disposal
      was the most capital intensive  alternative.

   2.  The remaining life  of a power plant has a significant  effect on the
      relative ranking of capital investment requirements for two of the
      four disposal alternatives being  evaluated  (untreated  and  Dravo).
      For a 500-MW plant  with 15 yr remaining life  (otherwise base case
      conditions), the untreated pond disposal  alternative is the least
      expensive,  followed by  the IUCS process.  The  Dravo process is again,
      as for  the  base case conditions,  the most expensive.   These results
      are illustrated in  Figures 16-18  and 44-46.

   3.  The ash and S contents  of  the coal  burned have a significant effect
      on the  capital investment  required  for the  disposal system.  The
      relative ranking of the four  alternatives,  however, remains unchanged
      for the concentration ranges  considered  (Figures 34-37).

   4.  As would be expectedj the  cost  of disposal  systems  for 500-MW plants
      with sludge containing  no  flyash  are considerably  less expensive,
      because of  the smaller  quantities of material  to be processed, than
      the cost of systems in  which  the  flyash is  removed  with the calcium
                                  119

-------
       sludge.   The relative ranking of capital investments  for the four
       alternatives is the same as for base case systems.  The ranking, how-
       ever,  is changed for the 200-MW (no flyash) plants  with the untreated
       pond disposal option being the least expensive.   This change in rank
       reflects the effect of variation in economy of  scale  among the systems
       on capital investments (Figures 38-39).

   5.   The distance to the disposal site greatly increases the capital invest-
       ments  for the untreated, Dravo, and Chemfix alternatives.   These
       increased values are primarily a result of the  additional  cost for
       pipelines and pumps.  The capital investment  for  the  IUCS  system is
       affected very little by the distance to the disposal  site  because
       little additional equipment is needed.  Operating costs are increased
       significantly (see Figures 40-43).  Trucks are used  for sludge transport.

   6.   Variations in fixation additive amounts have  little effect on capital
       investments for the IUCS and Dravo processes.   Equivalent  (additive
       amount variations having similar effect on degree and rate of fixation)
       variations for the Chemfix process cause the  capital  investment require-
       ments  to be significantly changed.

   7.   Case variations for disposal of sludge in ponds constructed on con-
       strained acreage (less than optimum based on  land and construction
       costs) have higher total capital investments  than the optimum (base
       case)  pond acreage.  These variations show the  potential problems for
       plants with a limited quantity of land available  for  ponding (therefore
       forced to make ponds deeper with higher dikes).

Annual Revenue Requirements

   1.   Base case revenue requirements for a new 500-MW plant are  lowest for
       the untreated ponding alternative followed by the IUCS process.  The
       alternative requiring the highest annual revenue  is the Chemfix process.

   2.   The remaining life of a power plant affects the annual revenue require-
       ments for the disposal alternative because of lower depreciation and
       capital changes.  The relative ranking of revenue requirements for the
       four disposal alternatives is unchanged for existing  500-MW plants from
       that of a new 500-MW plant.  These rankings,  however, change for 200-MW
       plants.   Specific cost data can be obtained from  Appendix  A and Figures
       47^9 .

   3.   The quantity of sludge for disposal affects the annual revenue require-
       ments  such that the relative rankings for the four  alternatives may
       change,  especially for smaller quantities.  Variations in  coal compo-
       sition (S and ash) and the exclusion of flyash  in the sludge illustrate
       these effects.
                                    120

-------
      The distance to the  disposal  site has a significant effect on total
      annual revenue requirements as  illustrated in Figures 41 and 43.
      For 500- and 1500-MW plants using the untreated process, the least
      expensive alternative is  to pump the 15% scrubber system effluent
      directly to the disposal  pond and the most costly method of transpor-
      tation is to use  trucks to haul dewatered sludge.  For 200-MW plants,
      the opposite of the  above is  true and trucking is the least expensive
      alternative and pipeline  transport of 15% solids slurry is the most
      expensive.
EFFECTS  OF CASE VARIATIONS  FOR EACH ALTERNATIVE

     The effects  of  case  variations on total capital investments and annual
revenue  requirements  for  each disposal alternative are shown in Tables 38-41.

Untreated Disposal

Capital  Investment—
     A major  portion  of the capital investment required for untreated sludge
disposal cases is for the disposal pond.   Any variation causing a significant
change in the quantity of sludge to be ponded results in considerable change
in total capital  investment requirement.   Changes having this effect include
the remaining life of the plant, coal composition, scrubbing process, and
the density of settled sludge in the disposal pond.   An example of this
effect as shown in Table  38 is the 20% increase in capital investment for
a new 500-MW  plant burning  5% S coal as compared to the base case 3.5% S coal.

     The use  of synthetic pond liners for disposal ponds results in an increase
in total capital  investment for a new 500-MW plant over the base case.  For
the range of  costs for pond liners considered ($1.50-$4.50/yd-O , capital
investment as compared to the base case increases from about 22 to 55%.  The
capital  investment is 16% less for the case with an unlined disposal pond
than that for the base case.   The capital investment required for untreated
ponding  is significantly  reduced for disposal sites located in excess of
about 3  mi from the  scrubber facilities if the slurry is dewatered to 35%
solids with a thickener before pipeline transport to the pond.  Capital
investments are 46-52% less for the disposal of untreated, dewatered (60%
solids)  sludge in a  landfill following truck transport than for the base
system for pond disposal.   The distance to the disposal site has little
effect in capital investments for these systems.

Revenue  Requirements—
     Annual revenue  requirements for a 200-MW and a 1500-MW plant are 61 and
206% of  annual revenue requirements for the base case.  These values illus-
trate the economy of  scale  for untreated  disposal systems.  The annual
revenue  requirements  for  case variations  involving distances to the disposal
site are 69%  (5-mi case)  and 129% (10-mi  case) more than the base case
annual revenue requirements.   If the slurry is thickened (35% solids) before
pumping  to the disposal pond, the annual  revenue requirements are less for
                                   121

-------
TABLE 38.   EFFECT OF CASE VARIATIONS ON TOTAL CAPITAL INVESTMENT




      AND ANNUAL REVENUE REQUIREMENTS - UNTREATED DISPOSAL
Percent change
from base case
Variation from base case
200 MW new
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S in coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Lime scrubbing process
Clarify (35% solids) and pump 1 mi
Clarify (35% solids) and pump 5 mi
Clarify (35% solids) and pump 10 mi
Clarify, filter (60% solids) and truck 1 mi
Clarify, filter (60% solids) and truck 5 mi
Clarify, filter (60% solids) and truck 10 mi
200 MW, constrained pond acreage (50% of optimum)
200 MW, constrained pond acreage (75% of optimum)
Constrained pond acreage (50% of optimum)
Constrained pond acreage (75% of optimum)
1500 MW, constrained pond acreage (50% of optimum)
1500 MW, constrained pond acreage (75% of optimum)
Pond settled density (40% solids)
Pond settled density (60% solids)
Unlined pond
Synthetic pond lining ($1.50/yd2)
Synthetic pond lining ($2. 50 /yd2)
Synthetic pond lining ($3.50/yd2)
Synthetic pond lining ($4.50/yd2)
Capital
investment
-43
-51
-60
-68
-15
-34
-49
112
76
33
-13
-11
10
-22
20
-61
-34
37
56
117
6
7
45
83
-52
-49
-46
-26
-41
32
5
184
122
17
-12
-16
22
34
45
55
Annual revenue
requirement
-39
-44
-51
-56
-11
-26
-35
106
78
44
21
-12
10
-20
18
-54
-30
39
69
129
-4
13
58
97
16
50
77
-25
-38
26
3
174
115
14
-10
16
18
30
40
49
                                122

-------
TABLE 39.   EFFECT OF CASE VARIATIONS ON TOTAL CAPITAL INVESTMENT




         AND ANNUAL REVENUE REQUIREMENTS - DRAVO PROCESS

Percent change
from base case
Variation from base case
200 MW new
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S in coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate (Calcilox, 5% of dry sludge)
Fixation additive rate (Calcilox, 10% of dry sludge)
Lime scrubbing process
Intermediate ponding and truck to landfill
200 MW, constrained pond acreage (50% of optimum)
200 MW, constrained pond acreage (75% of optimum)
Constrained pond acreage (50% of optimum)
Constrained pond acreage (75% of optimum)
1500 MW, constrained pond acreage (50% of optimum)
1500 MW, constrained pond acreage (75% of optimum)
Capital
investment
-42
-45
-52
-58
-11
-24
-36
100
72
41
16
-11
8
-20
18
-49
-18
61
29
57
-4
5
-12
-48
-14
-28
56
29
234
168
Annual revenue
requirement
-46
-45
-48
-49
-5
-11
-15
113
106
90
81
-12
11
-21
20
-54
-24
56
21
40
-10
13
-8
-1
-34
-38
36
128
204
158
                                123

-------
TABLE 40.  EFFECT OF CASE VARIATIONS ON TOTAL CAPITAL INVESTMENT

         AND ANNUAL REVENUE REQUIREMENTS - IUCS PROCESS


                                                   Percent  change
                                                   from base case
       Variation from base case
 Capital
investment
Annual revenue
 requirement
200 MW new
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S in coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate (lime, 3% of dry sludge)
Fixation additive rate (lime, 5% of dry sludge)
Lime scrubbing process
-33
-31
-31
-32
-1
-3
-4
88
86
81
77
-13
12
-16
15
-32
-8
69
6
11
-4
0
-3
-33
-30
-30
-28
2
3
5
97
101
102
106
-14
13
-12
17
-34
-12
54
23
41
-6
5
-4
                               124

-------
TABLE 41.   EFFECT OF CASE VARIATIONS ON TOTAL CAPITAL INVESTMENT

        AND ANNUAL REVENUE REQUIREMENTS - CHEMFIX PROCESS


                                                   Percent change
                                                   from base case
        Variation from base case
 Capital
investment
Annual revenue
 requirement
200 MW
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S in coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate (Portland cement, 22% of dry
sludge)
Fixation additive rate (Portland cement, 12% of dry
sludge)
Lime scrubbing process
Transport by truck to disposal area
-32
-30
-31
-31
-1
-2
-3
78
77
72
69
-12
5
-18
10
-43
-25
35
49
99

20

9
-8
13
-35
-33
-32
-31
2
3
5
106
111
112
115
-11
9
-15
18
-46
-26
40
24
43

95

45
-11
-4
                                125

-------
the 5- and 10-mi cases as compared to the unthickened slurry.   These estimates
are 58% (5 mi) and 97% (10 mi) greater than  the  base case.   The 1-mi case is
more expensive (13%) for pumping the 35% solids  slurry than the base case
(15% solids slurry).  Truck transport of dewatered sludge (60% solids)  to a
landfill for disposal is more expensive than the base case for the 1-mi dis-
tance.  The 5- and 10-mi truck-transport case variations are less expensive
than the equivalent cases for pipeline transport (see Table 38).   Annual
revenue requirements for a 500-MW system increase with increasing constraints
on pond acreage, decreasing settled density  of pond solids, and increasing
cost of synthetic pond lining.

Dravo Process

Capital Investment—
     Capital investments are affected by the size of disposal  pond required
as with the untreated pond cases and therefore case variations with a smaller
pond  (quantity of sludge for disposal) require less capital investment.  The
Dravo process variation for intermediate ponding, truck transport, and  land-
fill disposal of treated sludge requires 47% less capital investment than
the base case (pond disposal).

Revenue Requirements—
     Remaining plant life affects revenue requirements very little.  The
distance to the disposal pond significantly  increases the revenue requirements.
The case for a 5-mi distance is 21% more than the base case and the 10-mi dis-
tance increases the costs by 40%.  The case  variations for changing the
amount of fixation additive result in a 10%  decrease in revenue requirements
below the base case requirements for one variation and a 13% increase for
the other variation.

     The revenue requirements for the Dravo  system for intermediate ponding,
truck transport, and landfill disposal are about the same (99%) as the  base
case.

IUCS Process

Capital Investment—
     The remaining life of the power plant has no significant  effect on
capital investment.  The quantity of sludge  for  disposal significantly
affects capital requirements and an economy  of scale exists.

     The IUCS process requires flyash for fixation and therefore capital
investments are increased for systems treating sludge that contains no fly-
ash.  Additional facilities are required to  add  flyash at the fixation facil-
ities.

     In all cases the sludge is transported  by truck to the landfill disposal
site and the capital investments are only slightly increased when  the distance
to the disposal site is increased to 5 and  10 mi (see Table 40).
                                    126

-------
     Changes  in  the  amount  of fixation additive have no significant effect
on the  capital investments.

Annual  Revenue Requirements—
     The  distance  to the disposal site increases the annual revenue require-
ments by  23%  for the 5-mi case and by 41% for the 10-mi case.

     Annual revenue  requirements are very slightly changed for case variations
considering the  changes in  additive rates and the remaining life of the plant.

Chemfix Process

Capital Investment—
     The  remaining life of  the power plant has no significant effect on the
capital investment for the  sludge disposal process.   As with other alter-
natives,  the  quantity of sludge affects the capital investment, but not as
significantly as the alternatives requiring a disposal pond.  The distance
to the  disposal  site causes the capital investment required for a new 500-MW
plant to  increase  49% when  increased from 1 to 5 mi and 99% when increased
to 10 mi.

     Increased amounts of fixation additives also significantly increase
the capital investment required.  When the amount of increase in additive
above the base case quantity results in a change in final sludge properties
and curing time  equivalent  to similar changes for other alternatives, the
capital investment is increased 20% above the base case capital investment.
The Chemfix case variation for truck transport of treated sludge from a new
500-MW plant  to  the disposal area (base case requires pipeline transport) is
less expensive  (13%) than the base case.

Annual  Revenue Requirements—
     Plant remaining life affects annual revenue requirements very little.
Annual  revenue requirements for case variations considering the increased
distances to  the disposal site are increased by 24% for the 5-mi case and
43% for the 10-mi  case.

     The  cost of increasing the amount of stabilization additive to change
final sludge  properties and the rate of stabilization such that the change
is equivalent to that considered for other processes results in a 95%
increase  in annual revenue  requirements.

     The  annual  revenue requirements for the case variation of truck transport
of treated sludge  to the disposal site are 4% less than the requirements for
the base  case.
                                   127

-------
RECOMMENDATIONS

     The evaluation of the four disposal alternatives  considered in this
study represents only a portion of the complete  economic  evaluation of  FGD
sludge disposal options.  The state of technology  for  sludge treatment  is
changing continuously and new options are available now that were not avail-
able when this study was started.  As a basic premise  for this study, the
four alternatives evaluated were considered to be  environmentally at^d eco-
nomically feasible.  Current or potential environmental regulations, as well
as more recent technology in FGD processes and disposal methods,  may preclude
the use of some alternatives from either an environmental or economic view-
point .

     Additional studies are therefore recommended  to evaluate current alter-
natives whose applications may pend further economic analysis and to reeval-
uate the economics of the disposal alternatives  in the  current study which
have had significant changes in process technology.  Examples of  these options
are disposal of gypsum in a landfill and the physical stabilization of FGD
sludge by blending or layering with flyash.
                                   128

-------
                               REFERENCES
1.   Crowe, J. L., and H. W. Elder.   Status  and Plans  for Waste  Disposal
    From Utility Applications of Flue Gas Desulfurization  Systems.
    In:  Proceedings of the Symposium on Flue Gas  Desulfurization,  New
    Orleans, Louisiana, March 1976.  EPA-600/2-76-136b  (NTIS  PB 262 722),
    May 1976.  Vol II, pp. 565-577.

2.   Leo, P. P. ,  and J. Rossoff.  Control of Waste  and Water Pollution  From
    Power Plant  Flue Gas Cleaning  Systems:  First  Annual R and  D Report.
    EPA-600/7-76-018 (NTIS PB 259  211), October  1976.

3.   Freas, R. C.  The Stabilization  and Disposal of Scrubber  Sludges -
    The Dravo Process.  Paper presented at  The American Petroleum Institute
    Committee on Refinery Environmental Control, Salt Lake City, Utah,
    September 1975.

4.   Lord, W. H.  FGD Sludge Fixation and Disposal.  Dravo  Corporation,
    Pittsburgh,  Pennsylvania, October 10, 1974.

5.   Taub, Steven I.  Treatment of  Concentrated Waste  Water to Produce
    Landfill Material.  Paper presented at  5th International  Pollution
    Engineering Exposition and Congress, Anaheim,  California, November 10,
    1976.

6.   Kleiman, Gerald.  Poz-0-Tec, A Practical Approach to Handling Flue Gas
    Scrubber Sludge.  In:  Proceedings of the American  Power  Conference,
    Chicago, Illinois, April 21-23,  1975.   Vol 37, pp.  816-824.

7.   Mullen, Hugh, Louis Ruggiano,  and Steven I.  Taub.   The Physical and
    Environmental Properties of Poz-0-Tec.  Paper  presented at  Engineering
    Foundation Conference ort Disposal of Flue Gas  Desulfurization Solids
    at Hueston Woods State Park, Ohio, October 17-22, 1976.

8.   IU Conversion Systems, Inc.  Poz-0-Tec  Process for  Economical and  Envi-
    ronmentally Acceptable Stabilization of Scrubber  Sludge and Ash.  Phila-
    delphia, Pennsylvania.

9.   Conner, Jesse R.  Ultimate Disposal of  Liquid  Wastes by Chemical Fixation.
    In:  Proceedings of the 29th Annual Purdue Industrial  Waste Conference,
    Purdue University, West Lafayette, Indiana,  May 7-9,  1974.   Part II,
    pp. 906-922.
                                   129

-------
10.   McGlamery,  G.  G.,  et al.   Detailed Cost Estimates for Advanced Effluent
     Desulfurization Processes.   EPA-600/2-75-006 (NTIS PB 242  541).
     January 1975.

11.   Jones,  J. W.   Research and Development for Control of Waste and Water
     Pollution From Flue Gas Cleaning Systems.  In:  Proceedings of the
     Symposium on  Flue  Gas Desulfurization, New Orleans, Louisiana, March
     1976.   EPA-600/2-76-136b  (NTIS PB 262 722), May 1976.  Vol II, pp. 579-
     604.

12.   Fling,  R. B.,  et al.  Disposal of Flue Gas Cleaning Wastes:  EPA Shawnee
     Field Evaluation—Initial Report.  EPA-600/2-76-070  (NTIS PB 251 876),
     March 1976.

13.   PEDCo-Environmental Specialists.  Flue Gas Desulfurization Systems:
     Summary Report.  November-December 1976.

14.   Sanning, D.  E.  Development of a Data Base for the Future Regulation
     of Flue Gas Desulfurization Sludge Disposal.  Paper presented at the
     ASME Winter Annual Meeting, Air Pollution Control Division, New York,
     December 1976.

15.   Holland, W.  F., et al.  The Environmental Effects of Trace Elements in
     Pond Disposal of Ash and Flue Gas Desulfurization Sludge.  EPRI 202
     (NTIS PB 252  090),  September 1975.

16.   Rossoff, J.,  and R. C. Rossi.  Disposal of Byproducts From Nonregener-
     able Flue Gas Desulfurization Systems:  Initial Report.  EPA-650/2-74-
     037a (NTIS  PB 237  114), May 1974.

17.   Princiotta,  F. T.   Sulfur Oxide Throwaway Sludge Evaluation Panel
     (SOTSEP), Vol II:   Final Report - Technical Discussion.  EPA-650/2-75-
     OlOb, (NTIS PB 242 619),  April 1975.

18.   Maloch, J.  L.   Chemical Fixation of FGD Sludges:  Physical and Chemical
     Properties.   In:  Proceedings of the Symposium on Flue Gas Desulfuri-
     zation, New Orleans, Louisiana, March 1976.  EPA-600/2-76-136b (NTIS PB
     262 722), May 1976.  Vol II, pp. 627-645.

19.   Rossoff, J.,  and R. C. Rossi.  Flue Gas Cleaning Waste Disposal:  EPA
     Shawnee Field Evaluation.  In:  Proceedings of the Symposium on Flue
     Gas Desulfurization, New Orleans, Louisiana, March 1976.   EPA-600/2-76-
     136b (NTIS  PB 262  722), May 1976.  Vol II, pp. 605-626.

20.   Selmeczi, J.  G.  Flue Gas Desulfurization and Stabilization.  Dravo
     Lime Company,  Pittsburgh, Pennsylvania, May 1975.

21.   Selmeczi, J.  G., et al.  Stabilization of Sludge Slurries.  U.S. Patent
     3,920,795,  November 1975.
                                     130

-------
22.  Mullen, Hugh, and Steven  I. Taub.   Tracing Leachate From Landfills -
    A Conceptual Approach.  Paper  presented  at National Conference on
    Disposal of Residue on Land, St. Louis,  Missouri,  September 14, 1976.

23.  Duquesne Light News.  Pittsburgh,  Pennsylvania,  October 1976.

24.  Conner, Jesse R.  Method  of Making Wastes  Nonpolluting and Disposable.
    U.S. Patent 3,837,872, September  1974.

25.  Chemfix Data Package  1.   Chemfix,  Pittsburgh,  Pennsylvania.
                        i
26.  Federal Power Commission.  Hydroelectric Power Evaluation, FPC P-35
     (1968) and Supplement No.  1, FPC P-38 (1969).   Superintendent  of Docu-
    ments, U.S. Government Printing Office,  Washington, DC  20402.

27.  U.S. Environmental Protection  Agency.   Standards of Performance for
    New Stationary Sources.   Fed.  Regist.,  Vol 36, No.  247, Part II,
    December 23, 1971.

28.  Peters, M. S. , and K. D.  Timmerhaus.   Plant Design and Economics for
    Chemical Engineers.   McGraw-Hill Book Company, New York, 1968.

29.  Guthrie, K. M.   Capital Cost Estimating.  Chem.  Eng.,  March 24, 1969.
    Vol 76, pp. 114-142.

30.  Popper, Herbert.  Modern  Cost  Engineering  Technique.   McGraw-Hill Book
    Company, New York,  1970.

31.  Perry, John H.   Chemical  Engineers' Handbook,  Fourth Edition,  McGraw-Hill
    Book Company, New York, 1963.

32.  Richardson Engineering Services,  Inc.   The Richardson Rapid System,
    Vol 1, 3, 4, Solano Beach, California,  1976.

33.  Pennsylvania Power  Company.  Bruce Mansfield Fact Sheet, April 1976.
                                    131

-------
                           APPENDIX A




TOTAL CAPITAL INVESTMENT AND ANNUAL REVENUE REQUIREMENT TABLES




                ALL PROCESSES AND CASE VARIATIONS
                                133

-------
                       TABLE A-l.   UNTREATED DISPOSALa

    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                                (Base case)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
                                                 Percent of   Percent ^of
                                                   direct    total capital
                                                 investment   investment
128
121
1,109
7
73
395
53
0
1,886
28
1,914
7,251
9,165
367
49
1,102
517
11,200
2,240
13,440
619
1,613
15,672
1,423
116
1.4
1.3
12.1
0.1
0.8
4.3
0.6
-
20.6
0.3
20.9
79.1
100.0
4.0
0.5
12.1
5.6
122.2
24.4
146.6
6.8
17.6
171.0
15.5
1.3
0.7
0.7
6.4
0.1
0.4
2.3
0.3
-
10.9
0.2
11.1
42.2
53.3
2.1
0.3
6.4
3.0
65.1
13.0
78.1
3.6
9.3
91.0
8.3
0.7
                                       17,211
187.8
100.0
a.
Basis
  New 500-MW plant (30-yr life); 772 klb/hr (15% solids)  sludge.
  Midwest plant location; average basis for cost scaling, mid-1979.
  Coal analysis (by wt ):  3.5% S (dry basis) 16% ash,
  Flyash removed with S02.
  S02 and flyash removed to meet NSPS.
  Limestone process with 1.5 stoichiometry based on S02 removed.
  Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
  50% solids settled density, 21.21 ft total depth, 407 acres.
                                      134

-------
                            TABLE  A-2.   UNTREATED  DISPOSAL

     TOTAL ANNUAL REVENUE REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
                                              Base case)
                                           Annual
                                          quantity
                  Unit
                 cost, $
    Total
annual revenue
requirements, $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
    Labor and materials
    4% of direct investment (plant)
    37, of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of total capital investment
Overhead
17,520  man-hr   12.50/man-hr
                                219,000
1,906
500
kkWh
hr
0.029/kWh
17.00/man-hr
76,600
217,500
55,300
8,500
576,900
576,900
                                940,300
                              1,480,100
    Basis
     Remaining plant life,  30 yr.
     Coal burned, 428,571  Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7',000 hr/yr.
     Total capital investment,  $17,211,000.
     Midwest plant location, mid-1980 operating  costs.
    Percent
   of total
annual revenue
 requirements
                                                   0.7


                                                   2.3
                                                   6.6
                                                   1.7
                                                   0.3
                                                  17.6

                                                  17.6
                                                  28.7
                                                  45.1
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
260,800
21,900
2,703,100
2,280,000
Dollars/dry ton Dollars/wet ton Mills/kWh
8.08 4.04 0.94
7.9
0.7
82.4
100.0
                                               135

-------
                     TABLE  A-3.  UNTREATED DISPOSAL

   TOTAL CAPITAL INVESTMENT  - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
               (Variation from base case:  new 200-MW plant)
                                        Total. k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
   78
   96
  746
    6

   66
  354
   41
1,387
1,408

3,652
5,060

  262
   38
  713
  329
6,402
  403
  922
9,007

  708
	85_

9,800
          Percent of
            direct
          investment
           Percent  of
          total capital
           investment
  1.5
  1.9
 14.8
  0.1
 27.4
  0.4
 27.8
 72.2
100.0

  5.2
  0.8
 14.0
  6.5
126.5
 25.3
151.8

  8.0
 18.2
178.0

 14.0
  1.7

193.7
  0.8
  1.0
  7.5
  0.1

  0.7
  3.6
  0.4
 14.1
  0.2
 14.3
 37.3
 51.6

  2.7
  0.4
  7.3
  3.3
 65.3
100.0
a.  Basis
      New 200-MW plant  (30-yr life); 316 klb/hr (15% solids) sludge.
      Midwest plant location; average basis  for  cost  scaling,  mid-1979.
      Coal analysis (by wt ) :  3.5%s (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based  on  S02 removed.
      Pond characteristics:   clay-lined,  1 mi  from scrubber facilities,  50%
      solids settled density, 18.13  ft  total depth, 202  acres.
                                        136

-------
                        TABLE  A-4.   UNTREATED  DISPOSAL

  TOTAL  ANNUAL  REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
                               (Variation from base case:   200-MW plant)
 Annual
quantity
   Unit
  cost, $
                                 Total
                              annual revenue
                              requirements , $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
    Labor and materials
     4% of direct investment (plant)
     3% of direct investment (pond)
  Electricity
  Analyses
     Subtotal conversion costs

     Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
17,520  man-hr   12.50/man-hr
   601 kkWh
   500 hr
0.031/kWh
17.00/hr
                              219,000


                               56,300
                              109,600
                               18,600
                                8,500
                              412,000

                              412,000
                                540,800
                                842,800
a.  Basis
     Remaining plant life,  30 yr.
     Coal burned, 175,238 Ib/hr,  9,200 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment,  $9,800,000.
     Midwest plant location,  mid-1980 operating costs.
                                                                                           Percent
                                                                                          of total
                                                                                       annual revenue
                                                                                        requirements
10.9


 2.8
 5.4
 0.9
 0.4
20.4

20.4
                                                  41.£
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements
196

21
1,602
2,014
Dollars /dry ton Dollars /wet ton
12.12 6.06
,700

,900
,200
,200
Mills /kWh
1.44
9.8

1.1
79.6
100.0


                                               137

-------
                       TABLE A-5.   UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case:   existing 200-MW plant, 25-yr remaining life)
                                         Total, kS
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                          81
                                          96
                                         746
                                           6

                                          66
                                         354
                                          41
                                       1,390

                                      	21
                                       1,411

                                       2.923
                                       4,334

                                         237
                                          36
                                         649
                                         293
                                       5,549

                                       1,110
                                       6,659

                                         374
                                         799
                                       7,832

                                         566
                                      	82

                                       8,480
                                                 Percent  of   Percent of
                                                   direct     total capital
                                                 investment   investment
  1.9
  2.2
 17.3
  0.1

  1.5
  8.2
  0.9

 32.1
 32.6
 67.4
100.0

  5.5
  0.8
 14.9
  6.8
128.0
 25.6
153.6

  8.6
 18.5
180.7

 13.1
  1.9

195.7
  0.9
  1.1
  8.8
  0.1

  0.8
  4.2
  0.5
 16.4
  0.2
 16.6
 65.4
 13.1
 78.5
100.0
a.
Basis
  Existing 200-MW plant (25-yr remaining life);  326 klb/hr  (15% solids)
  sludge; Midvest  plant location; average basis  for cost  scaling, mid-1979.
  Coal analysis (by wt) :   3>5% g  (dry basis)   16%  agh<
  Flyash removed with S02-
  SOo and flyash removed to meet NSPS.
  Limestone process with 1.5 stoichiometry based on SOo  removed.
  Pond characteristics:  clay-lined,  1 mi from scrubber  facilities,
  50% solids settled density, 17.20 ft total depth, 162 acres.
                                       138

-------
                         TABLE  A-6.   UNTREATED  DISPOSAL

   TOTAL ANNUAL  REVENUE REQUIREMENTS -  REGULATED UTILITY  ECONOMICS
                (Variation  from base case:   existing 200-MW plant,  25-yr remaining  life)
                                           Annual
                                          quantity
                  Unit
                 cost, $
                  Total
              annual revenue
              requirements, $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment  (plant)
    37. of direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
17,520  man-hr   12.50/man-hr
   992  kkWh
   500  hr
0.031/kWh
17.00/hr
219,000


 56,400
 87,700
 30,800
  8,500
402,400

402,400
    Basis
     Remaining plant  life, 25 yr.
     Coal burned, 180,952 Ib/hr, 9,500 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $8,480,000.
     Midwest plant location, mid-1980  operating costs.
                  Percent
                 of total
              annual revenue
               requirements
11.9


 3.0
 4.8
 1.7
 0.5
21.9

21.9
Capital charges
Depreciation, interim replacement, and
insurance at 6.4% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements

501,200



729,300


185,800

21,900
1,438,200
1,840,600
Dollars/dry ton Dollars/wet ton Mills/kWh
10.62 5.31 1.32

27.2



39.6


10.1

1.2
78.1
100.0


                                                139

-------
                       TABLE A-7.   UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


 (Variation from base case;  existing 200-MW plant, 20-yr  remaining  life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
    81
    96
   746
     6

    66
   354
    41
 1,390

	21
 1,411

 2,034
 3,445
   203
    32
   567
   246
 4,493

   899
 5,392

   336
   647
 6,375

   392
	77_

 6,844
           Percent of
             direct
           investment
           Percent of
          total capital
           investment
  2.3
  2.8
 21.6
  0.2

  1.9
 10,
  1.
 40.3
  0.7
 41.0
 59.0
100.0

  5.9
  0.9
 16.5
  7.1
130.4
 26.1
156.5

  9.8
 18.8
185.1
 11.4
  2.2

198.7
  1.2
  1.4
 10.8
  0.1

  1.0
  5.2
  0.6

 20.3
 29.7
 50.3

  3.0
  0.5
  8.3
  3.6
 65.7
 93.2

  5.7
  1.1

100.0
a.  Basis
      Existing 200-MW plant (20-yr remaining life); 326 klb/hr  (15% solids)
      sludge; Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with S02•
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 15.88 ft total depth, 112 acres.
                                        140

-------
                          TABLE A-8.   UNTREATED DISPOSAL


    TOTAL  ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS


               (Variation from base case:  existing 200-MW  plant,  20-yr remaining life)

                                                                                           Percent
                                                                          Total           of total
                                           Annual          Unit        annual revenue     annual revenue
                                          quantity	cost, $	requirements,  $	requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 7.0% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
17,520 man-hr   12.50/man-hr
   992 kkVh
   500 hr
0.031/kWh
17.00/hr
219,000


 56,400
 61,000
 30,800
  8,500
375,700

375,700
                                 446,300
                                 588,600
   Basis
     Remaining plant  life, 20 yr.
     Coal burned,  180,952 Ib/hr, 9,500 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment $6,844,000.
     Midwest plant location, mid-1980 operating  costs.
                                                   13.7
 3.5
 3.8
 1.9
 0.5
23.4
                                                   23.4
                                                   36.7
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
172,400
21,900
1,229,200
1,604,900
Dollars/dry ton Dollars/wet ton Mills/kWh
9.26 4.63 1.15
10.7
1.4
76.6
100.0
                                                  141

-------
                       TABLE  A-9.  UNTREATED DISPOSAL3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


 (Variation from base case:  existing 200-MW  plant,  15-yr remaining  life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
    81
    96
   746
     6

    66
   354
    41
 1,390

	21
 1,411

 1,319
 2,730

   172
    29
   496
   206
 3,633

   727
 4,360

   304
   523
 5,187

   252
	72

 5,511
           Percent of
             direct
           investment
           Percent of
          total capital
           investment
  3.0
  3.5
 27.3
  0.2

  2.4
 13.0
  1.5

 50.9

  0.8
 51.7

 48.3
100.0

  6.3
  1.1
 18.2
  7.5
133.1

 26.6
159.7
 11.1
 19.2
190.0
  9.3
  2.6

201.9
  1.5
  1.7
 13.6
  0.1

  1.2
  6.4
  0.7

 25.2

  0.4
 25.6

 23.9
 49.5

  3.1
  0.5
  9.1
  3.7
 65.9

 13.2
 79.1
100.0
a.  Basis
      Existing 200-MW plant (15-yr remaining life); 326 klb/hr (15% solids)
      sludge; Midwest  plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS,
      Limestone process with 1.5 stoichiometry based on SOo  removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber  facilities,
          solids settled density, 14.48 ft total depth, 72 acres.
                                       142

-------
                       TABLE  A-10.   UNTREATED DISPOSAL

  TOTAL  ANNUAL REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
                 (Variation from base  case:  existing 200-MW plant,  15-yr remaining life)
                                           Annual
                                          quantity
                  Unit
                 cost, $
                  Total
              annual revenue
              requirements,  $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
    Labor and materials
     4% of direct investment (plant)
     37, of direct investment (pond)
  Electricity
  Analyses
     Subtotal conversion costs

     Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 8.7% of total capital
   investment less  land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
17,520 man-hr   12.50/man-hr
   992 kkWh
   500 hr
0.031/kWh
17.00/hr
219,000


 56,400
 39,600
 30,800
  8,500
354,300

354,300
                                 421,300
                                 473,900
    Basis
     Remaining plant life, 15 yr.
     Coal burned, 180,952 Ib/hr,  9,500 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $5,511,000.
     Midwest  plant location,  mid-1980 operating costs.
                  Percent
                 of total
              annual revenue
               requirements
15.3


 3.9
 2.8
 2.1
 0.6
24.7

24.7
                                                   29.4
                                                   33.1
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
161,700
21,900
1,078,800
1,433,100
Dollars/dry ton Dollars/wet ton Mills/kWh
8.27 4.14 1.02
11.3
1.5
75.3
100.0
                                                143

-------
                       TABLE  A-11.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case;  existing 500-MW  plant,  25-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
   128
   121
 1,109
     7

    73
   417
    53

 1,908

	29
 1,937

 5,759
 7,696

   326
    45
   989
   453
 9,509

 1,902
11,411

   565
 1,369
13,345

 1,126
   107

14,578
           Percent of
             direct
           investment
           Percent"of
          total capital
           investment
  1.7
  1.6
 14.4
  0.1

  0.9
  5.4
  0.7
 24.8

  0.4
 25.2

 74.8
100.0

  4.2
  0.6
 12.9
  2.9
123.6

 24.7
148.3

  7.3
 17.8
173.4

 14.6
  1.4

189.4
  0.9
  0.8
  7.5
  0.1
  0.5
  2.9
  0.4
 13.1
  0.2
 13.3
 39.5
 52.8

  2.2
  0.3
  6.8
  3.1
 65.2
 13.1
 78.3

  3.9
  9.4
 91.6
  7.7
  0.7

100.0
a.  Basis
      Existing 500-MW plant (25-yr remaining life); 789 klb/hr (15% solids)
      sludge;  Midwest  plant location;  average basis for cost scaling, mid-1979.
      Coal analysis (by wt) :   3,5% S  (dry basis),  16% ash.
      Flyash removed with SOo.
      S02 and flyash removed to meetNSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 20.09 ft total depth, 372 acres.
                                         144

-------
                           TABLE  A-12.   UNTREATED DISPOSAL3


      TOTAL ANNUAL REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS


               (Variation  from base  case:  existing 500-MW  plant, 25-yr remaining  life)

                                                                                           Percent
                                                                          Total            of total
                                           Annual         Unit        annual revenue    annual revenue
                                          quantity	cost, $	requirements, $    requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6.4% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
17,520 man-hr   12.50/man-hr
 2,037  kkWh
   500  hr
0.029/kWh
17.00/hr
                 219,000
 77,500
172,800
 59,100
  8,500
536,900
                                 536,900
                                 854,100
                               1,253,700
a.  Basis
     Remaining plant life,  25 yr.
     Coal burned, 438,095 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment $14,578,000.
     Midwest plant location, mid-1980 operating  costs.
                                                    7.5
 2.7
 6.0
 2.0
 0.3
18.5
                                                   18.5
                                                   29.4
                                                   43.2
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
238,900
21,900
2,368,600
2,905,500
Dollars/dry ton Dollars/wet ton Mills/kWh
7.01 3.51 0.83
8.2
0.7
81.5
100.0
                                                 145

-------
                       TABLE A-13.   UNTREATED DISPOSAL3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
    (Variation from base case;  existing  500-MW plant,  20-yr remaining life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
11,399
           Percent of   Percent of
             direct    total capital
           investment   investment
128
121
1,109
7
73
417
53
1,908
29
1,937
3,998
5,935
273
39
843
372
7,462
1,492
8,954
496
1,074
10,524
778
97
2,2
2.0
18.7
0.1
1.2
7.0
0.9
32.1
0.5
32.6
67.4
100.0
4.6
0.7
14.1
6.3
125.7
25.2
150.9
8.4
18.0
177.3
13.2
1.6
1.1
1.1
9.7
0.1
0.6
3.6
0.5
16.7
0.3
17.0
35.1
52.1
2.4
0.3
7.4
3.3
65.5
13.1
78.6
4.3
9.4
92.3
6.8
0.9
192.1
100.0
a.  Basis
      Existing 500-MW plant (20-yr remaining life); 789  klb/hr (15% solids)
      sludge; Midwest plant location; average basis for  cost scaling, mid-1979
      Coal analysis (by wt):  3.5% S  (dry basis),  16%  ash.
      Flyash removed with S02-
      S02 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on  S02  removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber  facilities,
      50% solids  settled density, 18.45  ft total depth,  222  acres.

                                        146

-------
                        TABLE  A-14.   UNTREATED DISPOSAL3

  TOTAL ANNUAL  REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
                (Variation  from base case:   existing 500-MW plant,  20-yr remaining  life)
                                           Annual
                                          quantity
                  Unit
                 cost,  $
                  Total
              annual  revenue
              requirements, $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment  (plant)
    3% of direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
17,520 man-hr   12.50/man-hr
 2,037  HcWh
   500  hr
 0.029/kWh
17.00/hr
219,000


 77,500
119,900
 59,100
  8,500
484,000

484,000
    Basis
     Remaining plant life, 20 yr.
     Coal burned, 438,095 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $11,399,000.
     Midwest plant location, mid-1980 operating costs.
                 Percent
                of total
             annual revenue
              requirements
 9.0


 3.2
 4.9
 2.4
 0.4
19.9

19.9
Capital charges
Depreciation, interim replacement, and
insurance at 7% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Dollars/dry ton
Equivalent unit revenue requirements 5.87




736,700

980,300


212,400
21,900
1,951,300
2,435,300
Dollars/wet ton Mills/kWh
2.94 0.70




30.2

40.3


8.7
0.9
80.1
100.0


                                               147

-------
                       TABLE A-15.  UNTREATED DISPOSAL3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


   (Variation from base case:  existing 500-MW plant, 15-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
                                         128
                                         121
                                       1,109
                                           7

                                          73
                                         417
                                          53

                                       1,908

                                      	29
                                       1,937

                                       2,584
                                       4,521

                                         224
                                          35
                                         719
                                         302
                                       5,801

                                       1,160
                                       6,961

                                         438
                                         835
                                       8,234

                                         500
                                      	88

                                       8,822
                                                 Percent of
                                                   direct
                                                 investment
           Percent of
          total capital
           investment
    .8
    ,7
 24.5
  0.2

  1.6
  9.2
  1.2
 42.2

  0.6
 42.8

 57.2
100.0

  5.0
  0.8
 15.8
  6.7
128.3

 25.7
154.0

  9.7
 18.4
182.1

 11.1
  1.9

195.1
  1.4
  1.4
 12.6
  0.1

  0.8
  4.7
  0.6

TO

  Q.3
 21.9

 29.4
 51.3

  2.5
  0.4
  8.2
  3.4
 65.8

 13.1
 78.9
100.0
a.
Basis
  Existing  500-MW plant  (15-yr remaining life); 789 klb/hr  (15% solids)
  sludge; Midwest plant  location;  average basis for cost scaling, mid-1979.
  Coal  analysis  (by wt).   3.5% S (dry basis), 16% ash.
  Flyash removed with S02-
  S02 and flyash removed to meet NSPS.
  Limestone process with 1.5 stoichiometry based on SO- removed.
  Pond  characteristics:   clay-lined,  1 mi from scrubber facilities,
  50% solids settled density,  16.71 ft, 143 acres.
                                       148

-------
                            TABLE  A-16.    UNTREATED  DISPOSAL

      TOTAL  ANNUAL REVENUE REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
                (Variation  from base case:  existing 500-MW plant,  15-yr remaining life)
                                           Annual
                                          quantity
                   Unit
                  cost,  $
                  Total
              annual  revenue
              requirements, $
                 Percent
                of total
             annual revenue
              requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    V, of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 8.7% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of total capital investment
Overhead
17,520 man-hr
 2,037 kkWh
   500 hr
12.50/man-hr
 0.029/kWh
17.00/hr
219,000


 76,300
 77,500
 59,100
  8,500
440,400

440,400
                                   716,400
                                   758,700
    Basis
     Remaining plant life, 15 yr.
     Coal burned,  438,095 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $8,822,000.
     Midwest plant location, mid-1980 operating  costs.
10.3


 3.6
 3.6
 2.8
 0.4
20.7

20.7
                                                     33.7
                                                     35.6
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
191,200
21,900
1,688,200
2,128,600
Dollars/dry ton Dollars/wet ton Mills/kWh
5.13 2.57 0.61
9,
1.
79.
100.

,0
,0
.3
,0

                                                   149

-------
                        TABLE A-17.  UNTREATED DISPOSAL

    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                (Variation from base case:  new 1500-MW plant)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
   237
   207
   ,922
    14

    77
   522
    53
 3,032

	45
 3,077

16,946
20,023

   587
    71
 1,997
   936
23,614

 4,723
28,337

 1,139
 3,400
32,876

 3,359
   220

36,455
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
  1.2
  1.0
  0.4
  2.6
  0.3

"15.1

  0.3
 15.4

 84.6
100.0

  2.9
  0.4
  9.9
  4.7
117.9

 23.6
141.5

  5.7
 17.0
164.2

 16.8
  1.1

182.1
  0.6
  0.6
  5.3
  0.1

  0.2
  1.4
  0.1

  8.3

  0.1
  8.4

 46.5
 54.9

  1.6
  0.2
  5.5
  2.6
 64.8

 12.9
 77.7

  3.1
  9.4
 90.2

  9.2
  0.6

100.0
a.  Basis
      New 1500-MW plant (30-yr life); 2,368 klb/hr  (15%  solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S  (dry basis), 16% ash.
      Flyash removed with SOo.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on  SOo removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 24.52 ft total depth,  761 acres.
                                       150

-------
                            TABLE  A-18.    UNTREATED  DISPOSAL

       TOTAL  ANNUAL REVENUE REQUIREMENTS  - REGULATED UTILITY ECONOMICS
                              (Variation from base case:   1500-MW plant)
                                           Annual
                                          quantity
                  Unit
                 cost, $
                  Total
              annual revenue
              requirements, $
                    Percent
                   of total
                annual revenue
                 requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
26,280 man-hr    12'.50/man-hr
 5,170 kkWh
 1,000 hr
0.027/kWh
17.00/hr
  328,500


  123,100
  508,400
  139,600
   17,000
1,116,600

1,116,600
                               1,972,600
                               3,135,100
a. Basis
     Remaining plant life,  30 yr.
     Coal burned, 1,285,714 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment, $36,455,000.
     Midwest plant location, mid-1980 operating costs.
 4.9


 1.8
 7.5
 2.1
 0.3
16.6

16.6
                                                   29.2
                                                   46.5
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
488,500
32j900
5,629,100
6,745,700
Dollars/dry ton Dollars/wet ton Mills/kWh
5.55 2.77 0.64
7.2
0.5
83.4
100.0
                                                  151

-------
                       TABLE  A-19.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
    (Variation  from base  case;   existing 1500-MW plant, 25-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
   241
   207
 1,922
    12

    77
   474
    53

 2,986

	45
 3,031

13,433
16,464

   514
    63
 1,750
   807
19,598

 3,920
23,518

 1,009
 2,822
27,349

 2,664
   199

30,212
           Percent of
             direct
           investment
           Percent of
          total capital
           investment
  1.5
  1.2
 11.6
  0.1

  0.5
  2.9
  0.3
 18.1
  0.3
 18.4
 81.6
100.0

  3.1
  0.4
 10.6
  4.9
119.0
 23.8
142.8

  6.1
 17.2
166.1

 16.2
  1.2

183.5
  0.8
  0.2
  1.6
  0.2
  9.9
 44.5
 54.5

  1.7
  0.2
  5.8
  2.7
 64.9
 12.9
 77.8
100.0
a.  Basis
      S-LU
      Existing 1500-MW plant  (25-yr remaining  life);  2,368  klb/hr (15% solids)
      sludge; Midwest plant  location;  average  basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5%  S  (dry basis),  16% ash.
      Flyash removed with  862.
      862 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based  on S02 removed.
      Pond characteristics:  clay-lined,  1 mi  from scrubber facilities,
      50% solids  settled  density, 24.52 ft total depth, 761 acres..

                                      152

-------
                           TABLE  A-20.    UNTREATED DISPOSAL

     TOTAL  ANNUAL REVENUE REQUIREMENTS  - REGULATED UTILITY ECONOMICS
                (Variation from base  case:  existing 1500-MW plant, 25-yr remaining life)
                                            Annual
                                           quantity
                   Unit
                  cost, $
                  Total
              annual revenue
              requirements, $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
    Labor and materials
     4% of direct investment (plant)
     3% of direct investment (pond)
  Electricity
  Analyses
     Subtotal conversion costs

     Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6.4% of total capital
   investment less  land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
26,280 man-hr    12.50/man-hr
 5,220kkWh
 1,000 hr
 0.027/kWh
17.00/hr
  328,500


  121,200
  403,000
  140,900
   17,000
1,010,600

1,010,600
                                 1,750,300
                                 2,598,200
a.  Basis
      Remaining plant  life, 25 yr.
      Coal burned,  1,314,286 Ib/hr, 9,200 Btu/kWh.
      Power plant on-stream time, 7,000 hr/yr.
      Total capital investment, $30,212,000.
      Midwest plant location, mid-1980 operating  costs.
                   Percent
                  of total
               annual revenue
                requirements
 5.6


 2.1
 6.9
 2.4
 0.3
17.3

17.3
                                                     30.0
                                                     44.6
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
434,800
32,900
4,816,200
5,826,800
Dollars/dry ton Dollars/wet ton Mills/kWh
4.69 2.35 0.55
7
0,
82,
100.

.5
.6
.7
.0

                                                 153

-------
                       TABLE A-21.  UNTREATED DISPOSAL3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


    (Variation from base case;  existing 1500-MW  plant,  20-yr remaining  life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
   241
   207
 1,922
    12

    77
   474
    53

 2,986

	45
 3,031

 9,312
12,343

   420
    54
 1,456
   648
14,921

 2,984
17,905

   859
 2,149
20,913

 1,817
   174

22,904
           Percent of
             direct
           investment
           Percent  of
          total capital
           investment
  2.0
  1.7
 15.6
  0.1
  0.6
  3.8
  0.4
 24.2

  0.4
 24.6

 75.4
100.0

  3.4
  0.4
 11.9
  5.2
120.9

 24.2
145.1

  7.0
 17.3
169.4

 14.8
  1.4

185.6
  1.0
  0.9
  8.4
  0.1

  0.3
  2.1
  0.2
 13.0

  0.2
 13.2

 40.7
 53.9

  1.8
  0.2
  6.5
  2.8
 65.2

 13.0
 78.2
100.0
a.  Basis
      Existing 1500-MW plant  (20-yr remaining  life);  2,368 klb/hr  (15% solids)
      sludge; Midwest plant location; average  basis  for cost scaling, mid-1979
      Coal analysis (by wt):  3.5% S  (dry  basis),  16% ash.
      Flyash removed with SOo.
      S02 and flyash removed  to meet  NSPS.
      Limestone process with  1.5 stoichiometry based  on SOo  removed.
      Pond characteristics:   clay-lined, 1 mi  from scrubber  facilities,
      50% solids settled density, 22.22  ft total depth, 519  acres.
                                        154

-------
                        TABLE  A-22.    UNTREATED  DISPOSAL3

   TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
(Variation from base case: existing
Annual
quantity
1500-MW plant,
Unit
cost, 5
20-yr remaining life)
Total
annual revenue
requirements, $
Percent
of total
annual revenue
requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
    Labor and materials
     4% of direct investment (plant)
     3% of direct investment (pond)
  Electricity
  Analyses
     Subtotal conversion costs

     Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 7.0% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
     Subtotal indirect costs

     Total annual revenue requirements


Equivalent unit revenue requirements
26,280  man-hr
 5,220  kkWh
 1,000  hr
12.50/man-hr
 0.027/kWh
17.00/hr
 Dollars/dry ton
328,500


121,200
279,300
140,900
 17,000
886,900

886,900
                1,463,900



                1,969,700


                  373,000

                   32,800
                3,839,400

                4,726,300

  Dollars/wet ton   Mills/kWh
       3.80
                        1.90
                                      0.45
    Basis
     Remaining plant  life, 20 yr.
     Coal burned,  1,314,286 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $22,904,000.
     Midwest plant location, mid-1980 operating costs.
                                                      6.9
2.6
5.9
3.0
0.4
                                                     30.9



                                                     41.7


                                                      7.9

                                                      0.7
                                                     81.2

                                                    100.0
                                              155

-------
                       TABLE A-23.  UNTREATED DISPOSAL

     TOTAL  CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS

  (Variation from base case;  existing 1500-MW plant, 15-yr remaining  life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total,k$
                                      16,999
                                                 Percent of   Percent of
                                                   direct    total capital
                                                 investment   investment
241
207
1,922
12
77
474
53
2,986
45
3,031
5,992
9,023
333
45
1,202
511
11,114
2,223
13,337
735
1,600
15,672
1,173
154
2.7
2.3
21.3
0.1
0.9
5.2
0.6
33.1
0.5
33.6
66.4
100.0
3.7
0.5
13.3
5.7
123.2
24.6
147.8
8.1
17.8
173.7
13.0
1.7
1.4
1.2
11.3
0.1
0.5
2.8
0.3
17.6
0.3
17.9
35.2
53.1
2.0
0.3
7.0
3.0
65.4
13.1
78.5
4.3
9.4
92.2
6.9
0.9
188.4
100.0
a.
Basis
  Existing 1500-MW plant (15-yr remaining life);  2,368 .Vlb/hr  (15%  solids)
  sludge; Midwest plant location; average basis  for  cost  scaling, mid-1979.
  Coal analysis (by wt):  3.5% S  (dry basis),  16% ash.
  Flyash removed with S02-
  S02 and flyash removed to meet NSPS.
  Limestone process with 1.5 stoichiometry based on  S02 removed.
  Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
  50% solids settled density, 20.26 ft total depth,  335 acres.
                                       156

-------
                          TABLE  A-24.    UNTREATED  DISPOSAL

    TOTAL  ANNUAL REVENUE REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
                 (Variation from base case:   existing  1500-MW plant, 15-yr remaining life)
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
    Labor and materials
     4% of direct investment  (plant)
     3% of direct investment  (pond)
  Electricity
  Analyses
     Subtotal conversion costs

     Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 8.7% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total  capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
     Subtotal indirect costs

     Total annual revenue requirements


Equivalent unit revenue requirements
                                             Annual
                                            quantity
 5,220 kkWh
 1,000 hr
                   Unit
                  cost, $
                                  Total
                              annual revenue
                              requirements,  $
26,280 man-hr     12.50/man-hr
                0.027/kWh
                17.00/hr
328,500


121,200
179,800
140,900
 17,000
787,400

787,400
                                1,363,500



                                1,461,900


                                  323,200

                                   32,900
                                3,181,500

                                3,968,900
Dollars/dry ton   Dollars/wet ton
      3.19              1.60
                                    Mills/kWh.
                                       0.38
    Basis
     Remaining plant life, 15 yr.
     Coal burned, 1,314,286 Ib/hr,  9,200 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital  investment, $16,999,000.
     Midwest  plant  location, mid-1980 operating costs.
                 Percent
                of total
              annual revenue
               requirements
                                                       3.3
3.1
4.5
3.5
0.4
                                                     34.4
                                                     80.2

                                                    100.0
                                                157

-------
                       TABLE  A-25. UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


            (Variation from base case:  ash in coal 12% by wt)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
111
102
986
7
69
381
53
1,709
26
1,735
6,218
7,953
339
46
987
464
9,789
1,958
11,747
553
1,410
13,710
1,215
106
Percent of
direct
investment
1.4
1.3
12.3
0.1
0.9
4.8
0.7
21.5
0.3
21.8
78.2
100.0
4.3
0.6
12.4
5.8
123.1
24.6
147.7
7.0
17.7
172.4
15.3
1.3
Percent of
total capital
investment
0.7
0.7
6.6
0.1
0.5
2.5
0.3
11.4
0.1
11.5
41.4
52.9
2.3
0.3
6.5
3.1
65.1
13.1
78.2
3.7
9.3
91.2
8.1
0.7
15,031
189.0
100.0
a.  Basis
      New 500-MW plant (30-yr life); 638 klb/hr (15% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 12% ash,  11,100 Btu/lb,
      Flyash removed with S02.
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 21.21 ft total depth, 407 acres.
                                      158

-------
                           TABLE  A-26.    UNTREATED  DISPOSAL

     TOTAL ANNUAL REVENUE REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
                             (Variation from base  case:  12% ash in coal)
Direct costs

Conversion costs
  Operating labor  and supervision
  Maintenance
   Labor and materials
     4% of direct  investment (plant)
     3% of direct  investment (pond)
  Electricity
  Analyses
     Subtotal conversion costs

     Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of  capital and taxes at
   8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative,  10% of operating labor
     Subtotal indirect costs

     Total annual  revenue requirements


Equivalent unit revenue requirements
                                             Annual
                                            quantity
 1,384  kkWh
   500  hr
                   Unit
                  cost, $
                                  Total
                              annual revenue
                              requirements,  $
17,520 man-hr    12.50/man-hr
                 0.029/kWh
                17.00/hr
219,000


 69,400
186,500
 40,100
  8.500
523,500

523,500
                                  822,600



                                1,292,700


                                  241,700

                                   21,900
                                2,378,900

                                2,902,400
Dollars/dry ton  Dollars/wet ton
      8.68              4.34
                                    Mills/kHh
                                      0.83
    Basis
     Remaining plant life, 30 yr.
     Coal burned, 405,405 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $15,031,000.
     Midwest  plant location, mid-1980 operating costs.
                 Percent
                 of total
              annual revenue
               requirements
 7.5


 2.4
 6.4
 1.4
 0.3
18.0

18.0
                                                     28.3
                                                     44.6
                                                     82.0

                                                    100.0
                                                  159

-------
                       TABLE A-27.  UNTREATED DISPOSAL3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


           (Variation from base case:  ash in coal 20% by wt)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
          Percent of   Percent of
            direct    total capital
          investment   investment
133
142
1,109
8
73
422
53
1,940
29
1,969
8,230
10,199
393
51
1,186
561
12,390
2,478
14,868
664
1,784
17,316
1,614
125
1.3
1.4
10.9
0.1
0.7
4.1
0.5
19.0
0.3
19.3
80.7
100.0
3.9
0.5
11.6
5.5
121.5
24.3
145.8
6.5
17.5
169.8
15.8
1.2
0.7
0.7
5.8
0.1
0.4
2.2
0.3
10.2
0.1
10.3
43.2
53.5
2.1
0.3
6.2
2.9
65.0
13.0
78.0
3.5
9.4
90.9
8.5
0.6
19,055
186.8
100.0
a.  Basis
      New 500-MW plant (30-yr life); 923 klb/hr  (15%  solids)  sludge.
      Midwest plant location; average basis for cost  scaling, mid-1979.
      Coal analysis (by wt):  3.5%  S  (dry basis),  20% ash,  9,900 Btu/lb,
      Flyash removed with SOo.
      S02 and flyash removed to meetNSPS.
      Limestone process with 1.5 stoichiometry based  on  S02 removed.
      Pond characteristics:   clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 21.21 ft total  depth,  407 acres.
                                     160

-------
                           TABLE A-28.   UNTREATED DISPOSAL3

       TOTAL ANNUAL REVENUE REQUIREMENTS - REGULATED UTILITY ECONOMICS
                            (Variation from base case:   20% ash in coal)
                                            Annual
                                           quantity
                   Unit
                  cost, $
                  Total
              annual revenue
              requirements, $
Direct costs

Conversion  costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of  direct investment  (plant)
    3% of  direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of  total capital investment
Overhead
17,520 man-hr    12.50/man-hr
 2,742  kkWh
   500  hr
 0.029/kWh
17.00/hr
219,000


 78,800
246,900
 79,500
  8,500
632,700

632,700
                                 1,039,000
                                 1,638,700
    Basis
     Remaining plant life,  30 yr.
     Coal burned, 454,545 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment,  $19,055,000.
     Midwest plant location, mid-1980 'operating costs.
                 Percent
                of total
             annual revenue
              requirements
                                                      6.1
2.2
6.8
2.2
0.2
                                                     17.5

                                                     17.5
                                                     45.4
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
276,600
21,900
2,976,200
3,608,900,
Dollars/dry ton Dollars/wet ton Mills/kWh
7.44 3.72 1.03
7,
0,
82.
100.

.7
.6
,5
0

                                                  161

-------
                       TABLE  A-29.  UNTREATED DISPOSAL3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
          (Variation from base case:  S in coal 2% by wt)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total,k$
                                           98
                                          117
                                          903
                                            6

                                           69
                                          381
                                           41
                                        1,615

                                       	24_
                                        1,639

                                        5,397
                                        7,036

                                          316
                                           44
                                          904
                                          423
                                        8,723

                                        1,745
                                       10,468

                                          507
                                        1,256
                                       12,231

                                        1,055
                                          101

                                       13,387
                                                 Percent of
                                                   direct
                                                 investment
           Percent of
          total  capital
           investment
  1.4
  1.7
 12.8
  0.1

  1.0
  5.4
  0.6

 23.0

  0.3
 23.3

 76.7
100.0

  4.5
  0.6
 12.9
  6.0
124.0

 24.8
148.8

  7.2
 17.8
173.8

 15.1
  1.4

190.3
 0.7
 0.9
 6.7
 0.1

 0.5
 2.9
 0.3

UTT

 0.2
 12.3
 13.0
 78.2
100.0
a.
Basis
  New 500-MW plant (30-yr life); 537 klb/hr  (15%  solids)  sludge.
  Midwest plant location; average basis for cost scaling, mid-1979.
  Coal analysis (by wt ) •  2% S  (dry basis).  16% ash,  10,700 Btu/lb HV.
  Flyash removed with S02«
  S02 and flyash removed to meet NSPS.
  Limestone process with 1.5 stoichiometry based on S02 removed.
  Pond characteristics:   clay-lined, 1 mi from scrubber facilities,
  50% solids settled density, 21.21 ft total depth, 407 acres.
                                      162

-------
                          TABLE  A-30.    UNTREATED  DISPOSAL3

      TOTAL  ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
                             (Variation from base  case:   2%  S  in  coal)
                                            Annual
                                           quantity
                   Unit
                   cost, $
                                    Percent
                   Total            of total
               annual revenue    annual revenue
               requirements, $	requirements
Direct costs

Conversion costs
  Operating labor and  supervision
  Maintenance
   Labor and materials
    W of direct investment  (plant)
    3% of direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion  costs

    Subtotal direct  costs

Indirect costs

Capital charges
  Depreciation, interim  replacement, and
   insurance at 6% of total capital
   investment less land  and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital  investment
Overhead
17,520 man-hr     12.50/man-hr
 1,697 kkWh
   500 hr
 0.029/kWh
17.00/hr
                  219,000
 65,600
161,900
 49,200
  8,500
504,200

504,200
                                   733,900
                                 1,151,500
a.  Basis
     Remaining  plant life, 30 yr.
     Coal burned, 420,561 Ib/hr,  9,000  Btu/kWh.
     Power plant on-stream time,  7,000  hr/yr.
     Total capital investment, $13,390,000.
     Midwest plant location,  mid-1980 operating costs.
                                                      3.3
 2.5
 6.1
 1.9
 0.3
19.1

19.1
                                                     43.7
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
227,500
21,900
2,134,800
2,639,000
Dollars/dry ton Dollars/wet ton Mills/kWh
9.37 4.69 0.75
8.
0.
80.
100.

.6
.8
,9
,0

                                                   163

-------
                       TABLE A-31.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


            (Variation from base case:  S in coal 5% by wt)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total,k$
                                                 Percent of   Percent of
                                                   direct    total capital
                                                 investment   investment
155
142
1,329
7
73
471
53
2,230
33
2,263
8,827
11,090
408
53
1,285
598
13,434
2,687
16,121
729
1,935
18,785
1,740
130
1.4
1.3
11.9
0.1
0.7
4.2
0.5
20.1
0.3
20.4
69.6
100.0
3.7
0.5
11.5
5.4
121.1
24.3
145.4
6.6
17.4
169.4
15.7
1.2
0.7
0.7
6.4
0.1
0.3
2.3
0.3
10.8
0.2
11.0
42.7
53.7
2.0
0.3
6.2
2.9
65.1
13.0
78.1
3.5
9.4
91.0
8.4
0.6
                                       20,655
186.3
100.0
a.
Basis
  New 500-MW plant (30-yr life); 1004 klb/hr  (15% solids)  sludge.
  Midwest plant location; average basis for cost scaling, mid-1979.
  Coal analysis (by wt):  5% S  (dry basis), 16% ash,  10,400 Btu/lb HV,
  Flyash removed with 502-
  862 and flyash removed to meet NSPS
  Limestone process with 1.5 stoichiometry based on SCK removed.
  Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
  50% solids settled density, 21.21 ft total  depth, 407 acres.
                                        164

-------
                         TABLE  A-32.   UNTREATED  DISPOSAL3

    TOTAL ANNUAL  REVENUE  REQUIREMENTS - REGULATED  UTILITY  ECONOMICS
                           (Variation from base case:   5% S in coal)
                                           Annual
                                          quantity
                   Unit
                  cost,  $
                                   Percent
                  Total            of total
              annual revenue    annual revenue
              requirements, $	requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment  (plant)
    3% of direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
17,520 man-hr    12.50/man-hr
 2,193 kkWh
   500 hr
 0.029/kWh
17.00/hr
219,000


 94,500
264,800
 63,600
  8,500
650,400

650,400
    Basis.
     Remaining plant  life, 30 yr.
     Coal burned,  432,692 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $20,655,000.
     Midwest plant location, mid-1980 operating costs.
                                                     5.7
2.4
6.9
1.6
0.2
Capital charges
Depreciation, interim replacement, and
insurance at 6% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

1,127



1,776


293

21
3,218
4,869

,100



,300


,400

,900
,700
,100

29.1



45.9


7.6

0.6
83.2
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
7.35 3.68
1.10

                                               165

-------
                       TABLE A-33.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


             (Variation from base case:   no flyash,  200-MW plant)
Total, k$
Percent of
direct
investment
Percent of
total capital
investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
    54
    74
   526
     3

    66
   338
    38
 1,099

	16_
 1,115

 2,263
 3,378

   212
    33
   530
   242
 4,395

   879
 5,274

   301
   633
 6,208

   435
	7^3

 6,716
  1.6
  2.2
 15.6
  0.1

  1.9
 10.0
  1.1

 32.5

  0.5
 33.0

 67.0
100.0

  6.3
  1.0
 15.6
  7.2
130.1

 26.0
156.1

  8.9
 18.8
183.8

 12.8
  2.2

198.8
  0.8
  1.1
  7.8
  0.1

  1.0
  5.0
  0.6
 16.4

  0.2
 16.6

 33.7
 50.3

  3.2
  0.5
  7.8
  3.6
 65.4

 13.1
 78.5
100.0
a.  Basis
      New 200-MW plant (30-yr life); 167 klb/hr  (15% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ashk
      Flyash removed independently of S02 and  sludge contains  no flyash,
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removal.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 16.29 ft total depth, 124 acres.
                                        166

-------
                          TABLE A-34.   UNTREATED  DISPOSAL3

      TOTAL  ANNUAL REVENUE REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
                        (Variation  from base case:  200-MW plant, no flyash)
                                           Annual
                                          quantity
                   Unit
                  cost, $
                  Total
              annual revenue
              requirements, $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
17,520  man-hr    12.50/man-hr
   392 kkWh
   500 hr
 0.031/kWh
17.00/hr
219,000


 44,600
 67,900
 12,200
  8,500
352,200

352,200
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned,  175,238 Ib/hr,  9,200 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $6,716,000.
     Midwest plant location, mid-1980 operating costs.
                 Percent
                of total
             annual revenue
              requirements
14.7


 3.0
 4.5
 0.8
 0.6
23.6

23.6
Capital charges
Depreciation, interim replacement, and
insurance at 6% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

,372



577


170

21
1,142
1,494

,500



,600


,700

,900
,700
,900

24.9



38.6


11.4

1.5
76.4
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
17.08 8.50
1.07

                                                 167

-------
                       TABLE  A-35. UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                     (Variation  from base  case:   no flyash)
Total, k$
Percent of
direct
investment
Percent of
total capital
investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
    88
    96
   746
     5

    66
   364
    53
 1,418
 1,439

 4,499
 5,938

   289
    41
   791
   372
 7,431

 1,486
 8,917

   442
 1,070
10,429
   876
11,397
  1.5
  1.6
 12.6
  0.1

  1.1
  6.1
  0.9

 23.9

  0.3
 24.2

 75.8
100.0

  4.9
  0.7
 13.2
  6.3
125.1

 25.1
150.2

  7.4
 18.0
175.6

 14.7
  1.6

191.9
  0.8
  0.8
  6.4
  0.1

  0.6
  3.2
  0.5
 12.4
                            0.2
                           12.6
                           39.5
                           52.1

                            2.5
                            0.4
                            6.9
                            3.3
                           65.2
 91.5

  7.7
  0.8

100.0
a.  Basis
      New 500-MW plant (30-yr life); 409 klb/hr (15% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis),  16% ash.
      Flyash removed independently of S02 and sludge contains no flyash
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 18.98 ft total depth, 250 acres.

                                        168

-------
                       TABLE  A-36.    UNTREATED DISPOSAL3

   TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY ECONOMICS
                        (Variation from base case:  separate  system, no flyash)
                                          Annual
                                         quantity
                  Unit
                 cost,  $
                                                                         Total
                                                                     annual  revenue
                                                  Percent
                                                 of total
                                              annual revenue
              requirements,  $	requirements
Direct costs

Conversion  costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    l>7. of  direct investment  (plant)
    3% of  direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion  costs

    Subtotal direct costs

Indirect costs
17,520  man-hr   12.50/man-hr
 1,071 kkWh
   500 hr
0.029/kWh
17.00/hr
                                 219,000
 57,600
135,000
 31,100
  8,500
451,200

451,200
    Basis
     Remaining plant  life, 30 yr.
     Coal burned, 428,571 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $11,397,000.
     Midwest plant location, mid-1980 operating costs.
                                                    9.5
 2.5
 5.9
 1.4
 0.4
19.7

19.7
Capital charges
Depreciation, interim replacement, and
insurance at 6% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements

625.700



980,100


210,000

21,900
1,837,700
2,288,900
Dollars/dry ton Dollars/wet ton Mills/kWh
10.63 5.32 0.65

27.3



42.8


9.2

1.0
80.3
100.0


                                                169

-------
                       TABLE  A-37.  UNTREATED DISPOSAL"

    TOTAL CAPITAL INVESTMENT -  PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


           (Variation from base case:  no flyash,  1500-MW plant)
                                         Total,  k$
Percent of   Percent of
  direct    total capital
investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
roads and railroads
Electrical
Instrumentation
Buildings
Subtotal
Services and miscellaneous
Subtotal excluding pond
Pond construction
Subtotal direct investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Subtotal
Contingency
Subtotal fixed investment
Allowance for startup and modifications
Interest during construction
Subtotal capital investment
Land
Working capital
Total capital investment
151
169
1,329
9

73
443
53
-
2,227
33
2,260
10,468
12,728
447
57
1,405
664
15,301
3,060
18,361
789
2,203
21,353
2,076
166
23,595
1.2
1.3
10.4
0.1

0.6
3.5
0.4
-
17.5
0.3
17.8
82.2
100.0
3.5
0.4
11.1
5.2
120.2
24.1
144.3
6.2
17.3
167.8
16.3
1.3
185.4
0.6
0.7
5.6
0.1

0.3
1.9
0.2
-
9.4
0.2
9.6
44.3
53.9
1.9
0.2
6.0
2.8
64.8
13.0
77.8
3.3
9.4
90.5
8.8
0.7
100.0

a.  Basis
      New 1500-MW plant (30-yr life); 1,228 klb/hr (15% solids) sludge.-
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3,5% S Cdry basis)? 16% ash,
      Flyash removed independently of S02 and sludge contains no  flyash.
      S0£ and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 23.12 ft total depth, 591 acres.

                                        170

-------
                           TABLE  A-38.   UNTREATED DISPOSAL

      TOTAL  ANNUAL REVENUE REQUIREMENTS - REGULATED UTILITY ECONOMICS
                         (Variation from base case:   1500-MW plant, no flyash)
                                           Annual
                                          quantity
                  Unit
                  cost, $
                  Total
              annual  revenue
              requirements, $
                  Percent
                 of  total
              annual  revenue
               requirements
Direct costs

Conversion  costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of  direct investment  (plant)
    3% of  direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of  total capital investment
Overhead
26,280 man-hr    12.50/man-hr
 2,872 kkWh
 1,000 hr
0.027/kWh
17.00/hr
328,500


 90,400
314,000
 77,500
 17,000
827,400

827,400
                                1,281,200
                                2,029,200
a.  Basis
     Remaining plant life,  30 yr.
     Coal burned, 1,285,714 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment $23,595,000.
     Midwest plant location, mid-1980 operating costs.
 7.2


 2.0
 6.9
 1.7
 0.4
18.2

18.2
                                                    28.2
                                                    44.6
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements



3,
4,
Dollars/dry ton Dollars/wet ton
7.04 3.52
374,900

32,900
718,200
545,600
Mills/kWh
0.43
8.

0,
81.
100,


,3

.7
.8
.0


                                                 171

-------
                        TABLE A-39.  UNTREATED DISPOSAL

    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
      (Variation from base case:  pond disposal 5 mi from facilities)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total,
   806
   119
 5,547
   249
   428
    53
	0
 7,210

   108
 7,318

 7,251
14,569

   367
    49
 1,977
   735
17,697

 3,539
21,236

 1,399
 2,548
25,183

 1,423
   230

26,836
          Percent  of
            direct
          investment
           Percent  of
          total capital
           investment
  5.5
  0.8
 38.1
  0.1
  1.7
  2.9
  0.4

 49.5

  0.7
 50.2

 49.8
100.0

  2.5
  0.3
 13.7
  5.0
121.5

 24.3
145.8

  9.6
 17.5
172.9

  9.7
  1.6

184.2
  3.0
  0.4
 20.7
  0.1

  0.9
  1.6
  0.2

 26.9

  0.4
 27.3
 13.2
 79.2

  5.2
  9.5
 93.9
  5.3
  0.8

100.0
a.  Basis
      New 500-MW plant (30-yr life); 772 klb/hr (15% solids) sludge.-
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt) :   3.5% S (dry basis),  16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 5 mi from  scrubber facilities,
      50% solids settled density, 21.21 ft total depth, 407 acres.

                                         172

-------
                         TABLE  A-40.    UNTREATED  DISPOSAL

     TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
              (Variation from base case:   disposal area 5 mi from scrubber  facilities)
                                          Annual
                                         quantity
                  Unit
                 cost, $
                  Total
               annual revenue
               requirements, $
                    Percent
                   of total
                annual revenue
                  requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment  (plant)
    3% of direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
35,040 man-hr   12.50/man-hr
 7,911 kkWh
   500 hr
0.029/kWh
17.00/hr
  438,000


  292,700
  217,500
  229,400
    8,500
1,186,100

1,186,100
a.  Basis
    Remaining plant life, 30 yr.
    Coal  burned, 428,571 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $26,836,000.
    Midwest plant location, mid-1980 operating costs.
                                                    7.9
5.3
3.9
4.2
0.2
                                                   21.5

                                                   21.5
Capital charges
Depreciation, interim replacement, and
insurance at 6% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements

1,511



2,307


478

43
4,341
5,527
Dollars/dry ton Dollars/wet ton
13.61 6.81

,000



,900


,300

,800
,000
,100
Mills /kWh
1.58

27.3



41.8


8.6

0.8
78.5
100.0


                                                   173

-------
                      TABLE A-41.  UNTREATED DISPOSAL

    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
      (Variation from base case:  pond disposal 10 mi from facilities)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total. k$ .
   850
   119
11,094
     9

   469
   636
    53
	0
13,230

   198
13,428

 7.251
20,679

   367
    49
 2,832
   960
24,887

 4,977
29,864

 2,261
 3,584
35,709

 1,423
   288

37,420
           Percent of   Percent of
             direct    total capital
           investment   investment
  4.1
  0.6
 53.5
  0.1

  2.3
  3.1
  0.3

 64.0

  0.9
 64.9

 35.1
100.0

  1.8
  0.2
 13.7
  4.6
120.3

 24.1
144.4

 10.9
 17.4
172.7
  6.9
  1.4

181.0
  2.3
  0.3
 29.7
  0.1

  1.2
  1.7
  0.1

 35.4

  0.5
 35.9

 19.4
 55.3

  1.0
  0.1
  7.5
  2.6
 66.5

 13.3
 79.8
100.0
a.  Basis
      New 500-MW plant (30-yr life); 772 klb/hr  (15% solids)  sludge.
      Midwest plant location; average basis for  cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash,
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS,
      Limestone process with 1.5 stoichiometry based on  S02  removed.
      Pond characteristics:  clay-lined, 10 mi from scrubber facilities,
      50% solids settled density, 21.21 ft total depth,  407  acres,
                                       174

-------
                          TABLE A-42.   UNTREATED  DISPOSAL

     TOTAL ANNUAL REVENUE REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
               (Variation  from base case:  disposal area 10 mi from scrubber facilities)
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    n of direct investment  (plant)'
    3% of direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 67, of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                                           Annual
                                          quantity
                   Unit
                  cost, $
                   Total
               annual revenue
               requirements,  $
35,040 man-hr   12.50/man-hr
10,261 kkwh
   500 hr
0.029/kWh
17.00/hr
  438,000


  537,100
  217,500
  297,600
    8,500
1,498,700

1,498,700
                                2,142,500



                                3,218,100


                                 600,500

                                  43,800
                                6,004,900

                                7,503,600

 Dollars/dry ton   Dollars/wet ton    Mills/kWh
                                              18.48
                         9.24
                                                                               2.14
a.  Basis
     Remaining plant  life, 30 yr.
     Coal burned,  428,571 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $37,420,000.
     Midwest plant location, mid-1980 operating costs.
                     Percent
                    of total
                 annual revenue
                  requirements
                                                     5.1
7.2
2.9
4.0
0.1
                                    20.0

                                    20.0




                                    28.5



                                    42.9


                                     8.0

                                     0.6
                                    80.0

                                   100.0
                                                   175

-------
                       TABLE A-43.  UNTREATED DISPOSAL3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
        (Variation from base case:  lime process, 1.1 stoichiometry)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
In s t rumen t at i on
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$.
   156
   147
 1,329
    72
   443
    53

 2,208

	33_
 2,241

 6,436
 8,677

   345
    47
 1,098
   496
10,663

 2,133
12,796

   636
 1,536
14,968

 1,258
   113

16,339
          Percent  of
            direct
          investment
           Percent of
          total capital
           investment
  1.8
  1.7
 15.3
  0.1

  0.8
  5.1
  0.6

 25.4

  0.4
 25.8

 74.2
100.0

  4.0
  0.5
 12.7
  5.7
122.9

 24.6
147.5

  7.3
 17.7
172.5

 14.5
  1.3

188.3
  1.0
  0.9
  8.1
  0.1

  0.4
  2.7
  0.3
 13.5
  0.2
 13.7
 39.4
 53.1

  2.1
  0.3
  6.7
  3.1
 65.3
 13.0
 78.3

  3.9
  9.4
 91.6
  7.7
  0.7

100.0
a.  Basis:
      New 500-MW plant (30-yr life); 1,008 klb/hr (10% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% s (dry basis). 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Lime process with 1.1 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 20.67 ft total depth, 359 acres.

                                        176

-------
                       TABLE  A-44.   UNTREATED DISPOSAL

    TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY ECONOMICS
                  (Variation from base case:  lime process with 1.1 stoichiometry)
                                          Annual
                                         quantity
                  Unit
                 cost, $
                  Total
              annual revenue
              requirements, $
Direct costs

Conversion costs
  Operating labor  and supervision
  Maintenance
   Labor and materials
    4% of direct  investment (plant)
    VI, of direct  investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
17,520  man-hr    12.50/man-hr
 1,906 kkWh
   500 hr
0.029/kWh
17.00/hr
219,000


 89,600
193,100
 55,300
  8,500
565,500

565,500
   Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $16,226,000.
     Midwest plant location,  mid-1980 operating costs.
                 Percent
                of total
              annual revenue
               requirements
 7.0


 2.8
 6.1
 1.8
 0.3
18.0

18.0
Capital charges
Depreciation, interim replacement, and
insurance at 6% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50Z of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements

898,100



1,395,400


255,100

21,900
2,570,500
3,136,000
Dollars/dry ton Dollars/wet ton Mills/kWh
8.87 4.44 0.90

28.7



44.5


8.1

0.7
82.0
100.0


                                                  177

-------
                       TABLE  A-45. UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
          (Variation from base case:   clarify and pump 1 mi from
                           facilities, 35% solids)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                                     Percent of
                                                       direct
                                           Total,  k$  investment
                       Percent of
                      total  capital
                       investment
1,051
187
697
7
97
422
54
2,515
38
2,553
7,251
9,804
425
63
1,217
544
12,053
2,411
14,464
721
1,736
16,921
1,423
146
10.7
1.9
7.1
0.1
1.0
4.3
0.6
25.7
0.3
26.0
74.0
100.0
4.3
0.6
12.5
5.5
122.9
24.6
147.5
7.4
17.7
172.6
14.5
1.5
5.6
1.0
3.8
0.1
0.5
2.3
0.3
13.6
0.2
13.8
39.2
53.0
2.3
0.4
6.6
2.9
65.2
13.0
78.2
3.9
9.4
91.5
7.7
0.8
18,490
188.6
100.0
a.  Basis
      New 500-MW plant (30-yr life); 331 klb/hr (35% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt);   3.5% S (dry basis), 16% ash.
      Flyash removed with 862.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      35% solids settled density, 21.21 ft total depth, 407 acres.
                                        178

-------
                         TABLE  A-46.    UNTREATED  DISPOSAL

     TOTAL  ANNUAL  REVENUE  REQUIREMENTS - REGULATED UTILITY  ECONOMICS
              (Variation from base case:   clarify and pump   1 mi from scrubber facilities)
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    n of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                                            Annual
                                           quantity
 1,996 kkWh
 1,000 hr
                   Unit
                  cost,  $
                 Total
              annual revenue
              requirements, $
                 Percent
                 of  total
              annual revenue
               requirements
26,280 man-hr    12.50/man-hr
0.029/kWh
17.00/hr
 Dollars/dry ton
                 328,500
102,100
217,500
 57,900
 17,000
723,000

723,000
                 1,015,300



                1,590,100


                  332,500

                   32,900
                2,970,800

                3,693,800

  Dollars/wet  ton  Mills/kWh
       9.10
                        4.55
                                       1.06
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  .7,000 hr/yr.
     Total capital investment, $18,490,000.
     Midwest plant location,  mid-1980 operating costs.
2.7
5.9
1.6
0.5
                                                     19.6

                                                     19.6




                                                     27.5



                                                     43.0


                                                      9.0

                                                      0.9
                                                     80.4

                                                    100.0
                                                  179

-------
                       TABLE A-47.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
          (Variation from base case:  clarify and pump 5 mi from
                          facilities, 35% solids)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                          Total, k$
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 1,736
   177
 3,484
     7

    97
   491
    53

 6,045

	91
 6,136

 7,251
13,387

   425
    63
 1,800
   690
16,365

 3,273
19,638

 1,239
 2,357
23,234

 1,423
   224

24,881
 13.0
  1.3
 26.0
  0.1

  0.7
  3.7
  0.4

 45.2

  0.6
 45.8

 54.2
100.0

  3.2
  0.
 13,
  5.2
122.2
 24.5
146.7

  9.3
 17.6
173.6
 10.6
  1.7

185.9
  7.0
  0.7
 13.9
  0.1

  0.4
  2.0
  0.2

 24.3

  0.4
 24.7

 29.1
 53.8

  1.7
  0.3
  7.2
  2.8
 65.8

 13.1
 78.9

  5.0
  9.5
 93.4

  5.7
  0.9

100.0
a.  Basis
      New 500-MW plant (30-yr life); 331 klb/hr (35% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis). 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 5 mi from scrubber facilities,
      35% solids settled density, 21.21 ft total depth, 407 acres.
                                         180

-------
                    TABLE  A-48.    UNTREATED DISPOSAL

TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED UTILITY  ECONOMICS
          (Variation from base case:  clarify and pump    5  mi  from scrubber facilities)
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                                        Annual
                                       quantity
                                        285 kkWh
                                      1,000 hr
  Unit
 cost,  $
    Total
annual revenue
requirements,  $
                                     35,040 man-hr    12.50/man-hr
0.029/kWh
17.00/hr
                                      Do_llars/dry ton
    438,000


    245,400
    217,500
    240,300
     17,000
  1,158,200

  1,158,200
                1,394,000



                2,139,800


                 458,900

                  43,800
                4,036,500

                5,194,700

  Dollars/wet ton   Mills/kWh
                                           12.79
                                                              6.40
                                                                            1.48
    Percent
   of total
annual revenue
 requirements
                                                                                           3.4
      4.7
      4.2
      4.6
      0.3
                                                                                          22.3
                                                                                          22.3
                                                                                          26.9
                                                                                          41.2
                                                                                          77.7

                                                                                         100.0
Basis
  Remaining plant  life, 30 yr.
  Coal burned,  428,571 Ib/hr, 9,000 Btu/kWh.
  Power plant  on-stream time, 7,000 hr/yr.
  Total capital investment, $24,881,000.
  Midwest plant location, mid-1980 operating costs.
                                               181

-------
                       TABLE  A-49. UNTREATED DISPOSAL3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


               (Variation from base case:  clarify and pump
                    10 mi from facilities, 35% solids)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                          Total, k$
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 1,761
   177
 6,969
     7

    97
   698
    53

 9,762

   146
 9,908

 7,251
17,159

   425
    63
 2,350
   833
20,830

 4,166
24,996

 1,775
 3,000
29,771

 1,423
   264

31,458
 10.3
  1.0
 40.5
  0.1

  0.6
  4.1
  0.3

 56.9
 42.3
100.0

  2.5
  0.4
 13.6
  4.9
121.4
 24.3
145.7

 10.3
 17.5
173.5
  8.3
  1.5

183.3
  5.6
  0.4
 22.2
  0.1

  0.3
  2.2
  0.2

 31.0

  0.5
 31.5

 23.0
 54.5

  1.4
  0.2
  7.5
  2.6
 66.2

 13.3
 79.5

  5.6
  9.5
 94.6

  4.6
  0.8

100.0
a.  Basis
      New 500-MW plant (30-yr life); 331 klb/hr (35% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 10 mi from scrubber facilities,
      35% solids settled density, 21.21 ft total depth, 407 acres.
                                        182

-------
                          TABLE A-50.   UNTREATED  DISPOSAL


     TOTAL ANNUAL  REVENUE REQUIREMENTS  -  REGULATED  UTILITY ECONOMICS


             (Variation  from base  case:   clarify and pump   10 mi from scrubber facilities)

                                                                                             Percent
                                                                           Total            of total
                                           Annual          Unit        annual revenue    annual revenue
                                           quantity	cost, $	requirements,  $	requirements
Direct costs

Conversion  costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    l<7, of  direct investment  (plant)
    37. of  direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of  total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total  annual revenue requirements


Equivalent  unit revenue requirements
35,040 man-hr    12.50/man-hr
10,746 kkWh
 1,000 hr
0.029/kWh
17.00/hr
 Dollars/dry  ton
                  438,000
  396,300
  217,500
  311,600
	17,000
1,380,400

1,380,400
                1,786,300



                2,705,400


                  534,400

                   43,800
                5,069,900

                6,450,300

  Dollars/wet  ton   Mills/kWh
      15.89
                         7.95
                                       1.84
    Basis
      Remaining plant life, 30 yr.
      Coal burned, 428,571 Ib/hr, 9,000 Btu/kWh.
      Power plant on-stream time, 7,000 hr/yr.
      Total capital  investment, $31,458,000.
      Midwest plant  location, mid-1980 operating  costs.
                                                      6.E
 6.1
 3.4
 4.8
 0.3
21.4

21.4
                                                     27.7



                                                     41.9


                                                      8.3

                                                      0.7
                                                     78.6

                                                    100.0
                                                     183

-------
                       TABLE A-51.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
 (Variation from base case:  clarify,  filter,  and  truck  to  landfill,  60%  solids)

                                                     Percent of   Percent of
                                                       direct    total capital
                                          Total,  k$  investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
      equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,094
   172

    85

    61
   427
    56
	97_
 2,992

	45_

 3,037

   538
 3,575

   276
    69
   629
   253
 4,802

   960
 5,762

   522
   691
 6,975

   976
   343

 8,294
 58.6
  4.8

  2.4

  1.7
 11.9
  1.6
  2.7
 83.7

  1.3

 85.0

 15.0
100.0

  7.7
  1.9
 17.6
  7.1
134.3

 26.9
161.2

 14.6
 19.3
195.1
 27.3
  9.6

232.0
 25.3
  2.1

  1.0

  0.7
  5.1
  0.7
  1.2
 36.1

  0.5

 36.6

  6.5
 43.1

  3.3
  0.8
  7.6
  3.1
 57.9

 11.6
 69.5

  6.3
  8.3
 84.1

 11.8
  4.1

100.0
a.  Basis
      New 500-MW plant (30-yr life); 193 klb/hr (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis),  16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS,
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Landfill disposal, 1 mi from scrubber facilities, 60% solids materials,
      land requirement - 188 acres at 30 ft deep.
                                          184

-------
                          TABLE A-52.    UNTREATED  DISPOSAL

      TOTAL ANNUAL  REVENUE REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
(Variation from base case: clarify, filter, and truck 1 mi



Direct costs
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs

Annual
quantity



35,046 man-hr
52,560 man-hr




410,125 tons
410,125 tons

2,086 kkWh
1,000 hr



Unit
cost, $



12.50/man-hr
17. 00 /man-hr




0.06/ton
0.16/ton

0.029/kWh
17.00/hr


from scrubber facilities)
Percent
Total
annual revenue
requirements, $



438,000
893,500

121,500

10,700
24,600
65,600

60,500
17,000
1,631,400
1,631,400
of total
annual revenue
requirements



11.5
23.5

3.2

0.3
0.6
1.7

1.6
0.4
42.8
42.8
Indirect costs

Capital charges
 Depreciation,  interim replacement,  and
  insurance at  7.83% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
 Plant, 50% of  conversion costs  less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit  revenue requirements
Dollars/dry  ton
               546,100



               713,300


               785,400

               133,200
              2,178,000

              3,809,400

Dollars/wet  ton   Mills/kWh
      9.38
                       4.69
                                      1.09
   Basis
     Remaining  plant life,  30  yr.
     Coal burned, 428,571 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment,  $18,490,000.
     Midwest plant location, mid-1980 operating costs.
                                                   14.4



                                                   18.7


                                                   20.6

                                                    3.5
                                                   57.2

                                                  100.0
                                                    185

-------
                       TABLE  A-53.  UNTREATED DISPOSAL3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
               (Variation from base case:  clarify,  filter,  and
                     truck 5 mi to landfill, 60% solids)
           Percent of
             direct
Total, k$  investment
                                                                  Percent of
                                                                 total capital
                                                                  investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
      equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
  2,094
    172

     85

     61
    427
     56
 	97_
  2,992

 	45.

  3,037

    809
  3,846

    276
     69
    629
    267
  5,087

  1,017
  6,104

    530
    732
  7,366

    976
    483

  8,825
 54.4
  4.5

  2.2
  1.2
 79.0
 21.0
100.0

  7.2
  1.8
 16.4
  6.9
132.3
 26.4
158.7

 13.8
 19.0
191.5
 23.8
  1.9

  1.0

  0.7
  4.8
  0.6
  1.1
 33.9

  0.5

 34.4

  9.2
 43.6

  3.1
  0.8
  7.1
  3.0
 57.6

 11.6
 69.2
229.5
100.0
a.  Basis
      New 500-MW plant (30-yr life); 193 klb/hr  (60%  solids)  sludge.
      Midwest plant location; average basis for cost  scaling, mid-1979.
      Coal analysis (by wt) :  3.5%  S  (dry basis),  16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS,
      Limestone process with 1.5 stoichiometry based  on S02 removed.
      Landfill disposal, 5 mi from  scrubber facilities, 60% solids  materials,
      land requirement-  188 acres at  30 ft  deep.
                                       186

-------
                            TABLE  A-54.    UNTREATED  DISPOSAL

       TOTAL ANNUAL REVENUE  REQUIREMENTS -  REGULATED UTILITY  ECONOMICS
(Variation from base case: clarify, filter,
Annual
quantity
and truck
Unit
cost,
5 mi from scrubber facilities)
Percent
Total of total
annual revenue annual revenue
$ requirements, $ requirements
Direct costs

Conversion  costs
  Operating labor and supervision
   Plant
   Solids  disposal equipment
  Maintenance—plant labor and material,
   4% of direct investment
  Landfill  operation
   Land preparation
   Trucks  (fuel and maintenance)
   Earthmoving equipment (fuel and
    maintenance)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
 35,040 man-hr
 87,600 man-hr
410,125 tons
410,125 tons

  2,086 kkWh
  1,000 hr
12.50/man-hr
17.00/man-hr
 0.20/ton
 0.16/ton

0.029/kWh
17.00/hr
Capital charges
  Depreciation, interim replacement, and
   insurance  at 7.83% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
  Plant, 50%  of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
  438,000
1,489,200

  121,500

   10,700
   82,000
   65,600

   60,500
   17.000
2,284,500

2,284,500
                                    576,800
                                    759,000


                                  1,112,000

                                    192,700
                                  2,640,5~00

                                  4,925,000

 Dollars/dry ton   Dollars/wet ton   Mills/kWh
      12.13              6.07            1.41
    Basis
      Remaining plant life, 30 yr.
      Coal burned,  428,571 Ib/hr, 9,000 Btu/kWh.
      Power plant on-strearn time, 7,000 hr/yr.
      Total capital investment, $24,881,000.
      Midwest plant location, mid-1980 operating costs.
 8.9
30.2

 2.5

 0.2
 1.7
 1.3

 1.2
 0.4
46.4

46.4
                                     11.7



                                     15.4


                                     22.6


                                   ~5Tr6

                                   100.0
                                                     187

-------
                       TABLE  A-55.  UNTREATED DISPOSAL^

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
               (Variation  from base case:   clarify,  filter, and
                     truck 10  mi  to landfill,  60% solids)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
      equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                                     Percent of
                                                       direct
                                           Total, k$ investment
                       Percent  of
                      total capital
                       investment
 2,094
   172

    85

    61
   427
    56
	97
 2,992

	45_

 3,037

 1,025
 4,062

   276
    69
   629
   279
 5,315

 1,063
 6,378

   535
   765
 7,678

   976
   595

 9,249
 51.6
  4.2

  2.1

  1.5
 10.5
  1.4
  2.4
 73.7

  1.1

 74.8

 25.2
100.0

  6.8
  1.7
 15.4
  6.9
130.8

 26.2
157.0

 13.2
 18.8
189.0
 24.1
 14.6

227.7
 22.6
  1.9

  0.9

  0.7
  4.6
  0.6
  1.0
 32.3

  0.5

 32.8

 11.1
 43.9

  3.0
  0.8
  6.8
  3.0
 57.5

 11.5
 69.0
100.0
a.  Basis
      New 500-MW plant (30-yr life); 193 klb/hr (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt)•   3.5% S (dry basis). 16% ash.
      Flyash removed with SC^.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on 502 removed.
      Landfill  disposal,  10 mi  from scrubber facilities,  land requirement
      188 acres at 30 ft deep.
                                       188

-------
                      TABLE  A-56.   UNTREATED  DISPOSAL

   TOTAL ANNUAL REVENUE  REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: clarify, filter, and



Direct costs
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
n of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs

Annual
quantity



35,040 man-hr
113,880 man-hr




410,125 tons
410,125 tons

2,086 kkWh
1,000 hr


truck 10 mi

Unit
cost, $



12. 50 /man-hr
17.00/man-hr




0.39/ton
0.16/ton

0.029/kWh
17.00/hr


from scrubber facilities)
Percent
Total
annual revenue
requirements, $



438,000
1,936,000

121,500

10,700
160,000
65,600

60,500
17,000
2,809,300
2,809,300
of total
annual revenue
requirements



7.5
33.3

2.1

0.2
2.8
1.1

1.0
0.3
48.3
48.3
Indirect costs

Capital charges
 Depreciation, interim replacement, and
  insurance at 7.83% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
601,200
795,500
   Basis
    Remaining plant life, 30 yr.
    Coal burned,  428,571 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment,  $31,458,000.
    Midwest plant location,  mid-1980 operating costs.
                  10.3
                  13.7
Plant, 507, of conversion costs less
utilities
Administrative, 107, of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
1
3
5
Dollars/dry ton Dollars/wet ton
14.40 7.20
,374,400
237,400
,008,500
,817,800
Mills /kWh
1.66
23.6
4.1
51.7
100.0
                                                 189

-------
                       TABLE A-57.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS

     (Variation from base case;  constrained  pond  acreage,  200-MW plant)

                                                     Percent of   Percent of
                                                       direct    total capital
                                          Total, k$  investment   investment

Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
78
96
746
6
66
354
41
1,387
21
1,408
5,726
7,134
326
45
885
427
8,817
1,763
10,580
485
1,270
12,335
354
85
1.1
1.3
10.4
0.1
0.9
5.0
0.6
19.4
0.3
19.7
80.3
100.0
4.6
0.6
12.4
6.0
123.6
24.7
148.3
6.8
17.8
172.9
5.0
1.2
0.6
0.7
5.8
0.1
0.5
2.8
0.3
10.8
0.2
11.0
44.8
55.8
2.6
0.4
6.9
3.3
69.0
13.8
82.8
3.8
10.0
96.6
2.8
0.6
12,774
179.1
100.0
a.
    Basis
      New 200-MW plant (30-yr life); 316 klb/hr  (15%  solids)  sludge.
      Midwest plant location; average basis for  cost  scaling, mid-1979.
      Coal analysis (by wt)•   3,5% s (dry basis), 16% ash.
      Flyash removed independently of SC^.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based  on  S02 removed.
      Pond characteristics:  clay-lined, 1 mi from  scrubber facilities,
      50% solids settled  density, pond  acreage - 50%  of  optimum,  101 acres,
                                       190

-------
                        TABLE A-58.   UNTREATED  DISPOSAL

    TOTAL ANNUAL REVENUE REQUIREMENTS  -  REGULATED UTILITY ECONOMICS
           (Variation from base  case:   200-MW plant, constrained pond acreage   50% of optimum)
Direct costs

Conversion  costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of  direct investment (plant)
    3% of  direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of  total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total  annual revenue requirements


Equivalent  unit revenue requirements
                                           Annual
                                          quantity
17,520 man-hr
   601 kkWh
   500 hr
                  Unit
                  cost, $
                 Total
              annual revenue
              requirements, $
                  Percent
                 of  total
              annual  revenue
               requirements
12.50/man-hr
0.031/kWh
17.00/hr
219,000


 56,300
171,800
 18,600
  8,500
474,200

474,200
                                  740,100
                                1,098,600


                                  127,600

                                   21,900
                                1,988,200

                                2,462,400

 Dollars/dry  ton   Dollars/wet ton   Mills/kWh
      14.81              7.41            1.76
                                                      8.9
2.3
7.0
0.8
0.3
                                    19.3

                                    19.3




                                    30.0



                                    44.6


                                     5.2

                                     0.9
                                    80.7

                                   100.0
   Basis
     Remaining plant life,  30  yr.
     Coal burned, 175,238 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment,  $12,774,000.
     Midwest plant location, mid-1980 operating costs.
                                                  191

-------
                       TABLE  A-59. UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


     (Variation from base case:  constrained pond acreage, 200-MW plant)

                                                     Percent  of   Percent of
                                                       direct    total capital
                                          Total, k$  investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
78
96
746
6
66
354
41
1,387
21
1,408
4,010
5,418
274
39
744
347
6,822
1,364
8,186
418
982
9,586
532
85
1.4
1.8
13.8
0.1
1.2
6.5
0.8
25.6
0.4
26.0
74.0
100.0
5.1
0.7
13.7
6.4
125.9
25.2
151.1
7.7
18.1
176.9
9.8
1.6
0.8
0.9
7.3
0.1
0.6
3.5
0.4
13.6
0.2
13.8
39.3
53.1
2.7
0.4
7.3
3.4
66.9
13.3
80.2
4.1
9.6
93.9
5.2
0.8
10,203
188.3
100.0
a.  Basis
      New 200-MW plant (30-yr life); 316 klb/hr (15% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
      Flyash removed independently of S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
       50% solids settled density, pond acreage - 75% of optimum, 152 acres.
                                       192

-------
                     TABLE  A-60.    UNTREATED DISPOSAL

   TOTAL ANNUAL  REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
         (Variation from base case:  200-MW plant,  constrained pond acreage    75% of optimum)
                                          Annual
                                         quantity
                  Unit
                 cost, $
    Total
annual  revenue
requirements, $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
17,520  man-hr    12.50/man-hr
                                 219,000
1,906 kkWh
500 hr
0.029/kWh
17.00/man-hr
42,200
120,300
55,300
8,500
445,300
445,300
    iasis
     Remaining plant life,  30  yr.
     Coal burned,  175,238 Ib/hr,  9,200 Btu/kWh.
     Power plant on-stream  time,  7,000 hr/yr.
     Total capital investment,  $10,203,000.
     Midwest plant location, mid-1980 operating  costs.
    Percent
   of  total
annual  revenue
 requirements
                                                    2.1
                                                    5.9
                                                    2.7
                                                    0.4
                                                   21.9

                                                   21.9
Capital charges
Depreciation, interim replacement, and
insurance at 6% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative. 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

575



877


113

21
1,587
2,033

,100



,500


,200

,900
,700
,000

28.3



43.2


5.6

1.1
78.1
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
12.23 6.12
1.45
	
                                               193

-------
                         TABLE  A-61. UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
        (Variation from base case:  constrained pond acreage,  500-MW plant)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
128
121
1,109
7
73
395
53
1,886
28
1,914
11,179
13,093
464
58
1,393
678
15,686
3,137
18,823
764
2,259
21,846
714
116
Percent of
direct
investment
1.0
0.9
8.4
0.1
0.6
3.0
0.4
14.4
0.2
14.6
85.4
100.0
3.5
0.4
10.7
5.2
119.8
24.0
143,8
5.8
17.3
166.9
5.4
0.9
Percent of
total capital
investment
0.6
0.5
4.9
0.1
0.3
1.7
0.2
8.3
0.1
8.4
49.3
57.7
2.0
0.3
6.2
3.0
69.2
13.8
83.0
3.4
9.9
96.3
3.2
0.5
22,676
173.2
100.0
a.  Basis
      New 500-MW plant (30-yr life); 772 klb/hr (15% solids) sludge.
      Midwest plant location, average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, pond acreage - 50% of optimum, 204 acres.
                                       194

-------
                         TABLE A-62.   UNTREATED  DISPOSAL

     TOTAL  ANNUAL REVENUE REQUIREMENTS  -  REGULATED  UTILITY ECONOMICS
(Variation from base case: constrained pond acreage
Annual Unit
quantity cost, $
50% of optimum)
Total
annual revenue
requirements, $
Percent
of total
annual revenue
requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    n of direct investment  (plant)
    y/, of direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
17,520 man-hr    12.50/man-hr
219,000
1,906 kkWh
500 hr
0.029/kWh
17.00/man-hr
76,600
335,400
55,300
8,500
694,800
694,800
                    5.2
                                                      1.8
                                                      8.0
                                                      1.3
                                                      0.2
Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total  capital
   investment less land and  working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
  Plant, 507. of conversion costs  less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                                1,310,800



                                1,950,100


                                  237,900

                                   21,900
                                3,472,500

                                A,215,500

 Dollars/dry ton   Dollars/wet  ton   Mills_/Wh_
      10.15              5.08           1.18
                   16.5

                   16.5




                   31.1



                   46.3


                    5.6

                    0.5
                   83.5

                  100.0
   Basis
     Remaining plant life,  30 yr.
     Coal burned, 428,571  Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment $22,676,000.
     Midwest plant location, mid-1980 operating costs.
                                                  195

-------
                       TABLE  A-63. UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
    (Variation from base case:  constrained pond acreage, 500-MW plant)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
128
121
1,109
7
73
395
53
1,886
28
1,914
7,965
9,879
386
51
1,157
547
12,020
2,404
14,424
646
1,731
16,801
1,068
116
Percent of
direct
investment
1.3
1.2
11.2
0.1
0.7
4.0
0.6
19.1
0.3
19.4
80.6
100.0
3.9
0.5
11.8
5.5
121.7
24.3
146.0
6.5
17.6
170.1
10.8
1.2
Percent of
total capital
investment
0.7
0.7
6.1
0.1
0.4
2.2
0.3
10.5
0.1
10.6
44.3
54.9
2.1
0.3
6.5
3.0
66.8
13.4
80.2
3.6
9.6
93.4
6.0
0.6
17,985
182.1
100.0
a.  Basis
      New 500-MW plant (30-yr life); 772 klb/hr  (15% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis),  16% ash.
      Flyash removed with S02'
      S0£ and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, pond acreage - 75% of optimum,  305 acres.
                                      196

-------
                        TABLE  A-64.    UNTREATED  DISPOSAL

    TOTAL  ANNUAL  REVENUE  REQUIREMENTS  - REGULATED UTILITY  ECONOMICS
                (Variation  from base case:  constrained pond acreage   75% of optimum)

                                                                                             Percent
                                                                           Total            of  total
                                           Annual          Unit        annual revenue     annual revenue
                                          quantity	cost, $	requirements ,	$	requirements
Direct costs

Conversion  costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of  direct investment  (plant)
    3% of  direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of  total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total  annual revenue requirements


Equivalent  unit revenue requirements
17,520 man-hr    12.50/man-hr
219,000
1,906 kkWh
500 hr
0.029/kWh
17. 00 /man-hr
76,600
239,000
55,300
8,500
598,400
598,400
                    6.5
                                                      2.3
                                                      7.1
                                                      1.6
                                                      0.3
                                1,008,100
                                 1,546,700


                                  189,700

                                   21,900
                                 2,766,400

                                 3,364,800

 Dollars/dry  ton   Dollars/wet ton   Mills/kWh
       8.29              4.15         "  0.96
                   30.0



                   46.0


                    5.6

                    0.7
                   82.2

                  100.0
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr,  9,000  Btu/kWh.
     Power plant on-stream time,  7,000  hr/yr.
     Total capital investment,  $17,985,000.
     Midwest plant location,  mid-1980 operating costs.
                                                    197

-------
                         TABLE  A-65. UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
     (Variation from base case:  constrained pond acreage,  1500-MW plant)

                                                     Percent of   Percent of
                                                       direct    total capital
                                          Total, k$  investment   investment

Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal


1




237
207
,922
14
77
522
53
0.
0.
6.
0.
0.
1.
0.
8
7
5
1
3
8
2
0
0
3
0
0
1
0
.5
.4
.9
.1
.2
.0
.1
Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 3,032

	45_
 3,077

26,144
29,221

   758
    88
 2,586
 1,248
33,901

 6,780
40,681

 1,454
 4,882
47,017

 1,680
   220

48,917
 10.4
  0.2
 10.6
 89.4
100.0

  2.6
  0.3
  8.8
  4.3
116.0
160.9

  5.7
  0.8

167.4
  6.2
  0.1
  6.3
 53.4
 59.7

  1.5
  0.2
  5.3
  2.6
 69.3
  3.0
 10.0
 96.2
  3.4
  0.4

100.0
a.  Basis
      New 1500-MW plant (30-yr life); 2,368 klb/hr (15% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with SOo.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, pond acreage - 50% of optimum,  380 acres.
                                        198

-------
                       TABLE A-66.   UNTREATED DISPOSAL

   TOTAL ANNUAL  REVENUE REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS


         (Variation from base case:  1500-MW plant, constrained pond acreage   507. of optimum)
                                           Annual
                                          quantity
                   Unit
                  cost,  $
    Total
annual revenue
requirements,  $
Direct costs

Conversion costs
  Operating labor  and supervision
  Maintenance
   Labor and materials
    4% of direct  investment (plant)
    3% of direct  investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of  capital and taxes at
   8.6% of total capital investment
Overhead
26,280 man-hr    12.50/man-hr
    328,500
5,170 kkWh
1,000 hr
0.027/kWh
17.00/man-hr
123,100
784,300
139,600
17,000
1,392,500
1,392,500
                                2,821,000
                                4,206,900
a. Basis
     Remaining plant life, 30 yr.
     Coal burned,  1,285,714 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $48,917,000.
     Midwest plant location, mid-1980 operating costs.
    Percent
   of total
annual revenue
 requirements
                                                      3.7


                                                      1.4
                                                      8.7
                                                      1.6
                                                      0.2
                                                     15.5

                                                     15.5
                                                     31.4
                      46.8
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
532,000
32,900
7,592,800
8,985,300
Dollars/dry ton Dollars/wet ton Kills/kWh
7.40 3.70 0.86
5.9
0.4
84.5
100.0
                                                     199

-------
                         TABLE A-67.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


   (Variation from base case:  constrained pond acreage, 1500-MW plant)

                                                     Percent of   Percent of
                                                       direct    total capital
                                          Total? k$  investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
237
207
1,922
14
77
522
53
3,032
45
3,077
18,637
21,714
620
74
2,109
996
25,513
5,103
30,616
1,198
3,674
35,488
2,520
220
1.1
1.0
8.9
0.1
0.3
2.4
0.2
14.0
0.2
14.2
85.8
100.0
2.9
0.3
9.7
4.6
117.5
23.5
141.0
5.5
16.9
163.4
11.6
1.0
0.6
0.5
5.0
0.1
0.2
1.4
0.1
7.9
0.1
8.0
48.8
56.8
1.6
0.2
5.5
2.6
66.7
13.4
80.1
3.1
9.6
92.8
6.6
0.6
38,228
176.0
100.0
a.  Basis
      New 1500-MW plant (30-yr life); 2,368 klb/hr (15% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt);   3.5% S (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, pond acreage -  75% of optimum,  571 acres.
                                      200

-------
                      TABLE A-68.   UNTREATED  DISPOSAL

   TOTAL ANNUAL REVENUE REQUIREMENTS -  REGULATED UTILITY  ECONOMICS


         (Variation from base  case:  1500-MW plant, constrained pond  acreage    75% of optimum)
                                          Annual
                                         quantity
                  Unit
                 cost, $
    Total
annual revenue
requirements, $
    Percent
   of total
annual revenue
 requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
26,280 man-hr    12.50/man-hr
                                 328,500
5,170 kkWh
1,000 hr
0.027/kWh
17.00/man-hr
123,100
559,100
139,600
17,000
1,167,300
1,167,300
    Basis
     Remaining plant life, 30 yr.
     Coal burned,  1,285,714 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment,  $38,228,000.
     Midwest plant location,  mid-1980 operating costs.
                       4.7


                       1.7
                       7.9
                       2.0
                       0.2
                      16.6

                      16.6
Capital charges
Depreciation, interim replacement, and
insurance at 6% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements

2,129,300



3,287,600


419,400

32,900
5,869,200
7,036,500
Dollars/dry ton Dollars/wet ton Mills/kWh
6.05 3.03 0.67

30.3



46.7


6.0

0.5
83. A
100.0


                                                  201

-------
                         TABLE  A-69.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
              (Variation from base case:  pond settled density 40%)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
129
121
1,109
7
73
395
53
1,887
28
1,915
8,848
10,763
408
53
1,223
584
13,031
2,606
15,637
697
1,876
18,210
1,735
125
Percent of
direct
investment
1.2
1.1
10.2
0.1
0.7
3.7
0.5
17.5
0.3
17.8
82.2
100.0
3.8
0.5
11.4
5.4
121.1
24.2
145.3
6.5
17.4
169.2
16.1
1.2
Percent of
total capital
investment
0.6
0.6
5.4
0.1
0.4
2.0
0.3
9.4
0.1
9.5
44.1
53.6
2.0
0.3
6.1
2.9
64.9
13.0
77.9
3.5
9.3
90.7
8.7
0.6
20,070
186.5
100.0
a.  Basis
      New 500-MW plant (30-yr life); 772 klb/hr  (15%  solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5%  S (dry basis),  16% ash.
      Flyash removed with S0?.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:   clay-lined, 1 mi from scrubber facilities,
      40% solids settled density, 21.21 ft total depth, 496 acres.
                                       202

-------
                          TABLE A-70.   UNTREATED DISPOSAL

      TOTAL  ANNUAL REVENUE REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
                       (Variation from base case:  40% solids settled density)
                                           Annual
                                          quantity
                   Unit
                  cost,  $
                  Total
              annual  revenue
              requirements, $
                  Percent
                 of  total
              annual revenue
               requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    k% of direct investment (plant)
    y/, of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
17,520 man-hr     12.50/man-hr
 1,906 kkWh
   500 hr
0.029/kWh
17.00/hr
                  219,000
 76,600
265,400
 55,300
  8.500
624,800

624,800
                                 1,091,500
                                1,724,500
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571  Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $20,070,000.
     Midwest plant location, mid-1980 operating costs.
 5.9



 2.0
 7.1
 1.5
 0.2
16.7

16.7
                                                     29.1
                                                     46.0
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements
284,700

21,900
3,122,600
3,747,400
Dollars/dry ton Dollars/wet ton Mills/kWh
11.54 5.77 1.07
7,

0,
83,
100,


.6

.6
.3
.0


                                                   203

-------
                       TABLE A-71.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
             (Variation from base case:  pond settled density 60%)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
In s t rumen t at i on
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
128
121
1,109
7
73
395
53
1,886
28
1,914
6,125
8,039
337
46
1,014
468
9,904
1,981
11,885
576
1,426
13,887
1,198
109
Percent of
direct
investment
1.6
1.5
13.8
0.1
0.9
4.9
0.7
23.5
0.3
23.8
76.2
100.0
4.2
0.6
12.6
5.8
123.2
24.6
147.8
7.2
17.7
172.7
14.9
1.4
Percent of
total capital
investment
0.8
0.8
7.3
0.1
0.5
2.6
0.3
12.4
0.2
12.6
40.3
52.9
2.2
0.3
6.7
3.1
65.2
13.0
78.2
3.8
9.4
91.4
7.9
0.7
15,194
189.0
100.0
a.  Basis
      New 500-MW plant (30-yr life); 772 klb/hr (15% solids) sludge,
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3,5% S (dry basis), 16% ash,
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS,
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:   clay-lined, 1 mi from scrubber facilities,
      60% solids settled density, 20.40 ft total depth, 342 acres.
                                      204

-------
                          TABLE A-72.   UNTREATED DISPOSAL

      TOTAL ANNUAL REVENUE REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
                       (Variation from base case:   607,  solids settled density)
                                           Annual
                                          quantity
                  Unit
                 cost, $
                 Total
             annual revenue
             requirements, $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
17,520 man-hr     12.50/man-hr
 1,906 kkWh
   500 hr
0.029/kWh
17.00/hr
219,000


 76,600
183,800
 55,300
  8,500
543,200

543,200
                                  833,200
                                1,306,700
a. Basis
     Remaining plant life,  30 yr.
     Coal burned, 428,571  Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $15;194,000.
     Midwest plant location, mid-1980 operating costs.
                 Percent
                of total
             annual revenue
              requirements
 7.4


 2.6
 6.2
 1.9
 0.3
18.4

18.4
                                                     28.3
                                                     44.3
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
243,900
21,900
2,405,700
2,948,900
Dollars/dry ton Dollars/wet ton Mills/kWh
6.05 3.03 1.66
8.3
0.7
81.6
100.0

                                                   205

-------
                       TABLE A-73.  UNTREATED DISPOSAL

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


                 (Variation from base case:  unlined pond)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
128
121
1,109
7
73
395
53
1,886
28
1,914
5,311
7,225
313
43
948
432
8,961
1,792
10,753
544
1,290
12,587
1,700
104
Percent of
direct
investment
1.8
1.7
15.3
0.1
1.0
5.5
0.7
26.1
0.4
26.5
73.5
100.0
4.3
0.6
13.1
6.0
124.0
24.8
148.8
7.5
17.9
174.2
23.6
1.4
Percent of
total capital
investment
0.9
0.8
7.7
0.1
0.5
2.7
0.4
13.1
0.2
13.1
36.9
50.2
2.2
0.3
6.6
3.0
62.3
12.4
74.7
3.8
9.0
87.5
11.8
0.7
14,391
199.2
100.0
a.  Basis
      New 500-MW plant (30-yr life) ;  772 klb/hr  (15% solids) sludge .
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt) :  3.5% S  (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on S0£ removed.
      Pond characteristics:   unlined  pond, 1 mi from scrubber facilities,
      50% solids settled density, 17.20 ft total depth, 486 acres.
                                       206

-------
                          TABLE A-74.   UNTREATED  DISPOSAL

     TOTAL ANNUAL REVENUE REQUIREMENTS  -  REGULATED  UTILITY ECONOMICS
                               (Variation  from base case:  unlined pond)
Direct costs.

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    n of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                                           Annual
                                          quantity
 1,906 kkWh
   500 hr
                   Unit
                  cost,  $
                  Total
              annual revenue
              requirements, $
                  Percent
                 of  total
              annual revenue
               requirements
17,520 man-hr    12.50/man-hr
0.029/kWh
17.00/hr
219,000


 76,600
159,300
 55,300
  8,500
518,700

518,700
                                   755,200
                                 1,237,600


                                   231,700

                                    21,900
                                 2,246,400

                                 2,765,100

 Dollars/dry ton   Dollars/wet  ton   Mills/kWh
       6.81              3.41           0.79
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr,  9,000  Btu/kWh.
     Power plant on-stream time,  7,000  hr/yr.
     Total capital investment, $14,391,000.
     Midwest plant location,  mid-1980 operating  costs.
                                      7.9
2.8
5.8
2.0
0.3
                                                     27.3
                                                     44.7
                                     81.2

                                    100.0
                                                  207

-------
                        TABLE  A-75. UNTREATED DISPOSAL

    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND  INSTALLATION ANALYSIS
          (Variation from base case:  synthetic lining, $l<50/yd2)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
   128
   121
 1,109
     7

    73
   395
    53

 1,886

	28
 1,914

 9,818
11,732

   432
    55
 1,295
   624
14,138

 2,828
16,966

   715
 2,036
19,717

 1,133
   144

20,994
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
  1.1
  1.0
  9.4
  0.1

  0 6
  3.4
  0.4

 16.1

  0.2
 16.3

 83.7
100.0

  3.7
  0.5
 11.0
  5.3
120.5

 24.1
144.6

  6.1
 17.4
168.1

  9.6
  1.2

178.9
  0.6
  0.6
  5.2
  0.1

  0.3
  1.9
  0.3
  9.0
  0.1
  9.1
 46.8
 55.9

  2.0
  0.3
  6.1
  3.0
 67.3
 13.5
 80.8

  3.4
  9.7
 93.9
  5.4
  0.7

100.0
a.  Basis
      New 500-MW plant (30-yr life); 772  klb/hr  (15%  solids)  sludge..
      Midwest plant location; average basis for  cost  scaling, mid-1979.
      Coal analysis (by wt):  3.5%  S  (dry basis),  16% ash.
      Flyash removed with  S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based  on  S02 removed.
      Pond characteristics:  synthetic lining, 1 mi from scrubber  facilities,
      50% solids settled density, 21.21  ft total depth,  407 acres.
                                       208

-------
                      TABLE  A-76.   UNTREATED DISPOSAL

  TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
                   (Variation  from base case:  synthetic-lined  pond, cost $1.50/yd')
                                           Annual
                                          quantity
                  Unit
                 cost, $
                  Total
               annual revenue
               requirements, $_
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of total capital investment
Overhead
17,520 man-hr   12.50/man-hr
 1,906 kkWh
   500 hr
0.029/kWh
17.00/hr
219,000


 76,600
294,500
 55,300
  8,500
653,900

653,900
                               1,183,000
                               1,805,500
    Basis
     Remaining plant life, 30 yr.
     Coal burned,  428,571 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $20,994,000.
     Midwest plant location, mid-1980 operating  costs.
                  Percent
                 of total
               annual revenue
                requirements
                                                     5.6
2.0
7.6
1.4
0.2
                                     16.8

                                     16.8




                                     30.5



                                     46.5
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
217
21
3,227
3,881
Dollars/dry ton Dollars/wet ton
9.50 4.75
,500
,900
,900
,800
Mills /kWh
1.11
5.6
0.6
83.2
100.0
                                               209

-------
                        TABLE A-77.  UNTREATED DISPOSAL
    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


          (Variation from base case:  synthetic lining, $2.50/yd )
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                                     Percent of   Percent of
                                                       direct    total capital
                                         Total, k$   investment   investment
128
121
1,109
7
73
395
53
1,886
28
1,914
11,202
13,116
465
58
1,395
679
15,713
3,143
18,856
765
2,263
21,884
1,042
144
1.0
0.9
8.5
0.1
0.5
3.0
0.4
14.4
0.2
14.6
85.4
100.0
3.5
0.4
10.6
5.2
119.8
24.0
143.8
5.8
17.2
166.8
7.9
1.1
0.6
0.5
4.8
0.1
0.3
1.7
0.2
8.2
0.1
8.3
48.6
56.9
2.0
0.2
6.1
2.9
68.1
13.6
81.7
3.3
9.9
94.9
4.5
0.6
23,070
175.9
100.0
a.  Basis
      New 500-MW plant (30-yr life); 772 klb/hr  (15%  solids)  sludge.
      Midwest plant location, average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5%  S  (dry basis),  16%  ash.
      Flyash removed with S02-
      S0£ and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on 862 removed.
      Pond characteristics:   synthetic lining, 1 mi from scrubber facilities,
      50% solids settled  density, 21.21  ft  total depth, 407 acres.
                                       210

-------
                       TABLE  A-78.    UNTREATED  DISPOSAL3

   TOTAL ANNUAL  REVENUE  REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
                   (Variation from base case:  synthetic-lined  pond  - cost $2.50/yd2)
                                           Annual
                                          quantity
                  Unit
                 cost, $
                 Total
             annual revenue
             requirements,  $
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4% of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement,  and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
17,520 man-hr    12.50/man-hr
 1,906 kkWh
   500 hr
0.029/kWh
17.00/hr
219,000


 76,600
336,000
 55,300
  8,500
695,400

695,400
                                1,313,000
                                1,984,000
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $23,070,000.
     Midwest  plant location,  mid-1980 operating costs.
                 Percent
                of total
             annual revenue
              requirements
 5.1


 1.8
 7.9
 1.3
 0.2
16.3

16.3
                                                    30.9
                                                    46.7
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements



3
4
Dollars/dry ton Dollars/wet ton
10.47 5.24
238,200

21,900
,557,100
,252,500
Mills/kWh
1.21
5.6

0.5
83.7
100.0


                                                211

-------
                        TABLE  A-79. UNTREATED DISPOSAL

    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND  INSTALLATION ANALYSIS
         (Variation from base case:  synthetic lining,  $3.50/yd2)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
   128
   121
 1,109
     7

    73
   395
    53

~1,886

	2_8_
 1,914

12,459
14,373

   493
    61
 1,484
   728
17,139

 3,428
20,567

   811
 2,468
23,846

   969
   144

24,959
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
  0.9
  0.8
  7.7
  0.1

  0.5
  2.7
  0.4

 13.1

  0.2
 13.3

 86.7
100.0

  3.4
  0.4
 10.3
  5.1
119.2

 23.9
143.1

  5.6
 17.2
165.9

  6.7
  1.0

173.6
  4.4
  0.1

  0.3
  1.6
  0.2
  7.6
  0.1
  7.7
 49.9
 57.6

  2.0
  0.2
  6.0
  2.9
 68.7
 13.7
 82.4

  3.2
  9.9
 95.5
  3.9
  0.6

100.0
a.  Basis
      New 500-MW plant (30-yr life); 772 klb/hr  (15% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash,
      Flyash removed with SC^.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  synthetic lining, 1 mi from scrubber facilities,
      50% solids settled density, 21.21 ft total depth, 407 acres.
                                        212

-------
                        TABLE  A-80.   UNTREATED DISPOSAL

     TOTAL ANNUAL  REVENUE REQUIREMENTS -  REGULATED  UTILITY ECONOMICS
                  (Variation from base case:  synthetic-lined pond   cost $3.50/yd2)
                                           Annual
                                          quantity
                  Unit
                  cost, $
                  Total
              annual revenue
              requirements, $
Direct costs

Conversion  costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    4X of  direct investment  (plant)
    3i? of  direct investment  (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of  total capital investment
Overhead
17,520 man-hr     12.50/man-hr
 1,906 kkWh
   500 hr
0.029/kWh
17.00/hr
219,000


 76,600
373,800
 55,300
  8,500
733,200

733,200
                                1,430,800
                                2,146,500
    Basis
     Remaining plant life,  30 yr.
     Coal burned, 428,571  Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment,  $24,959,000.
     Midwest plant location, mid-1980 operating costs.
                  Percent
                 of  total
              annual revenue
               requirements
 4.8


 1.7
 8.1
 1.2
 0.2
16.0

16.0
                                                    31.2
                                                    46.8
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
257,100
21,900
3,856,300
4,589,500
Dollars/dry ton Dollars/wet ton Mills/kWh
11.30 5.65 1.31
5.
0.
84.
100.

6
5
0
0

                                                  213

-------
                        TABLE  A-81.  UNTREATED DISPOSAL

    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND  INSTALLATION ANALYSIS
          (Variation from base case:  synthetic lining,  $4.50/yd2)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total,  k$
 1,886

	28^
 1,914

13,616
15,530
   518
    64
 1,565
   772
18,449

 3,690
22,139

   852
 2,657
25,648

   915
   144

26,707
          Percent of   Percent of
            direct    total capital
          investment   investment


1




128
121
,109
7
73
395
53
0
0
7
0
0
2
0
.8
.8
.1
.1
.5
.5
.3
0
0
4
0
0
1
0
.5
.4
.1
.1
.3
.5
.2
 12.1
  0.2
 12.3
 87.7
100.0

  3.3
  0.4
 10.1
  5.0
118.8
 23.8
142.6
172.0
  7.1
  0.1
  7.2
 51. Q
 58.2

  1.9
  0.2
  5.9
  2.9
 69.1
 13.8
 82.9

  3.2
  9.9
 96.0

  3.5
  Q.I

100.0
a.  Basis
      New 500-MW plant (30-yr life); 772 klb/hr (15% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt ) :   3.5% S (dry basis), 16% ash.
      Flyash removed with SOo.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on  S02  removed.
      Pond characteristics:  synthetic lining, 1  mi from scrubber  facilities,
      50% solids  settled  density,  21.21 ft total  depth, 407 acres.
                                       214

-------
                     TABLE A-82.   UNTREATED DISPOSAL

  TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
                  (Variation from base case:  synthetic-lined pond - cost $4.50/yd )
                                           Annual
                                          quantity
                  Unit
                 cost, $
                 Total
             annual revenue
             requirements, $
                 Percent
                of total
              annual revenue
               requirements
Direct costs

Conversion costs
  Operating labor and supervision
  Maintenance
   Labor and materials
    n of direct investment (plant)
    3% of direct investment (pond)
  Electricity
  Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
17,520 man-hr     12.50/man-hr
 1,906 kkWh
   500 hr
0.029/kWh
17.00/hr
219,000


 76,600
408,500
 55,300
  8,500
767,900

767,900
                                1,538,900
                                2,296,800
a. Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $26,707,000.
     Midwest  plant location,  mid-1980 operating costs.
                                    4.5
 1.6
 8.3
 1.1
 0.2
15.7

15.7
                                   31.4
                                   46.9
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
274,500
21,900
4,132,100
4,900,000
Dollars /dry ton Dollars /wet ton Mills /kWh
12.07 6.04 1.40
5.6
0.4
84.3
100.0

                                                 215

-------
                        TABLE A-83.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                               (Base case)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 2,272
   262
   657
   313

   164
   974
   113
   115
 4,870

	73_
 4,943

 7,410
12,353

   821
   162
 1,627
   649
15,612

 3,122
18,734

 1,132
 2,248
22,114

 1,450
   550

24,114
          Percent of   Percent of
            direct    total capital
          investment   investment
 18.4
  2.1
  5.3
  2.5

  1.3
  7.9
  0.9
  0.9
 39.4

  0.6
 40.0

 60.0
100.0

  6.6
  1.3
 13.2
  5.3
126.4

 25.3
151.7

  9.2
 18.1
179.0
 11.7
  4.5

195.2
  9.4
  1.1
  2.7
  1.3

  0.7
  4.0
  0.5
  0.5
 20.2

  0.3
 20.5

 30.7
 51.2

  3.4
  0.7
  6.7
  2.7
 64.7

 13.0
 77.7
  4.7
  9.3
 91.7
  6.0
100.0
a.  Basis
      New 500-MW plant (30-yr life); 347 klb/hr  (36%  solids)  sludge.
      Midwest plant location; average basis for cost  scaling, mid-1979.
      Coal analysis (by wt):  3.5%  S  (dry basis),  16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based  on S02 removed.
      Pond characteristics:   clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 21.38 ft total depth, 414 acres.
      Calcilox added at 7% of dry solids.
                                        216

-------
                             TABLE A-84.    DRAVO PROCESS

      TOTAL ANNUAL  REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
(Base case)



Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
37. of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs

Annual
quantity


4,053 tons
28,378 tons


35,040 man-hr




3,577 kkWh
1,000 hr



Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




.029/kWh
17.00/hr


Total
annual revenue
requirements , $


194,500
1,645,900
1,840,400

438,000


197,700
222,300
103,700
17,000
978,700
2,819,100
Percent
of total
annual revenue
requirements


2.9
24.6
27.5

6.5


3.0
3.3
1.6
0.2
14.6
42.1
Indirect costs

Capital charges
 Depreciation, interim replacement,  and
  insurance at 6% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes  at
  8.6% of total capital investment
Overhead
 Plant, 50% of conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements
Equivalent unit revenue requirements
                                1,326,800

                                2,073,800


                                  437,500
                                   43,800
                                3,881,900

                                6,701,000

Dollars/dry ton   Dollars/wet ton_ _Mills/kWh
     15.32
                      7.66
                                     1.91
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $24,114,000.
     Midwest plant location, mid-1980 operating costs.
 19.8

 31.0


  6.5
  0.6
 57.9

100.0
                                                  217

-------
                        TABLE A-85.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                 (Variation from base case:  200-MW plant)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 1,405
   179
   451
   116

   141
   795
   100
   115
 3,302

	50_
 3,352

 3,479
 6,831

   682
   144
 1,048
   414
 9,119

 1,824
10,943

   746
 1.313
13,002

   676
   264

13,942
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 20.5
  2.6
  6.6
  1.7

  2.1
 10.6
  1.5
  1.7
 48.3

  0.8
 49.1

 50.9
100.0

 10.0
  2.1
 15.3
  6.1
133.5

 26.7
160.2
 10.2
  1.3
  3.2
  0.8

  1.0
  5.7
  0.7
  0.8
 23.7

  0.3
 24.0
 65.4
204.1
100.0
a.  Basis
      New 200-MW plant (30-yr life); 141 klb/hr (36% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 17.87 ft total depth, 193 acres.
      Calcilox added at 7% of dry solids.
                                       218

-------
                              TABLE   A-86.    DRAVO  PROCESS

      TOTAL  ANNUAL REVENUE REQUIREMENTS - REGULATED  UTILITY ECONOMICS
(Variation




Direct costs
Delivered raw materials
Lime (pebble) 1
Calcilox 10
Subtotal raw materials cost
Conversion costs
Operating labor and supervision 25
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity 2
Analyses 1
Subtotal conversion costs
Subtotal direct costs
from base case :


Annual
quantity


,519 tons 48
,623 tons 58


,280 man-hr 12




, 130 kkWh 0 .
,000 hr 17


200-MW plant)


Unit
cost, $


.00/ton
.00/ton


. 50/man-hr




031/kWh
.00/man-hr



Total
annual revenue
requirements , $


72,900
616,100
689,000

328,500


134,100
104,400
'66,000
17,000
650,000
1,339,000
Percent
of total
annual revenue
requirements


2.0
16.9
18.9

9.0


3.7
2.9
1.8
0.5
17.9
36.8
Indirect costs

Capital charges
  Depreciation, interim replacement, and
  insurance at 6% of  total capital
  investment less land and working
  capital
  Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
  utilities
  Administrative, 10%  of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                                780,100            21.4



                              1,199,000            32.9


                                292,000            8.0

                                 32,900            0.9
                              2,304,000            63.2

                              3,643,000           100.0

Dollars/dry  ton   Dollars/wet ton   Mills/kWh
    20.41              10.21          2.60
a.  Basis
     Remaining plant life,  30 yr.
     Coal burned, 175,238  Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment, $13,942,000.
     Midwest plant location, mid-1980 operating  costs.
                                                 219

-------
                        TABLE A-87,  DRAVO  PROCESS3

     TOTAL CAPITAL INVESTMENT - PROCESS  EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 200-MW plant,  25-yr remaining life)

                                                      Percent of   Percent of
                                                        direct    total capital
                                         Total,  k$    investment   investment
Process equipment                            1,503
Piping and insulation                          187
Transport lines                                451
Foundation and structural                      119
Excavation, site preparation,
 roads and railroads                           146
Electrical                                     798
Instrumentation                                100
Buildings                                      115
     Subtotal                                3,419

Services and miscellaneous                 	51_
     Subtotal excluding pond                 3,470

Pond construction                            2,990
     Subtotal direct investment              6,460

Engineering design and supervision             654
Architect and engineering contractor           140
Construction expense                         1,025
Contractor fees                                396
     Subtotal                                8,675

Contingency                                  1,735
     Subtotal fixed investment             10,410

Allowance for startup and modifications        742
Interest during construction                 1,249
     Subtotal capital investment           12,401

Land                                           578
Working capital                                279

     Total capital investment              13,258
 46.3
100.0

 10.1
  2.2
 15.9
  6.1
134.3
192.0

  8.9
  4.3

205.2
 11.3
  1.4
  3.4
  0.9

  1.1
  6.0
  0.8
  0.9
 25.8

  0.4
 26.2

 22.5
 48.7

  4.9
  1.1
  7.7
  3.0
 65.4

 13.1
 78.5
100.0
a.  Basis
      Existing 200-MW plant (25-yr remaining life) ;  146 klb/hr  (36%  solids)
      sludge: Midwest plant location; average basis  for cost  scaling, mid-1979.
      Coal analysis (by wt):  3.5% S  (dry basis),  16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on 862 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 17.33 ft total  depth, 165 acres.
      Calcilox added at 7% of dry solids.
                                         220

-------
                                TABLE  A-88.    DRAVO PROCESS

       TOTAL ANNUAL  REVENUE  REQUIREMENTS -  REGULATED  UTILITY ECONOMICS
(Variation from base



Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
case: existing


Annual
quantity
1,712 tons
11,981 tons
200-MW plant, 25


Unit
cost, $
48.00/ton
58.00/ton
25,280 man-hr 12.50/man-hr

2,177 kkWh
1,000 hr


0.031/kWh
17.00/man-hr

yr remaining life)

Total
annual revenue
requirements, $
82,200
694,900
777,100
328,500

138,800
89,700
67,500
17,000
541,500
1,418,600

Percent
of total
annual revenue
requirements
2.3
18.9
21.2
9.0

3.8
2.4
1.8
0.5
17.5
38.6
Indirect costs

Capital charges
 Depreciation, interim replacement, and
  insurance at 6.4% of total capital
  investment less land and working
  capital
 Average cost of capital  and taxes at
  8.6% of total capital investment
Overhead
 Plant, 5IK of conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue  requirements
Equivalent unit revenue requirements
                                 793,700



                               1,140,200


                                 287,000

                                 32,900
                               2,253,800

                               3,672,400

Dollars/dry ton   Dollars/wet ton   Mills/kWh
 21.6



 31.1


  7.8

  0.9
 61.4

100.0
     19.87
                        9.94
                                      2.62
     Remaining plant life, 25  yr.
     Coal burned, 180,952 Ib/hr, 9,500 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment,  $13,258,000.
     Midwest plant location, mid-1980 operating costs.
                                                   221

-------
                        TABLE  A-89.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case:  existing 200-MW plant, 20-yr remaining life)

                                                     Percent of   Percent of
                                                       direct    total capital
                                         Total, k$   investment   investment

Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
1,503
187
451
119
146
798
100
115
3,419
51
3,470
2,093
5,563
620
136
942
354
7,615
1,523
9,138
705
1,097
10,940
384
273
27.0
3.4
8.1
2.2
2.6
14.3
1.8
2.1
61.5
0.9
62.4
37.6
100.0
11.1
2.4
17.0
6.4
136.9
27.4
164.3
12.7
19.7
196.7
6.9
4.9
12.9
1.6
3.9
1.0
1.3
6.9
0.9
1.0
29.5
0.4
29.9
18.1
48.0
5.3
1.2
8.1
3.1
65.7
13.1
78.8
6.1
9.4
94.3
3.3
2.4
11,597
208.5
100.0
a.  Basis
      Existing 200-MW plant (20-yr remaining life) ; 146 klb/hr (36% solids)
      sludge; Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined,  1 mi from scrubber facilities,
      50% solids settled density,  16.86 ft total depth, 110 acres.
      Calcilox added at 7% of dry solids.
                                         222

-------
                             TABLE A-90.    DRAVO  PROCESS

      TOTAL ANNUAL  REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base



Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
case: existing 200-MW plant, 20-yr remaining life)

Annual
quantity


1,712 tons
11,981 tons


25,280 man-hr




2,177 kkWh
1,000 hr



Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.031/kWh
17 . 00/man-hr


Total
annual revenue
requirements, $


82,200
694,900
777,100

328,500


138,800
62,800
67,500
17,000
614,600
1,391,700
Percent
of total
annual revenue
requirements


2.4
20.1
22.5

9.5


4.0
1.8
1.9
0.5
17.7
40.2
Indirect costs

Capital charges
 Depreciation, interim replacement,  and
  insurance at 7% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
765,800
997,300
   Basis
     Remaining plant life, 20 yr.
     Coal burned, 180,952 Ib/hr, 9,500  Btu/kWh.
     Power plant on-stream time, 7,000  hr/yr.
     Total capital investment, $11,597,000.
     Midwest plant location, mid-1980 operating costs.
                  22.1
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
273,600
32,900
2,069,600
3,451,300
Dollars/dry ton Dollars/wet ton Mills/kWh
18.37 9.37 2.47
7,
1.
59,
100,
.9
.0
.8
.0
                                               223

-------
                          TABLE  A-91.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION  ANALYSIS
   (Variation from base case:  existing 200-MW plant,  15-yr  remaining life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 1,503
   187
   451
   119

   146
   798
   100
   115
 3,419
_  ^
 3,470

 1,349
 4,819

   588
   133
   869
   317
 6,726

 1,345
 8,071

   672
   969
 9,712

   258
   269

10,239
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 31.2
  3.9
  9.4
  2.5

  3.0
 16.6
  2.1
  2.4
 70.9

  1.1
 72.0

 28.0
100.0

 12.2
  2.8
 18.0
  6.6
139.6

 27.9
167.5

 13.9
 20.1
201.5
  5.4
  5.6

212.5
 14.7
  1.8
  4.4
  1.2

  1.4
  7.8
  1.0
  1.1
 33.4
 13.2
 47.1

  5.7
  1.3
  8.5
  3.1
 65.7
 13.1
 78.8

  6.6
  9.5
 94.9

  2.5
  2.6

100.0
a.  Basis
      Existing 200-MW plant (15-yr remaining life); 146 klb/hr  (36%  solids)
      sludge; Midwest  plant location; average basis for cost  scaling, mid-1979.
      Coal analysis (by wt);  3.5% S  (dry basis),  16%  ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 14.57  ft total  depth, 74 acres.
      Calcilox added at 7% of dry solids.
                                        224

-------
                               TABLE  A-92.   DRAVO PROCESS

       TOTAL  ANNUAL REVENUE  REQUIREMENTS -  REGULATED UTILITY  ECONOMICS
(Variation from base case: existing


Annual
quantity
Direct costs
Delivered raw materials
Lime (pebble) 1,712 tons
Calcilox 11,981 tons
Subtotal raw materials cost
Conversion costs
Operating labor and supervision 26,280 man-hr
Maintenance
Labor and materials
4X of direct investment (plant)
3% of direct investment (pond)
Electricity 2,177 kkWh
Analyses 1,000 hr
Subtotal conversion costs
Subtotal direct costs
200-MW plant,


Unit
costT $


48.00/ton
58.00/ton


12.50/man-hr




0.031/kWh
17.00/man-hr


15-yr remaining life)

Total
annual revenue
requirements, $


82,200
694,900
777,100

328,500


138,800
40,500
67,500
17,000
592,300
1,369,400

Percent
of total
annual revenue
- requirements


2.4
20.5
22.9

9.7


4.1
1.2
2.0
0.5
17.5
40.4
Indirect costs

Capital charges
  Depreciation, interim replacement, and
  insurance at 8.7% of total capital
  investment less land and working
  capital
  Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
844,900
880,600
a.  Basis
     Remaining plant life, 15 yr.
     Coal burned, 180,952  Ib/hr, 9,500  Btu/hr.
     Power plant on-stream time, 7,000  hr/yr.
     Total capital investment, $10,239,000.
     Midwest plant location, mid-1980 operating costs.
                  24.9
                  26.0
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
262,400
32,900
2,020,800
3,390,200
Dollars/dry ton Dollars/wet ton Mills/kWh
18.35 9.18 2.42
7.
1.
59.
100,
,7
,0
.6
.0
                                                225

-------
                          TABLE  A-93.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND  INSTALLATION ANALYSIS
   (Variation from base case:  existing 500-MW plant,  25-yr  remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                                     Percent  of   Percent of
                                                        direct    total capital
                                         Total,  k$   investment   investment
 2,275
   262
   657
   313

   167
   982
   113
	97
 4,866

	73
 4,939

 5,888
10,827
   791
   160
 1,507
   587
13,872

 2,774
16,646

 1,076
 1,998
19,720

 1,147
   549

21,416
 21.0
  2.4
  6.1
  2.9

  1.5
  9.1
  1.0
  0.9
 44.9

  0.7
 45.6

 54.4
100.0
  7.3
  1.5
 13.9
  5.4
128.1

 25.6
153.7
  9.9
 18.5
182.1
197.8
 10.6
  1.2
  3.1
  1.5

  0.8
  4.6
  0.5
  0.4
 22.7

  0.4
 23.1

 27.5
 50.6

  3.7
  0.8
  7.0
  2.7
 64.8

 12.9
 77.7
  5.0
  9.4
 92.1

  5.4
  2.5

100.0
a.  Basis
      Existing 500-MW plant (25-yr remaining life);  354.5 .klb/hr  (36%  solids)
      sludge; Midwest plant location; average basis  for  cost scaling,  mid-1979,
      Coal analysis (by wt):  3..5% S  (dry basis),  16%  ash.
      Flyash removed with S02-
      S02 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on  S02  removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber  facilities,
      50% solids settled density, 20.26  ft total  depth,  328  acres.
      Calcilox added at 7% of dry solids.
                                        226

-------
                           TABLE  A-94.    DRAVO  PROCESS

   TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED UTILITY ECONOMICS
(Variation from base



Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
case: existing 500-MW plant, 25-yr remaining life)

Annual Unit
quantity cost, S


4,144 tons 48.00/ton
29,008 tons 58.00/ton


35,040 man-hr 12. 50/man-hr




3,593 kkWh 0.029/kWh
1,000 hr 17.00/man-hr


Total
annual revenue
requirements, S


198,900
1,682,500
1,881,400

438,000


197,600
176,600
104,200
17,000
933,400
2,814,800
Percent
of total
annual revenue
requirements


3.1
26.4
29.5

6.8


3.1
2.8
1.6
0.3
14.6
44.1
Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6.4% of total capital
   investment less land and working
   capital
  Average cost of capital  and taxes at
   8.67, of  total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total  annual revenue  requirements


Equivalent  unit revenue requirements
                              1,262,100



                              1,841,800


                                414,500

                                 43,800
                              3,562,300

                              6,377,100

Dollars/dry  ton   Dollars/wet ton  Mills/kWh
                                              14.23
                                                                7.12
                                                                              1.82
a.  Basis
     Remaining plant  life, 25 yr.
     Coal burned,  438,095 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment $21,416,000.
     Midwest plant location, mid-1980 operating  costs.
 28.9


  6.5

  0.7
 55.9

100.0
                                              227

-------
                          TABLE  A-95. DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case:  existing 500-MW plant, 20-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
2,275
262
657
313
167
982
113
97
4,866
73
4,939
4,070
9,009
736
155
1,358
510
11,768
2,354
14,122
1,005
1,695
16,822
821
538
Percent of
direct
investment
25.2
2.9
7.3
3.5
1.8
10.9
1.3
1.1
54.0
0.8
54.8
45.2
100.0
8.2
1.7
15.0
5.7
130.6
26.2
156.8
11.2
18.7
186.7
9.1
6.0
Percent of
total capital
investment
12.5
1.4
3.6
1.7
0.9
5.4
0.6
0.6
26.8
0.4
27.2
22.3
49.5
4.1
0.8
7.5
2.8
64.7
13.0
77.7
5.5
9.3
92.5
4.5
3.0
18,181
201.8
100.0
a.  Basis
      Existing 500-MW plant (20-yr remaining life); 354.5 klb/hr (36% solids)
      sludge; Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on SC>2 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 17.82 ft -total depth, 235 acres.
      Calcilox added at 7% of dry solids.
                                       228

-------
                             TABLE A-96.    DRAVO  PROCESS3

     TOTAL ANNUAL REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
case: existing


Annual
quantity


4,144 tons
29,008 tons


35,040 man-hr




3,593 kkWh
1,000 hr


500-MW plant,


Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.029/kWh
17. 00 /man-hr


20-yr remaining life)

Total
annual revenue
requirements, $


198,900
1,682,500
1,881,400

438,000


197,600
122,100
104,200
17,000
878,900
2,760,300

Percent
of total
annual revenue
requirements


3.4
28.3
31.7

7.4


3.3
2.1
1.7
0.3
14.8
46.5
Indirect costs

Capital charges
 Depreciation, interim replacement,  and
  insurance at 7.0% of total capital
  investment less land and working  '.
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
1,177,500
1,572,200
a.  Basis
     Remaining plant life, 20 yr.
     Coal burned, 438,095 Ib/hr,  9,200 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $18,281,000.
     Midwest plant location, mid-1980 operating  costs.
                    26.5
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
387,400
43,800
3,180,900
5,941,200
Dollars/dry ton Dollars/wet ton Mills/kWh
13.26 6.63 1.70
6.
0.
53,
100,

,5
,7
.5
.0

                                                229

-------
                          TABLE  A-97.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND  INSTALLATION ANALYSIS


   (Variation from base case:  existing 500-MW plant,  15-yr  remaining life)

                                                     Percent of   Percent of
                                                       direct    total capital
                                         Total, k$   investment   investment
Process equipment                           2,275        30.0
Piping and insulation                         262         3.5
Transport lines                               657         8.7
Foundation and structural                     313         4.1
Excavation, site preparation,
 roads and railroads                          167         2.2
Electrical                                    982        12.9
Instrumentation                               113         1.5
Buildings                                  	97^         1.3
     Subtotal                               4,866        64.2

Services and miscellaneous                 	73_         1.0
     Subtotal excluding pond                4,939        65.2

Pond construction                           2,640        34.8
     Subtotal direct investment             7,579       100.0

Engineering design and supervision            687         9.1
Architect and engineering contractor          150         2.0
Construction expense                        1,232        16.2
Contractor fees                               447         5.9
     Subtotal                              10,095       133.2

Contingency                                 2,019        26.6
     Subtotal fixed investment             12,114       159.8

Allowance for startup and modifications       947        12.5
Interest during construction                1,454        19.2
     Subtotal capital investment           14,515       191.5

Land                                          509         6.7
Working capital                               529         7.0

     Total capital investment              15,553       205.2
 14.7
  1.7
  4.2
  2.0

  1.1
  6.3
  0.7
  0.6
 31.3

  0.4
 31.7

 17.0
 48.7
 13.0
 77.9
100.0
a.  Basis
      Existing 500-MW plant (15-yr remaining life); 354.5 klb/hr  (36% solids)
      sludge; Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis  (by wt):  3.5% S  (dry basis),  16% ash.
      Flyash removed with S02.
      862 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on SG2 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 16.87 ft total depth, 145 acres.
      Calcilox added at 7% of dry solids.
                                        230

-------
                             TABLE A-98.   DRAVO PROCESS

     TOTAL ANNUAL  REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
(Variation from base



Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
case: existing 500-MW plant, 15-yr remaining life)
Percent

Annual
quantity


4,144 tons
29,008 tons


35,040 man-hr




3,593 kkWh
1,000 hr



Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.029/kWh
17. 00 /man-hr


Total
annual revenue
requirements , $


198,900
1,682,500
1,881,400

438,000


197,600
79,200
104,200
17,000
836,000
2,117,400
of total
annual revenue
requirements


3.4
29.4
32.8

7.6


3.5
1.4
1.8
0.3
14.6
47.4
Indirect costs

Capital charges
 Depreciation, interim replacement,  and
  insurance at 8.7% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
 Plant, 50% of conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                              1,262,800



                              1,337,500


                                365,900

                                 43,800
                              3,010,100

                              5,727,500

Dollars/dry ton   Dollars/wet ton   Mills/kWh
     12.78
                       6.39
                                      1.64
   Basis
     Remaining plant life,  15  yr.
     Coal burned, 438,095 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment  $15,553,000.
     Midwest  plant location, mid-1980 operating costs.
 22.0



 23.4


  6.4

  0.8
 52.6

100.0
                                                  231

-------
                        TABLE  A-99.  DRAVO PROCESS3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                (Variation from base case:  1500-MW plant)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 4,363
   424
   978
   540

   241
 1,301
   119
   115
 8,081

   121
 8,202

17,358
25,560

 1,136
   207
 2,823
 1,127
30,853

 6,171
37,024

 1,967
 4,443
43,434
 3,414
 1,387

48,235
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 17.0
  1.7
  3.8
  2.1

  0.9
  5.1
  0.5
  0.5
 31.6

  0.5
 32.1

 67.9
100.0

  4.4
  0.8
 11.1
  4.4
120.7
169.9

 13.4
  5.4

188.7
  9.1
  0.9
  2.0
  1.1
  0.2
 16.8

  0.2
 17.0

 36.0
 53.0
 12.8
 76.8

  4.1
  9.2
 90.1
  7.0
100.0
a.  Basis
      New 1500-MW plant (30-yr life); 1040  klb/hr (36% solids)  sludge,
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt) :   3.5%  5 (dry basis), 16%  ash,
      Flyash removed with S02«
      S02 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on S02  removed.
      Pond characteristics:  clay-lined,  1 mi from scrubber  facilities,
      50% solids settled density, 26.39 ft  total  depth, 975  acres.
      Calcilox added at 7% of dry solids.
                                      232

-------
                              TABLE A-100.   DRAVO  PROCESS

      TOTAL ANNUAL REVENUE REQUIREMENTS  - REGULATED UTILITY ECONOMICS
(Variation from base case: 1500-MW


Annual Unit
quantity cost, $
Direct costs
Delivered raw materials
Lime (pebble) 12,163 tons 48.00/ton
Calcilox 85,050 tons 58.00/ton
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity 8,733 kkWh 0.027/kWh
Analyses 1,500 hr 17.00/hr
Subtotal conversion costs
Subtotal direct costs
plant)

Total
annual revenue
requirements, $


583,800
4,932,900
5,516,700

547,500


328,100
520,700
235,800
25,500
1,657,600
7,174,300

Percent
of total
annual revenue
requirements


4.1
34.6
38.7

3.8


2.3
3.6
1.7
0.2
11.6
50.3
Indirect costs

Capital charges
  Depreciation, interim replacement, and
  insurance at 6% of total capital
  investment less land and working
  capital
  Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
2,606,000
3,718,200
a.  Basis
     Remaining plant  life, 30 yr.
     Coal burned,  1,285,714 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $48,235,000.
     Midwest plant location, mid-1980 operating costs.
                   18.3
                   26.0
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
710,900
54,800
7,089,900
14,264,200
Dollars /dry ton Dollars /wet ton Mills /kWh
10.87 5.44 1.36
5.0
0.4
49.7
100.0
                                             233

-------
                          TABLE A-101.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case:  existing 1500-MW plant,  25-yr  remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total,  k$
 4,431
   424
   522
   548

   243
 1,367
   119
   115
 7,769

   117
 7,886

13,758
21,644

 1,051
   197
 2,533
   993
26,418

 5,284
31,702

 1,794
 3,804
37,300

 2,697
 1.385

41,382
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 20.5
  2.0
  2.4
  2.5

  1.1
  6.3
  0.6
  0.5
 35.9

  0.5
 36.4

 63.6
100.0

  4.9
  0.9
 11.7
  4.6
122.1

 24.4
146.5
  8.3
 17.5
172.3
 12.5
  6.4

191.2
  0.3
 19.1
 33.2
 52.3

  2.5
  0.5
  6.1
  2.4
 63.8
 12.8
 76.6
100.0
a.  Basis
      Existing 1500-MW plant (25-yr remaining life);  1063 klb/hr  (36% solids)
      sludge; Midwest pliant location; average basis for  cost  scaling, mid-1979.
      Coal analysis  (by wt):  3.5% S  (dry basis),  16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based  on  S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 24.96 ft total  depth,  770 acres.
      Calcilox added at 7% of dry solids.
                                       234

-------
                              TABLE A-102.   DRAVO  PROCESS

        TOTAL  ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
(Variation from base



Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
case: existing 1500-MW plant, 25-yr remaining life)
Percent

Annual Unit
quantity cost, $


12,432 tons 48.00/ton
86,800 tons 58.00/ton


43,800 man-hr 12.50/man-hr




8,775 kkWh 0.027/kWh
1,500 hr 17.00/man-hr


Total
annual revenue
requirements , $


596,700
5,034,400
5,631,100

547,500


315,400
412,700
236,900
25,500
1,538,000
7,169,100
of total
annual revenue
requirements


4.3
36.4
40.7

4.0


2.3
3.0
1.7
0.2
11.2
51.9
Indirect costs

Capital charges
  Depreciation, interim  replacement, and
  insurance at 6.4%  of  total capital
  investment less land  and working
  capital
  Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
  utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue  requirements
                              2,387,200



                              3,558,900


                                650,600

                                 54,800
                              6,651,500

                             13,820,600

Dollars/dry ton   Dollars/wet ton   Mills/kWh
                                             10.30
                                                                5.15
                                                                              1.32
a.  Basis
     Remaining plant life, 25 yr.
     Coal burned,  1,314,286 Ib/hr,  9,200 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $41,382,000.
     Midwest plant location, mid-1980 operating costs.
 17.3



 25.7


  4.7

  0.4
 48.1

100.0
                                                  235

-------
                         TABLE A-103.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case:  existing 1500-MW plant, 20-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 4,431
   424
   522
   548

   243
 1,367
   119
   115
 7,769

   117
 7,886

 9.514
17,400

   954
   187
 2,231
   842
21,614

 4,323
25,937

 1,642
 3,112
30,691

 1,874
 1,359

33,924
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 25.4
  2.4
  3.0
  3.1

  1.4
  7.9
  0.7
  0.7
 44.6

  0.7
 45.3

 54.6
100.0

  5.5
  1.1
 12.8
  4.8
124.2

 24.9
149.1
 10.8
  7.8
195.0
 13.1
  1.3
  1.5
  1.6

  0.7
  4.0
  0.4
  0.3
 22.9

  0.3
 23.2
 63.7
 12.8
 76.5
  5.5
100.0
a.  Basis
      Existing 1500-MW plant (20-yr remaining life) ;  1063 klb/hr  (36% solids)
      sludge; Midwest plant location; average basis for  cost  scaling, mid-1979.
      Coal analysis (by wt) :  3.5% S  (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based  on  S02 removed.
      Pond characteristics:  clay-lined, 1 mi from  scrubber facilities,
      50% solids settled density, 22.62 ft total depth,  535 acres.
      Calcilox added at 7% of dry solids.
                                        236

-------
                              TABLE  A-104.   DRAVO PROCESS

      TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY ECONOMICS
(Variation from base case: existing


Annual
quantity
Direct costs
Delivered raw materials
Lime (pebble) 12,432 tons
Calcilox 86,800 tons
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity 8,775 kkWh
Analyses 1,500 hr
Subtotal conversion costs
Subtotal direct costs
1500-MW plant, 20-yr remaining life)

Total
Unit annual revenue
cost, $ requirements, $


48.00/ton 596,700
58.00/ton 5,034,400
5,631,100

547,500


315,400
285,400
0.027/kWh 236,900
17.00/man-hr 25,500
1,410,700
7,041,800

Percent
of total
annual revenue
requirements


4.7
39.5
44.2

4.3


2.5
2.2
1.8
0.2
11.0
55.2
Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 7.0% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of  total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total  annual revenue requirements
Equivalent  unit revenue requirements
                              2,148,400



                              2,917,500


                                586,900

                              	54,800
                              5,707,600

                             12,749,400

Dollars/dry  ton   Dollars/wet ton  Mills/kWh
      9.50
                       4.75
                                      1.21
a.  Basis
     Remaining plant life,  20 yr.
     Coal burned, 1,314,286 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment, $33,924,000.
     Midwest plant location, mid-1980 operating  costs.
                                                  16.9
 22.9
  4.6
	CK4_
 44.8
100.0
                                                237

-------
                         TABLE A-105.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


   (Variation from base case:  existing 1500-MW plant, 15-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
4,431
424
522
548
243
1,367
119
115
7,769
117
7,886
6,129
14,015
866
178
1,973
714
17,746
3,549
21,295
1,517
2,555
25,367
1,199
1,339
Percent of
direct
investment
31.7
3.0
3.7
3.9
1.7
9.8
0.8
0.8
55.4
0.9
56.3
43.7
100.0
6.2
1.3
14.0
5.1
126.6
25.3
151.9
10.8
18.3
181.0
8.6
9.5
Percent of
total capital
investment
15.8
1.5
1.9
2.0
0.9
4.9
0.4
0.4
27.8
0.4
28.2
22.0
50.2
3.1
0.6
7.1
2.6
63.6
12.7
76.3
5.4
9.2
90.9
4.3
4.8
27,905
199.1
100.0
a.  Basis
      Existing 1500-MW plant (15-yr remaining life); 1063  klb/hr (36%  solids)
      sludge; Midwest plant location; average basis for  cost  scaling, mid-1979
      Coal analysis (by wt) :   3.5% S  (dry basis),  16%  ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on  S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 20.40 ft total depth,  343 acres.
      Calcilox added at 7% of dry solids.
                                       238

-------
                               TABLE A-106.   DRAVO  PROCESS

     TOTAL  ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
(Variation from base
:erials
; materials cost
: and supervision
:erials
: investment (plant)
: investment (pond)
iversion costs
rect costs
case: existing 1500-MW plant, 15-yr remaining life)
Total
Annual Unit annual revenue
quantity cost, $ requirements, $
12,432 tons 48.00/ton 596,700
86,800 tons 58.00/ton 5,034.400
5,631,100
43,800 man-hr 12. 50/man-hr 547,500
315,400
183,900
8,775kkWh 0.027/kWh 235,900
1,500 hr 17.00/man-hr 25,500
1,309,200
6,940,300
Percent
of total
annual revenue
requirements
4.9
41.5
46.4
4.5
2.6
1.5
2.0
0.2
10.8
57.2
Direct costs
  Lime (pebble)
  Calcilox
Conversion costs
  Operating labo
  Maintenance
    Labor and ma
    4% of direc
    3% of direc
  Electricity
  Analyses
Indirect costs

Capital charges
  Depreciation,  interim replacement, and
   insurance at  8.7% of total capital
   investment less  land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
  Plant, 50% of  conversion costs less
   utilities
  Administrative, 10% of operating labor
     Subtotal indirect costs

     Total annual revenue requirements


Equivalent unit  revenue requirements
                              2,206,900



                              2,399,800


                                536,200

                                 54,800
                              5,197,700

                             12,138,000

Dollars/dry  ton   Dollars/wet ton   Mills/kWh
      9.04
                       4.52
                                      1.16
    Basis
     Remaining plant life, 15 yr.
     Coal burned, 1,314,286 Ib/hr,  9,200  Btu/kWh.
     Power plant on-stream time,  7,000  hr/yr.
     Total capital investment, $27,105,000.
     Midwest  plant location, mid-1980 operating costs.
                                                  18.2
  4.4

  0.4
 42.8

100.0
                                                 239

-------
                         TABLE A-107.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
               (Variation from base case:  12% ash in coal)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
2,066
  217
  487
  290

  156
  965
  113
  115
4,409
 4,475

 6,398
10,873

   805
   162
 1,474
   589
13,903

 2,781
16,684

 1,029
 2,002
19,715

 1,253
   478

21,446
         Percent of
           direct
         inves tment
 Percent  of
total capital
 investment
             0.7
            41.2
            58.8
           100.0

             7.4
             1.5
            13.6
             5.4
           127.9
            25.5
           153.4

             9.5
            18.4
           181.3
            11.5
             4.4

           197.2
      9.6
      1.0
      2.3
      1.4
      0.6
     20.6
     29.8
     50.7

      3.7
      0.8
      6.9
      2.7
     64.8
    100.0
a.  Basis
      New 500-MW plant (30-yr life); 286 klb/hr C36% solids) sludge,
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis),  12% ash,  11,100 Btu/lb HV,
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on  S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 20.59  ft total depth,  358 acres.
      Calcilox added at 7% of dry solids.
                                        240

-------
                              TABLE  A-108.   DRAVO PROCESS

      TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
(Variation




Direct costs
Delivered raw materials
Lime (pebble) 3
Calcilox 23
Subtotal raw materials cost
Conversion costs
Operating labor and supervision 35
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity 3
Analyses 1
Subtotal .conversion costs
Subtotal direct costs
from base case


Annual
quantity


,350 tons
,443 tons


,040 man-hr




,235 kkWh
,000 hr


: 12% ash in


Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.029/kWh
17. 00 /man-hr


coal)

Total
annual revenue
requirements, $


160,800
1,359,700
1,520,500

438,000


179,000
191,900
93,800
17,000
919,700
2, 440 ,,200

Percent
of total
annual revenue
requirements


2.7
23.0
25.7

7.4


3.0
3.2
1.6
0.3
15.5
41.2
Indirect costs

Capital charges
  Depreciation,  interim replacement, and
  insurance at  6% of total capital
  investment less land and working
  capital
  Average cost of capital and  taxes at
  8.6% of total capital investment
Overhead
1,182,900
1,842,400
a,.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 405,405 Ib/hr, 9,000  Btu/kWh.
     Power plant on-stream time, 7,000  hr/yr.
     Total capital investment, $21,446,000.
     Midwest  plant location, mid-1980 operating costs.
                   20.0
                   31.1
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
413
43
3,482
5,922
Dollars/dry ton Dollars/wet ton
16.43 8.22
,000
,800
,100
,300
Mills /kWh
1.69
7.0
0.7
58.8
100.0

                                              24.1

-------
                        TABLE A-109.   DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                (Variation from base case:  20% ash in coal)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 2,519
   272
   697
   382

   172
 1,092
   119
   115
 5,368
_
 5,449

 7,905
13,354

   868
   171
 1,744
   688
16,825

 3,365
20,190

 1,229
 2,423
23,842

 1,556
   630

26,028
          Percent of
            direct
          investment
           Percent  of
          total capital
           investment
 18.8
  2.0
  5.2
  2.9

  1.3
  8.2
  0.9
  0.9
 40.2

  0.6
 40.8

 59.2
100.0

  6.5
  1.3
 13.0
  5.2
126.0

 25.2
151.2
  9.2
 18.1
178.5
 11.7
  4.7

194.9
  9.6
  1.0
  2.7
  1.5

  0.7
  4.2
  0.5
  Q.4
 20.6
  0.3
 20.9
 30.4
 51.3

  3.3
  0.7
  6.7
  2.7
 64.7
 12.9
 77.6

  4.7
  9.3
 91.6
  6.0
  2.4

100.0
a.  Basis
      New 500-MW plant (30-yr life); 414 klb/hr (36% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt);  3.5% s (dry basis), 20% ash, 9,900 Btu/lb HV.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS,
      Limestone process with 1.5 stoichiometry based on 862 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 21.60 ft total depth, 445 acres.
      Calcilox added at 7% of dry solids.
                                        242

-------
                             TABLE  A-110.   DRAVO  PROCESS

      TOTAL ANNUAL REVENUE REQUIREMENTS  - REGULATED UTILITY  ECONOMICS
(Variation




Direct costs
Delivered raw materials
Lime (pebble) 4
Calcilox 33
Subtotal raw materials cost
Conversion costs
Operating labor and supervision 35
Maintenance
Labor and materials
n of direct investment (plant)
3% of direct investment (pond)
Electricity 4
Analyses 1
Subtotal conversion costs
Subtotal direct costs
from base case:


Annual
quantity


,844 tons 48
,908 tons 58


,040 man-hr 12




,435 kkWh 0.
,000 hr 17


20% ash in


Unit
cost, $


.00/ton
.00/ton


.50/man-hr




029/kWh
.00/man-hr


coal)

Total
annual revenue
requirements , $


232,500
1,966,700
2,199,200

438,000


218,000
237,100
128,500
17,000
1,038,700
3,237,900

Percent
of total
annual revenue
requirements


3.1
26.6
29.7

5.9


3.0
3.2
1.7
0.2
14.0
43.7
Indirect costs

Capital charges
 Depreciation, interim replacement, and
  insurance at 6% of total  capital
  investment less land and  working
  capital
 Average cost of capital and  taxes at
  8.6% of total capital investment
Overhead
 Plant, 507, of conversion costs  less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
Dollars/dry ton
                              1,430,500



                              2,238,400


                                455,100

                                 43,800
                              4,167,800

                              7,405,700

                  Dollars/wet ton   Mills/kWh
     15.58
                       7.79
                                      2.12
   Basis
    Remaining plant  life, 30 yr.
    Coal burned,  454,545 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $26,028,000.
    Midwest plant location, mid-1980 operating  costs.
 19.3



 30.2


  6.2

  0.6
 56.3

100.0
                                                   243

-------
                       TABLE A-lll.  DRAVO PROCESSa

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


              (Variation from base case:  2% S in coal)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total,
k$
Percent of
direct
investment
Percent of
total capital
investment
 1,865
   215
   487
   230

   153
   862
   102
   115
 4,029

	60
 4,089

 5,605
 9,694

   759
   154
 1,348
   540
12,495

 2,499
14,994

   939
 1,799
17,732

 1,096
   423

19,251
 19.2
  2.2
  5.0
  2.4

  1.6
  8.9
  1.1
  1.2
 41.6

  0.6
 42.2

 57.8
100.0

  7.8
  1.6
 13.9
  5.6
128.9

 25.8
154.7

  9.7
 18.5
182.9
 11.3
  4.4

198.6
                9.7
                1.1
                2.5
                1.2

                0.8
                4.5
                0.5
                0.6
               20.9
                0.4
               21.3
               29.1
               50.4

                3.9
                0.8
                7.0
                2.8
               64.9
               13.0
               77.9

                4.9
                9.3
               92.1
                5.7
                2.2

              100.0
a.  Basis
      New 500-MW plant (30-yr life); 241 klb/hr (36% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   2% S (dry basis), 16% ash, 10,700 Btu/lb HV.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      19.95 ft total depth, 313 acres.
      Calcilox added at 7% of dry solids.
                                          244

-------
                            TABLE  A-112.    DRAVO PROCESS

     TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
(Variation




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
from base case:


Annual
quantity


2,818 tons
19,730 tons


35,040 man-hr




3,137 kkWh
1,000 hr


: 2% S in coal)


Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.029/kWh
17.00/man-hr




Total
annual revenue
requirements, ?


135,300
1,144,300
1,279,600

438,000


163,600
168,100
91,000
17,000
877,700
2,157,300

Percent
of total
annual revenue
requirements


2.6
21.5
24.1

8.2


3.1
3.2
1.7
0.3
16.5
40.6
Indirect costs

Capital charges
 Depreciation, interim replacement,  and
  insurance at 6% of total capital
  investment less land and working
  capital
 Average cost of  capital and taxes at
  8.6Z of total capital investment
Overhead
 Plant, 50% of conversion costs less
  utilities
 Administrative,  10% of operating labor
    Subtotal indirect costs

    Total annual  revenue requirements
Equivalent unit revenue requirements
                              1,063,900



                              1,655,600


                                393,400

                                 43,800
                              3,156,700

                              5,314,000

Dollars/dry  ton   Dollars/wet ton   Mills/kWh
     17.45
                       8.73
                                                                              1.52
a.  Basis
     Remaining plant  life, 30 yr.
     Coal burned,  470,561 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $19,251,000.
     Midwest plant location", mid-1980 operating  costs.
 20.0



 31.2


  7.4

  0.8
 59.4

100.0
                                                  245

-------
                       TABLE A-113.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
              (Variation from base case:  5% S in coal)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 2,652
   273
   657
   402

   176
 1,089
   119
   115
 5,483
 5,567

 9,073
14,640

   897
   174
 1,866
   742
18,319

 3,684
22,003

 1,303
 2,652
25,958

 1,790
   675

28,423
          Percent of
            direct
          investment
           Percent  of
          total capital
           investment
 18.1
  1.9
  4.5
  2.7

  1.2
  7.4
  0.8
  0.8
 37.4

  0.6
 38.0

 62.0
100.0

  6.1
  1.2
 12.7
  5.0
125.0

 25.0
150.3

  8.9
 18.1
177.3
 12.2
  4.6

194.1
  9.4
  1.0
  2.3
  1.4

  0.6
  3.8
  0.4
  0.4
 19.3
  0.3
 19.6
 31.9
 51.5

  3.2
  0.6
  6.5
  2.6
 64.4
 13.0
 77.4

  4.6
  9.3
 91.3
  6.3
  2.4

100.0
a.  Basis
      New 500-MW plant (30-yr life); 450.9 klb/hr (36% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   5% S (dry basis), 16% ash, 10,400 Btu/lb HV.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on SOo removed.
      Pond characteristics:  clay-lined,  1 mi from scrubber facilities.
      5Q% solids settled density, 22.31 ft total depth, 511 acres.
      Calcilox added at 7% of dry solids.
                                         246

-------
                           TABLE A-114.   DRAVO PROCESS

     TOTAL  ANNUAL REVENUE  REQUIREMENTS - REGULATED UTILITY ECONOMICS
(Variation




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
from base case


Annual
quantity


5,271 tons
36,750


35,040 man-hr




4,515 kkWh
1,000 hr


: 57, S in coal)


Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.029/kWh
17.00/man-hr


—

Total
annual revenue
requirements , $


253,000
2,131,500
2,384,500

438,000


226,700
272,200
130,900
17,000
1,084,800
3,469,300

Percent
of total
annual revenue
requirements


3.2
26.6
29.8

5.5


2.8
3.4
1.6
0.2
13.5
43.3
Indirect costs

Capital charges
 Depreciation, interim replacement,  and
  insurance at 6% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
1,563,500
2,453,000
a.  Basis
     Remaining plant  life, 30 yr.
     Coal burned,  432,692 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $28,523,000.
     Midwest plant location, mid-1980 operating costs.
                    19.5
                    30.6
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
477
43
4,537
8,006
Dollars/dry ton Dollars/wet ton
14.08 7.04
,000
,800
,300
,600
Mills /kWh
2.29
6.0
0.6
56.7
100.0
                                                247

-------
                       TABLE A-115.  DRAVO PROCESS

     TOTAL  CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


             (Variation  from base  case:   no  flyash,  200-MW plant)
                                                     Percent of   Percent of
                                                       direct    total capital
                                         Total,k$   investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 1,033
   162
   326
   130

   132
   787
    99
   115
 2,784

	42_
 2,826

 3,105
 5,931

   658
   140
   925
   371
 8,025

 1.605
 9,630
   653
 1,156
11,439

   602
   201

12,242
 17.4
  2.7
  5.5
  2.2

  2.2
  1.3
  1.7
  1.9
 46.9

  Q.7
 47.6

 52.4
100.0

 11.1
  2.4
 15.5
  6.3
135,.3

 27.1
162.4

 11.0
 19.5
192.9
 10.1
  3.4

206.4
  8.4
  1.3
  2.7
  1.1

  1.1
  6.4
  0.8
  0.9
 22.7
  0.4
 23.1
 13.1
 78.7
100.0
a.  Basis
      New 200-MW plant (30-yr life); 75 klh/hr (36% solids) sludge,
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt) s  3,5% S (dry basts), 16% ash.
      Flyash removed independently of S0£ and sludge contains no flyash.
      S02 and flyash removed to meet NSPS,
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 17.43 ft total depth, 172 acres.
      Calcilox added at 7% of dry solids.
                                        248

-------
                             TABLE A-116.   DRAVO  PROCESS

      TOTAL  ANNUAL  REVENUE  REQUIREMENTS  - REGULATED UTILITY  ECONOMICS
(Variation




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
from base case:


Annual
quantity


879 tons
6,153 tons


26,280 man-hr




2,078 kkWh
1,000 hr


200-MW plant , no


Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.031/kWh
17. 00 /man-hr


flyash)

Total
annual revenue
requirements, $


42,200
356,900
399,100

328,500


113,000
93,200
64,400
17,000
616,100
1,015,200

Percent
of total
annual revenue
requirements


1.4
11.6
13.0

10.7


3.7
3.0
2.1
0.6
20.1
33.1
Indirect costs

Capital charges
 Depreciation,  interim replacement,  and
  insurance at  6% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6X of total capital investment
Overhead
 Plant, 507, of  conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit  revenue requirements
                                686,300



                              1,052,800


                                275,900

                                 32,900
                              2,047,900

                              3,063,100

Dollars/dry ton    Dollars/wet ton   Mills/kWh
     25.74
                      12.87
                                      2.19
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 175,238 Ib/hr,  9,200 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $12,242,000.
     Midwest plant location, mid-1980 operating costs.
 22.4



 34.4


  9.0

  1.1
 66.9

100.0
                                                 249

-------
                       TABLE A-117.  DRAVO PROCESS"

     TOTAL CAPITAL INVESTMENT  - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


                   (Variation from base case:  no flyash)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total,
                                                 Percent of   Percent of
                                                   direct    total capital
                                                 investment   investment
1,668
203
451
212
143
888
103
115
3,783
57
3,840
6,161
10,001
775
155
1,352
552
12,835
2,567
15,402
924
1,848
18,174
1,207
364
16.7
2.0
4.5
2.1
1.4
8.9
1.0
1.2
37.8
0.6
38.4
61.6
100.0
7.7
1.5
13.6
5.5
128.3
25.7
154.0
9.2
18.5
181.7
12.1
3.6
8.5
1.0
2.3
1.1
0.7
4.5
0.5
0.6
19.2
0.3
19.5
31.2
50.7
3.9
0.8
6.8
2.8
65.0
13.0
78.0
4.7
9.3
92.0
6.1
1.9
                                       19,745
197.4
100.0
a.
Basis
  New 500-MW plant (30-yr life) ; 184 klb/hr (36% solids) sludge.
  Midwest plant location; average basis for cost scaling, mid-1979.
  Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
  Flyash removed independently of S02 and sludge contains no flyash.
  S02 and flyash removed to meet NSPS.
  Limestone process with 1.5 stoichiometry based on S02 removed.
  Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
  50% solids settled density, 20.40 ft total depth, 345 acres.
  Calcilox added at 7% of dry solids.
                                         250

-------
                             TABLE  A-118.    DRAVO PROCESS

       TOTAL ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED  UTILITY  ECONOMICS
(Variation from base case: separate system for disposal/removal of flyash)
Percent



Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
y/, of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs

Annual Unit
quantity cost, $


2,149 tons 48,00/ton
15,050 tons 58.00/ton


35,040 man-hr 12.50/man-hr




2,569 kkWh 0.029/kWh
1,000 hr 17.00/man-hr


Total
annual revenue
requirements , $


103,200
872,900
976,100

438,000


153,600
184,800
74,500
17,000
867,900
1,844,000
of total
annual revenue
requirements


2.0
17.2
19.2

8.7


3.0
3.6
1.5
0.3
17.1
36.3
Indirect costs

Capital charges
  Depreciation,  interim replacement,  and
  insurance at  6% of total capital
  investment less land and working
  capital
  Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
  Plant, 50% of  conversion costs less
  utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit  revenue requirements
                              1,090,400            21.5



                              1,698,100            33.5


                                396,700             7.8

                                 43,800             0.9
                              3,229,000            63.7

                              5,073,000           100.0

Dollars/dry ton  Dollars/wet ton   Mills/kWh
     17.48             8.74           1.45
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $19,745,000.
     Midwest plant location,  mid-1980 operating costs.
                                                 251

-------
                       TABLE A-119.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND  INSTALLATION ANALYSIS


            (Variation from base case:  no flyash, 1500-MW plant)
                                                     Percent of   Percent of
                                                       direct    total capital
                                         Total, k$   investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,989
   291
   779
   342

   189
 1,131
   119
   115
 5,955
 6,044

14,394
20,438

 1,030
   189
 2,302
   951
24,910

 4,982
29,892

 1,550
 3,587
35,029

 2,849
   844

38,722
 14.6
  1.4
  3.8
  1.7

  0.9
  5.5
  0.6
  0.6
 29.1

  0.5
 29.6

 70.4
100.0
 24.4
146.3

  7.6
 17.5
171.4
 14.0
  4.1

189.5
  7.7
  0.8
  2.0
  0.9

  0.5
  2.9
  0.3
  0.3
 15.4

  0.2
 15.6

 37.2
 52.8

  2.6
  0.5
  5.9
  2.5
 64.3

 12.9
 77.2
100.0
a.  Basis
      New 1500-MW plant (30-yr life); 551.6klb/hr (36% solids)  sludge,
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5%  S  (dry basis), 16%  ash.
      Flyash removed independently of 502 and sludge contains no flyash.
      S0£ and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on  S02 removed.
      Pond characteristics:  clay-lined,  1 mi from scrubber facilities,
      50% solids settled density, 25.00 ft total  depth,  814 acres.
      Calcilox added at 7% of dry solids.
                                       252

-------
                         TABLE A-120.   DRAVO  PROCESS3

     TOTAL  ANNUAL REVENUE  REQUIREMENTS - REGULATED UTILITY ECONOMICS
(Variation from base case :




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox — . .. - - '
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
n of direct investment (plant)
y/, of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
1500-MW plant, separate system for


Annual
quantity


6,451 tons
45,150 tons


43,800 man-hr




6,034 kkWh
1,500 hr




Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.027/kWh
17.00/man-hr


disposal /removal

Total
annual revenue
requirements, $


309,600
2,618,700
2,928,300

547,500


241,800
431,800
162,900
25,500
1,409,500
4,337,800
of flyash)
Percent
of total
annual revenue
requirements


3.0
25.0
28.0

5.3


2.3
4.1
1.6
0.2
13.5
41.5
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 67. of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements



3,330


623

54
6,109
10,447
Dollars /dry ton Dollars /wet ton
12.01 6.01
,™

,100


,300

,800
,900
,700
Mills /kWh
1.00
20.1

31.9


6.0

0.5
58.5
100.0


   Basis
    Remaining plant life, 30 yr.
    Coal burned, 1,285,714 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time,  7,000 hr/yr.
    Total capital investment, $38,722,000.
    Midwest plant location, mid-1980 operating  costs.
                                              253

-------
                       TABLE A-121.  DRAVO PROCESS

    TOTAL CAPITAL INVESTMENT  - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case:  disposal pond 5 mi from scrubber facilities)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
   2,955
     246
   3,484
     315

     337
   1,073
     112
     115
   8,637

     130
   8,767

   7,410
  16,177

     913
     185
   2,201
     796
  20,272

   4,054
  24,326

   1,692
   2,919
  28,937

   1,450
     607

  30,994
                                                     Percent of
                                                       direct
                                                     investment
           Percent of
          total capital
           investment
 18.3
  1.5
 21.5
  2.0

  2.1
  6.6
  0.7
  0.7
 53.4

  0.8
 54.2

 45.8
100.0

  5.6
  1.1
 13.7
  4.9
125.3
 25.1
150.4

 10.5
 18.0
178.9
  9.0
  3.7

191.6
  9.5
  0.8
 11.2
  1.0

  1.1
  3.5
  0.4
  0.4
 27.9

  0.4
 28.3

 23.9
 52.2

  2.9
  0.6
  7.1
  2.6
 65.4

 13.1
 78.5

  5.5
  9.4
 93.4
  4.6
  2.0

100.0
a.  Basis
      New 500-MW plant (30-yr life); 347 klb/hr (36% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt);   3.5% S (dry basis),  16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:   clay-lined, 5 mi from scrubber facilities,
      50% solids settled density, 21.38  ft total depth, 414 acres.
      Calcilox added at 7% of dry solids.
                                          254

-------
                             TABLE A-122.   DRAVO  PROCESS3

      TOTAL  ANNUAL REVENUE REQUIREMENTS - REGULATED  UTILITY  ECONOMICS
(Variation from base
Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
case: disposal area 5 mi from scrubber facilities)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements


4,053 tons 48.00/ton 194,
28,378 tons 58.00/ton 1,645,
1,840,

35,040 man-hr 12.50/man-hr 438,


350,
222,
10,200 kkWh 0.029/kWh 295,
1,000 hr 17.00/man-hr 17,
1,323,
3,164,


500
900
400

000


700
300
800
000
800
200


2.4
20.3
22.7

5.5


4.3
2.7
3.6
0.2
16.3
39.0
Indirect  costs

Capital charges
  Depreciation, interim replacement,  and
  insurance at 6% of total capital
  investment less land and working
  capital
  Average cost of capital and taxes at
  8,6% of total capital investment
Overhead
  Plant,  50% of conversion costs less
  utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements
Equivalent unit revenue requirements
                              1,736,200



                              2,665,500


                                514,000

                                 43,800
                              4,959,500

                              8,123,700

Dollars/dry  ton   Dollars/wet ton   Mills/kWh
18.57
                  9.29
                                 2.32
   Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr,  9,000  Btu/kWh.
     Power plant on-stream time,  7,000  hr/yr.
     Total capital investment, $30,994,000.
     Midwest plant location,  mid-1980 operating costs.
                                             21.4
                                              6.3

                                              0.5
                                             61.0

                                            100.0
                                               255

-------
                       TABLE A-123.  DRAVO PROCESS3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
    (Variation from base case:   .disposal pond 10 mi from scrubber facilities)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total.
 2,932
   246
 6,969
   315

   516
 1,108
   112
   115
12,363

   185
12,548

 7,410
19,958

 1,039
   216
 2,726
   934
24,873

 4,975
29,848

 2,244
 3,582
35,674

 1,450
   641

37,765
            Percent of
              direct
            investment
            Percent  of
           total capital
            investment
 14.9
  1.2
 34.9
  1.6

  2.6
  5.5
  0.6
  0.6
 61.9

  1.0
 62.9

 37.1
100.0

  5.2
  1.1
 13.6
  4.7
124.6
 25.0
149.6

 11.2
 17.9
178.7

  7.3
  3.2

189.2
  0.5
 33.2
 19.6
 52.8

  2.8
  0.6
  7.2
  2.5
 65.9
 94.5

  3.8
  1.7

100.0
a.  Basis
      New 500-MW plant (30-yr life); 347 klb/hr  (36% solids)  sludge,
      Midwest plant location; average basis for  cost scaling, mid-1979.
      Coal analysis (by wt);  3.5% S (dry basis), 16% ash.
      Flyash removed with S02«
      S02 and flyash removed to meet NSPS,
      Limestone process with 1.5 stoichiometry based on SOo removed.
      Pond characteristics:  clay-lined, 10 mi from scrubber  facilities,
      50% solids settled density, 21,38  ft total depth, 414  acres.
      Calcilox added at 7% of dry solids.

                                        256

-------
                             TABLE  A-124.    D&AVO  PROCESS3

      TOTAL  ANNUAL REVENUE REQUIREMENTS  - REGULATE!) UTILITY  ECONOMICS
(Variation from base




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor- and materials
4% of direct investment (plant)
3% of direct investment (pond);
Electricity
Analyses
Subtotal conversion costs
case: disposal


Annual
quantity


4,053 tons
28,378 tons


35,040''man-hr




11,000 kkWh
1,000 hr

area 10 mi from


Unit
- .cost,. $ .


48.-00'/ton
58. 00 /ton


12.50/man-lir




0.029/kWK
17.00/man-hr

scrubber facilities)

Total
annual revenue
requirements1, $'_


194,500
1,64-5,900
1,840,400

438,000


501,900
2 22 ,-300
319,000
. 17,060'
1,418,200

Percent
of totial
annual revenue
requirements


2.1
17. 6
19'. 7

4v6''


5: 4
2.4'
3.4'
0.2
16.0'
    Subtotal direct costs

Indirect  costs

Capital charges'
  Depreciation, interim replacement, arid
  insurance at 6% of total capi'tal
  investment less land and working
  capital
  Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
3,3 38', 600
2,140,400
3',247,800
   Basis
     Remaining plaiit life,  30 yr.
     Coal burnedy 428,571  Ib/hr, 9,000 Btu/kWh.
     Power plant on-streatn time, 7,000 hr/yr.
     Total capital investment, $37,765,000.
     Midwest plant location, mid-1980 operating costs.
                                                                                         35'. 7'
                    22.8
                    34V7
Plant, 50% of conversion costs less
utilities
Administrative', 1-0% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
589,600
43,800
6,021,600
9,360,200
Dollars/dry ton Dollar's/wet ton . Mills/kWH
21.39 10.-70 2.67
6
0
64
100
.3
.5
.3
.0'
                                               257

-------
                       TABLE A-125.  DRAVO PROCESS

    TOTAL CAPITAL INVESTMENT  - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
(Variation from base case:



Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
roads and railroads
Electrical
Instrumentation
Buildings
Subtotal
Services and miscellaneous
Subtotal excluding pond
Pond construction
Subtotal direct investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Subtotal
Contingency
Subtotal fixed investment
Allowance for startup and modifications
Interest during construction
Subtotal capital investment
Land
Working capital
Total capital investment
Calcilox added at 5%)


Total, k$
2,208
262
657
234

161
754
110
97
4,483
67
4,550
7,312
11,862
806
158
1,557
629
15,012
3,002
18,014
1,070
2,162
21,246
1,420
454
23,120
Percent of
direct
investment
18.6
2.2
5.5
2.0

1.4
6.4
0.9
0.8
37.8
0.6
38.4
61.6
100.0
6.8
1.3
13.2
5.3
126.6
25.3
151.9
9.0
18.2
179.1
12.0
3.8
194.9
Percent of
total capital
investment
9.6
1.1
2.8
1.0

0.7
3.3
0.5
0.4
19.4
0.3
19.7
31.6
51.3
3.5
0.7
6.7
2.7
64.9
13.0
77.9
4.6
9.4
91.9
6.1
2.0
100.0

a.  Basis
      New 500-MW plant  (30-yr  life);  344 klb/hr (36% solids) sludge.
      Midwest  plant  location;  average basis  for cost  scaling,  mid-1979.
      Coal analysis  (by wt) -  3.5% s  (dry basis), 16% ash,
      Flyash removed with  S02.
      S02 and  f lyash removed to meet NSPS.
      Limestone  process with 1.5  stoichiometry based  on S09  removed.
      Pond characteristics:  clay-lined,  1 mi  from  scrubber  facilities,
      50% solids settled density,  21.42 ft  total  depth, 406 acres.
      Calcilox added at 5% of  dry solids.

                                        258

-------
                           TABLE A-126.   DRAVO PROCESS

     TOTAL  ANNUAL  REVENUE  REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
(Variation from base case: 5% Calcilox added to dry solids)



Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs

Annual Unit
quantity cost, $


4,053 tons 48.00/ton
20,269 tons 58.00/ton


35,040 man-hr 12.50/man-hr




3,102 kkWh 0.029/kWh
1,000 hr 17.00/man-hr


Total
annual revenue
requirements , $


194,500
1,175,600
1,370,100

438,000


182,000
219,400
90,000
17,000
946,400
2,316,500
Percent
of total
annual revenue
requirements


3.2
19.5
22.7

7.2


3.0
3.6
1.5
0.3
15.6
38.3
Indirect costs

Capital charges
  Depreciation,  interim replacement, and
  insurance at  6% of total  capital
  investment less land and  working
  capital
  Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
1,274,800
1,988,300
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr, 9,000  Btu/kWh.
     Power plant on-stream time, 7,000  hr/yr.
     Total capital investment, $23,120,000.
     Midwest  plant location, mid-1980 operating costs.
                   21.1
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
428
43
3,735
6,051
Dollars /dry ton Dollars /wet ton
14.05 7.05
,200
,800
,100
,600
Mills/kWh
1.73
7.1
0.7
61.7
100.0

                                               259

-------
                      TABLE A-127.   DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT  - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
             (Variation  from base  case;   Calcilox added at 1070)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 2,379
   262
   657
   397

   169
 1,118
   119
   115
 5,216

	78
 5,294

 7,564
12,858

   859
   171
 1,694
   669
16,251

 3,250
19,501

 1,194
 2,340
23,035

 1,485
   689

25,209
           Percent of
             direct
           investment
            Percent of
           total capital
            investment
 18.5
  2.1
  5.1
  3.1

  1.3
  8.7
  0.9
  0.9
 40.6

  0.6
 41.6

 58.4
100.0

  6.7
  1.3
 13.2
  5.2
126.4

 25.3
151.7
  9.3
 18.2
179.1
 11.6
  5.4

196.1
 30.0
 51.0
  3.4
  0.7
  6.7
  2.7
 64.5
 12.9
 77.4

  4.7
  9.3
 91.4
  5.9
  2.7

100.0
a.  Basis
      New 500-MW plant (30-yr life); 350 klb/hr  (36% solids) sludge,
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3,5% S (dry basis), 16% ash.
      Flyash removed with S02«
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 21.48  ft total depth, 424 acres.
      Calcilox added at 10% of dry solids.
                                        260

-------
                            TABLE A-128.   DRAVO PROCESS

      TOTAL ANNUAL  REVENUE  REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
base case: 10%


Annual
quantity


4,053 tons
40,400 tons


35,040 man-hr




3,200 kkWh
1,000 hr


Calcilox added


Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.029/kWh
17.00/man-hr


to dry solids)

Total
annual revenue
requirements, $


194,500
2,354,800
2,549,300

438,000


211,800
226,900
92,800
17,000
986,500,
3,535,800

Percent
of total
annual revenue
requirements


2.6
31.1
33.7

5.8


2.8
3.0
1.2
0.2
13.0
46.7
Indirect costs

Capital charges
 Depreciation, interim replacement, and
  insurance at 67. of  total, capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
1,382,100
2,168,000
   Basis
    Remaining plant life, 30 yr.
    Coal burned,  428,571 Ib/hr,  9,000 Btu/kWh.
    Power plant on-stream time,  7,000 hr/yr.
    Total capital investment,  $25,209,000.
    Midwest plant location,  mid-1980 operating  costs.
                    18.2
                    28.6
Plant, 50% of conversion costs less
utilities
Administrative, 107. of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
446
43
4,040
7,576
Dollars/dry ton Dollars/wet ton
16.85 8.43
,900
,800
,800
,600
Mills/kWh
2.16
5.9
0.6
53.3
100.0

                                                 261

-------
                       TABLE A-129.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS

       (Variation from base case;   lime process  with 1.1 stoichiometry
                            based  on S02  removed)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 1,933
   230
   657
   262

   165
   800
    90
   115
 4,252

	64
 4,316

 6,669
10,985

   605
   III
 1,469
   593
13,763

 2,753
16,516

   985
 1,982
19,483

 1,306
   529

21,318
           Percent of
             direct
           investment
            Percent  of
           total capital
            investment
 17.6
  2.1
  6.0
  2.4

  1.5
  7.3
  0.8
  1.0
 38.7

  0.6
 39.3

 60.7
100.0
  5.5
  1.0
 13.4
  5.4
125.3

 25.1
150.4

  9.0
 18.0
177.4
 11.9
  4.8

194.1
  9.1
  1.1
  3.1
  1.2
  0.3
 20.3
 31.2
 51.5
100.0
a.  Basis
      New 500-MW plant (30-yr life); 301.8klb/hr (36% solids) sludge,
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with S02«
      S02 and flyash removed to meet NSPS.
      Lime process with 1.1 stoichiometry based on S02 removed.
      Pond characteristics:   clay-lined, 1 mi from scrubber facilities,
      50% solids settled density, 20.80 ft total depth, 373 acres,
      Calcilox added at 7% of dry solids.
      Scrubber system underflow 10% solids (all other cases 1570) .
                                        262

-------
                            TABLE  A-130.    DRAVO  PROCESS3

     TOTAL ANNUAL REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: lime process with 1.1



Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
k% of direct investment (plant)
37, of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs

Annual
quantity


3,528 tons
27,703 tons


35,040 man-hr




3,600 kkWh
1,000 hr



Unit
cost, $


48.00/ton
58.00/ton


12.50/man-hr




0.029/kWh
17.00/man-hr


stoichiometry)
Total
annual revenue
requirements, $


169,300
1,606,800
1,776,100

438,000


172,600
200,100
104,400
17,000
932,100
2,708,200
Percent
of total
annual revenue
requirements


2.7
26.1
28.8

7.1


2.8
3.2
1.7
0.3
15.1
43.9
Indirect costs

Capital charges
 Depreciation, interim replacement,  and
  insurance at 6% of total capital
  investment less land and working
  capital
 Average cost of capital  and taxes at
  8.63! of total capital investment
Overhead
1,169,000
1,833,300
   Basis
     Remaining  plant life,  30 yr.
     Coal burned, 25,894 Ib/hr, 10,166 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment, $21,318,000.
     Midwest plant location, mid-1980 operating costs.
                    19.0
                    29.7
Plant, 50% of conversion costs less
utilities
Administrative, 105? of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
413,900
43,800
3,460,000
6,168,200
Dollars/dry ton Dollars/wet ton Mills/kWh
8.10 4.05 1.76
6.
0.
56.
100.

7
7
1
0

                                              263

-------
                        TABLE A-131.   DRAVO  PROCESS

      TOTAL  CAPITAL  INVESTMENT  -  PROCESS  EQUIPMENT AND INSTALLATION ANALYSIS
(Variation from base case:   intermediate ponding and truck to landfill for disposal)
                                          Total, k$
Process equipment
Piping and  insulation
Transport lines
Foundation  and structural
Excavation, site preparation,
  roads and  railroads
Electrical
Instrumentation
Buildings
      Subtotal

Services and miscellaneous
      Subtotal excluding trucks and
      equipment

Trucks and  earthmovlng equipment
      Subtotal direct investment

Engineering design  and supervision
Architect and engineering contractor
Construction expense
Contractor  fees
      Subtotal

Contingency
      Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
      Subtotal capital investment

Land
Working capital

      Total  capital  investment
 2,272
   262

   313

   714
   974
   113
   115
 4,763

	n

 4,834

   739
 5,573

   530
   133
   925
   354
 7,515

 1,503
 9,018

   828
 1,082
10,928

 1,007
   735

12,670
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 40.7
  4.7

  5.6
  1.3
 86.7
 13.3
100.0

  9.5
  2.4
 16.5
  6.4
134.8
 27.0
161.8

 14.9
 19.4
196.1
 18.1
 13.2

227.4
 17.9
  2.1

  2.5

  5.6
  7.7
  0.9
  0.9
 37.6

  0.6

 38.2

  5.8
 44.0

  4.2
  1.0
  7.3
  2.8
 59.3
100.0
a.  Basis
      New 500-MW plant  (30-yr life);  347  klb/hr  (36%  solids)  sludge,
      Midwest plant location; average basis  for  cost  scaling,, mid-1979.
      Coal analysis (by wt):  3.5%  S  (dry basis),  16% ash.
      Flyash removed with  S02-
      S02 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based  on S02 removed..
      Landfill acreage 271 acres, 30  ft depth; intermediate ponding and
      disposal of  50% solids sludge,  1 mi from scrubber facilities,
      Calcilox added at 7% of dry solids.
                                         264

-------
                            TABLE A-132.   DRAVO PROCESS

      TOTAL  ANNUAL  REVENUE  REQUIREMENTS - REGULATED  UTILITY  ECONOMICS
(Variation from base case: intermediate ponding, transport by truck)




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material ,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs


Annual
quantity


4,053 tons
28,378 tons



35,040 man-hr
52,560 man-hr




677,000 tons
677,000 tons

3,577 kkWh
1,000 hr



Unit
cost, $


48. 00/ton
58. 00/ton



12.50/man-hr
17. 00/man-hr




0.06/ton
0.16/ton

0.029/kWh
17. 00/man-hr


Total
annual revenue
requirements, $


194,500
1,645,900
1,840,400


438,000
893,500

222,900

11,000
40,600
108,300

103,700
17,000
1,835,000
Percent
of total
annual revenue
requirements


2.9
24.9
27.8


6.6
13.4

3.4

0.2
0.6
1.6

1.6
0.3
27.7
    Subtotal direct costs

Indirect costs
3,675,400
   Basis
    Remaining plant life, 30 yr.
    Coal burned, 428,571 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $12,670,000.
    Midwest plant location, mid-1980 operating costs.
                                                                                   55.5
Capital charges
Depreciation, interim replacement, and
insurance at 7.8% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements

855



1,089


865

133
2,944
6,619

,700



,600


,700

,200
,200
,600

12.9



16.5


13.1

2.0
44.5
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
15.13 7.57
1.89

                                            265

-------
                       TABLE A-133.  DRAVO PROCESS

     TOTAL CAPITAL  INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


     (Variation from base case:  constrained pond acreage, 200-MW plant)
                                         Total, k$
           Percent of
             direct
           investment
           Percent of
           total  capital
           investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 1,405
   179
   451
   116

   141
   795
   100
   115
 3,302

	50
 3,352

 7,838
11,190

   809
   157
 1,400
   602
14,158

 2,832
16,990

   915
 2,039
19,944

   493
   264

20,701
 12.7
  1.6
  4.0
  1.0

  1.3
  7.1
  0.9
  1.0
 29.6

  0.4
 30.0

 70.0
100.0

  7.2
  1.4
 12.5
  5.4
126.5

 25.3
151.8

  8.2
 18.2
178.2
  4.4
  2.4

185.0
  6.7
  0.9
  2.2
  0.6

  0.7
  3.8
  0.5
  0.6
 16.0
 37.9
 54.1

  3.9
  0.7
  6.7
  2.9
 68.4
100.0
a.  Basis
      New  200-MW  plant  (30-yr  life);  141 klb/hr  (36% solids)  sludge.
      Midwest plant  location;  average basis  for  cost scaling,  mid-1979.
      Coal analysis  (by wt);   3.5% S  (dry basis),  16%  ash.
      Flyash removed with SOo-
      S02  and flyash removed to meet  NSPS.
      Limestone process with 1.5  stoichiometry based on S02  removed.
      Pond characteristics:  clay-lined,  1 mi from scrubber  facilities,  50%
      solids settled density,  pond acreage - 50% of optimum,  96  acres.
      Calcilox added at 7%  of  dry solids.
                                          266

-------
                               TABLE A-134.    DRAVO  PROCESS

        TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED UTILITY  ECONOMICS
(Variation from base case

Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
: 200-MW plant, constrained pond

Annual Unit
quantity cost, $
1,519 tons 48.00/ton
10,623 tons 58.00/ton
26,280 man-hr 12. 50/man-hr
2,130 kkWh 0.031/kWh
1,000 hr 17.00/hr

acreage 50% of optimum)
Percent
Total
annual revenue
requirements, $
72,900
616,100
689,000
328,500
134,100
235,100
66,000
17,000
780,700
1,469,700
of total
annual revenue
requirements
1.6
13.9
15.6
7.4
3.0
5.3
1.5
0.4
17.7
33.2
Indirect costs

Capital charges
 Depreciation, interim replacement,  and
  insurance at 6%  of total capital
  investment less  land and working
  capital
 Average cost of capital and taxes at
  8.63! of total capital investment
Overhead
 Plant, 50% of conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements
Equivalent unit revenue requirements
                                781,900



                              1,780,300


                                357,400

                                 33,900
                              2,953,500

                              4,423,200

Dollars/dry  ton   Dollars/wet ton   Mills/kWh
     24.78
                      12.39
                                      3.16
   Basis
     Remaining plant life, 30 yr.
     Coal burned, 428,571 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $20,701,000.
     Midwest plant location, mid-1980 operating  costs.
                                                  17.7
 40.2
 66.8

100.0
                                                267

-------
                       TABLE A-135.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
              (Variation from base case:  disposal pond acreage
                         constrained, 200-MW plant)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 1,405
   179
   451
   116

   141
   795
   100
   115
 3,302

    50
 3,352

 5,537
 8,889

   746
   151
 1,220
   505
11,511

 2,302
13,813

   828
 1,658
16,299

   742
   264

17,305
           Percent of
             direct
           investment
            Percent of
           total capital
            investment
 15.8
  2.0
  5.1
  1.3

  1.6
  8.9
  1.1
  1.3
 37.1

  0.6
 37.7

 62.3
100.0

  8.4
  1.7
 13.7
  5.7
129.5

 25.9
155.4

  9.3
 18.7
183.4
  8.3
  3.0

194.7
  8.1
  1.0
  2.6
  0.7

  0.8
  4.6
  0.6
  0.7
 19.1
 66.5
100.0
a.  Basis
      New 200-MW plant (30_yr life); 141 klb/hr (36% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on SOo removed.
      Pond characteristics:  clay-lined,  1 mi from scrubber facilities,
      50% solids settled density, pond acreage - 75% of optimum, 145 acres.
      Calcilox  added  at  7% of dry  solids.
                                        268

-------
                             TABLE A-136.   DRAVO  PROCESS

       TOTAL ANNUAL  REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case :




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
200-Mft plant, constrained pond acreage 75% of

Total
Annual Unit annual revenue
quantity cost, $ requirements,


72,900
616,100
689,000

26,280 man-hr 12.50/man-hr 328,500


134,100
166,100
2,130 kkWh 0.031/kWh 66,000
1,000 hr 17.00/hr 17,000
652,300
1,341,300
optimum)
Percent
of total
annual revenue
$ requirements


1.8
14.9
16.7

7.9


3.2
4.0
1.6
0.4
15.9
32.4
Indirect costs

Capital charges
  Depreciation, interim replacement, and
  insurance at 67, of total capital
  investment less land and working
  capital
  Average cost of capital and  taxes at
  8.6% of total capital investment
Overhead
  977,900
1,488,200
a.  Basis
     Remaining plant life,  30 yr.
     Coal burned,  175,238 lb/hr, 9,200 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment,  $17,305,000.
     Midwest plant location, mid-1980 operating costs.
                   23.7
                   36.0
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements
293,200

32,900
2,792,200
4,133,500
Dollars/dry ton Dollars/wet ton Mills/kWh
23.16 72.39 2.95
7

0
67
100


.09

.8
.6
.0


                                             269

-------
                      TABLE A-137.   DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
            (Variation from base case:   constrained pond acreage)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 2,272
   262
   657
   313

   164
   974
   113
   115
 4,870

	73
 4,943

16,361
21,304

 1,024
   182
 2,265
   982
25,757

 5,151
30,908

 1,455
 3,709
36,072

 1,075
   550

37,697
           Percent of
             direct
           investment
            Percent of
           total capital
            investment
 10.7
  1.2
  3.1
  1.5

  0.8
  4.6
  0.5
  0.5
 22.9

  0.3
 23.2

 76.8
100.0

  4.8
  0.9
 10.6
  4.6
120.9

 24.2
145.1
  6.8
 17.4
169.3
  5.0
  2.6

176.9
  0.2
 13.1
  3.9
 95.7

  2.8
  1.5

100.0
a.  Basis
      New 500-MW plant (30-yr life); 347 klb/hr (36% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with S02-
      S0£ and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Pond characteristics:  clay-lined, 1 mi from scrubber facilities, 50%
      solids settled density, pond acreage - 50% of optimum, 207  acres.
      Calcilox added at 7% of dry solids.
                                       270

-------
                            TABLE A-138.   DRAVO PROCESS

      TOTAL  ANNUAL REVENUE  REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
37. of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
case: constrained pond acreage - 50% of optimum)

Total
Annual Unit annual revenue
quantity cost, $ requirements, $


194,500
1,645,900
1,840,400

35,040 man-hr 12.50/man-hr 438,000


197,700
490,800
3,577 kkWh 0.029/kWh 103,700
1,000 hr 17.00/hr 17,000
1,247,200
3,087,600

Percent
of total
annual revenue
requirements


2.1
18.1
20.2

4.8


11.2
5.4
1.1
0.2
13.7
33.9
Indirect costs

Capital charges
 Depreciation, interim replacement,  and
  insurance at 6% of total capital
  investment less land and working
  capital
 Average cost of capital  and taxes at
  8.6% of total capital investment
Overhead
2,164,300
3,241,900
   Basis
     Remaining plant life,  30 yr.
     Coal burned,  175,238 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $37,697,000.
     Midwest plant location, mid-1980 operating costs.
                   23.8
                   35.6
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
571,800
43,800
6,021,800
9,109,400
Dollars/dry ton Dollars/wet ton Mills/kWh
20.82 10.41 2.60
6.
0.
66.
100,
,3
,5
,1
,0
                                              271

-------
                       TABLE A-139.  DRAVO PROCESS

    TOTAL CAPITAL  INVESTMENT  - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
             (Variation  from base  case:   constrained pond acreage)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
                                            2,272
                                              262
                                              657
                                              313
                                              164
                                              974
                                              113
                                              115
                                           4,870

                                          	73
                                           4,943

                                          11,740
                                          16,683

                                              926
                                              173
                                           1,946
                                              815
                                          20,543

                                           4,109
                                          24,652

                                           1,291
                                           2,958
                                          28,901

                                           1,610
                                              550

                                          31,061
                                                     Percent of
                                                       direct
                                                     investment
            Percent of
           total  capital
            investment
 13.6
  1.6
  3.9
  1.9

  1.0
  5.8
  0.7
  0.7
 29.2
  0.4
 29.6
 70.4
100,0

  5.6
  1.0
 11.6
  4.9
123.1
 24.7
147.8

  7.7
 17.7
173.2

  9.7
  3.3

186.2
  7.4
  0.8
  2.1
  1.0

  0.5
  3.1
  0.4
  0.4
 15.7
  0.2
 15.9

 37.8
 53.7
100.0
a.  Basis
      New 500-MW plant  (30-yr life); 347 klb/hr  (36%  solids)  sludge.
      Midwest plant location; average basis for  cost  scaling, mid-1979.
                              3.5%  S (dry basis),  16% ash.
      Coal analysis  (by wt):
      Flyash removed with S0
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based  on S02  removed.
      Pond characteristics:  clay-lined,  1 mi from scrubber  facilities, 50%
      solids settled density, pond  acreage -  75%  of optimum, 310 acres.
      Calcilox added at 7%  of dry solids.
                                        272

-------
                             TABLE  A-140.   DRAVO PROCESS

      TOTAL  ANNUAL REVENUE  REQUIREMENTS - REGULATED UTILITY ECONOMICS
(Variation from base case: constrained pond acreage


Annual Unit
quantity cost, $
Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision 35,040 man-hr 12.50/man-hr
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity 3,577 kkWh 0.025/kWh
Analyses 1,000 hr 17.00/hr
Subtotal conversion costs
Subtotal direct costs
75% of optimum)

Total
annual revenue
requirements , $


194,500
1,645,900
1,840,400

438,000


197,700
352,200
103,700
17,000
1,108,600
2,949,000

Percent
of total
annual revenue
requirements


2.5
20.8
23.3

5.5


2.5
4.5
1.3
0.2
14.0
37.3
Indirect costs

Capital charges
 Depreciation, interim replacement, and
  insurance at 6% of total capital
  investment less land and working
  capital
 Average cost of capital  and taxes at
  8.6% of total capital investment
Overhead
1,734,-100
2,671,200
   Basis
     Remaining plant life,  30 yr.
     Coal burned, 428,571 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $31,061,000.
     Midwest plant location, mid-1980 operating costs.
                   21.9
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
502
43
4, .951
7,900
Dollars/dry ton Dollars/wet ton
18.06 9.03
,500
,800
,600
,600
Mills /k.Wh
2.25
6.4
0.6
62.7
100.0

                                               273

-------
                       TABLE A-141.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


    (Variation  from base  case:  constrained  pond acreage,  1500-MW plant)
                                         Total, k$
           Percent of
             direct
           investment
            Percent of
           total capital
            investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and .supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 4,363
   424
   978
   540

   241
 1,301
   119
   115
 8,081

   121
 8,202

38,813
47,015

 1,504
   244
 4,143
 1,791
54,697

10,939
65,636

 2,682
 7,876
76,194

 2,517
 1,387

80,098
  9.3
  0.9
  2.1
  1.1

  0.5
  2.8
  0.3
  0.2
 17.2
  0.3
 17.4
 82.6
100.0

  3.2
  0.5
  8.8
  3.8
116.3
 23.3
139.6

  5.7
 16.8
162.1

  5.3
  3.0

170.4
  5.4
  0.5
  1.2
  0.7
  0.3
  1.6
  0.2
  0.2
 10.1
  0.1
 10.2
 13.6
 81.9
100.0
a.  Basis
      New 1500-MW plant (30-yr life); 1,040 klb/hr  (36% solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt) :  3.5% S (.dry basis), 16% ash.
      Flyash removed with SOo.
      S02 and flyash removed to meet NSES.
      Limestone process with 1.5 stoichiometry based on SOo removed.
      Pond characteristics:  clay-lined, 1 mi from  scrubber facilities, 50%
      solids settled density, pcmd acreage -  50% of optimum,  487 acres.
      Calcilox added at 7% of dry solids.
                                       274

-------
                              TABLE A-142.   DRAVO  PROCESS

       TOTAL  ANNUAL REVENUE REQUIREMENTS - REGULATED UTILITY ECONOMICS
(Variation from base case:




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
3% of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
1500-MW plant, constrained pond acreage 50% of

Total
Annual Unit annual revenue
quantity cost, $ requirements, $


538,800
4,932,900
5,516,700

43,800 man-hr 12.50/man-hr 547,500


328,100
1,164,400
8,733 kkWh 0.027/kWh 235,800
1,500 hr 17.00/hr 25,500
2,301,300
optimum)
Percent
of total
annual revenue
requirements


2.9
24.2
27.1

2.7


1.6

5.7
0.1
11.3
    Subtotal direct  costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 6% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                             7,818,000




                             4,571,600



                             6,888,400


                             1,032,800

                                54,800
                            12,547,600

                            20,365,600

Dollars/dry ton   Dollars/wet ton   Mills/kWh
     15.52
                        7.76
                                      1.94
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 1,285,714 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $80,098,000.
     Midwest plant location, mid-1980 operating costs.
                                                                                          38.4
 22.4
  5.0

  0.3
 61.6

100.0
                                                 275

-------
                       TABLE A-143.  DRAVO PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS

     (Variation from base case:  constrained pond acreage, 1500-MW plant)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
4,363
424
978
540
241
1,301
119
115
8,081
121
8,202
27,732
35,934
1,326
226
3,483
1,460
42,469
8,486
50,915
2,318
6,110
59,343
3,773
1,387
Percent of
direct
investment
12.2
1.2
2.7
1.5
0.7
3.6
0.3
0.3
22.5
0.3
22.8
77.2
100.0
3.7
0.6
9.7
4.1
118.1
23.6
141.7
6.5
16.9
165.1
10.5
3.9
Percent of
total capital
investment
6.8
0.6
1.5
0.8
0.4
2.0
0.2
0.2
12.5
0.2
12.7
43.0
55.7
2.1
0.3
5.4
2.3
65.8
13.1
78.9
3.6
9.5
92.0
5.8
2.2
64,503
179.5
100.0
a.  Basis
      New 1500-MW plant (30-yr life); 1,040 klb/hr  (36%  solids)  sludge.
      Midwest plant location;  average basis for cost scaling, mid-1979.
      Coal analysis (by wt) ;   3.57, S  (dry  basis), 16%  ash.
      Flyash removed with S02-
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removed.
      Pond characteristics:   clay-lined, 1 mi from scrubber facilities,  50%
      solids settled density,  pond acreage - 75% of optimum, 731 acres.
      Calcilox added at 7% of dry solids.
                                        276

-------
                           TABLE A-144.   DRAVO  PROCESS

     TOTAL  ANNUAL  REVENUE  REQUIREMENTS - REGULATED  UTILITY  ECONOMICS
(Variation from base case:




Direct costs
Delivered raw materials
Lime (pebble)
Calcilox
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Maintenance
Labor and materials
4% of direct investment (plant)
n of direct investment (pond)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
1500-MW plant, constrained pond acreage 75% of

Total
Annual Unit annual revenue
quantity cost, $ requirements, $


583,800
4,932,900
5,516,700

43,800 man-hr 12.50/man-hr 547,500


328,100
682,000
8,733 kkWh 0.027/kWh 235,800
1,500 hr 17.00/hr 25,500
1,818,900
7,355,600
optimum)
Percent
of total
annual revenue
requirements


3.4
28.5
31.9

3.2


1.9
3.9
1.4
0.1
10.5
42.4
Indirect costs

Capital charges
 Depreciation, interim replacement, and
  insurance at 67. of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
3,560,600
5,547,300
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned,1,285,714 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $64,503,000.
     Midwest plant location, mid-1980 operating costs.
                    20.6
                    32.1
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
791
54
9,954
17,289
Dollars /dry ton Dollars /wet ton
13.17 6.59
,600
,800
,300
,900
Mills/kWh
1.65
4.6
0.3
57.6
100.0
                                                277

-------
                        TABLE A-145. IUCS PROCESS3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND  INSTALLATION ANALYSIS
                                (Base case)
                                                     Percent of   Percent of
                                                       direct    total capital
                                         Total,  k$  investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and.supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,551
   176

   136

   115
   639
    70
   550
 4,237

	64_

 4,301

   581
 4,882

   392
    98
   839
   320
 6,531

 1,306
 7,837

   726
   940
 9,503

   676
   538

10,717
 52.2
  3.6

  2.8

  2.4
 13.1
  1.4
 11.3
 86.8

  1.3

 88.1

 11.9
100.0

  8.0
  2.0
 17.2
  6.6
133.8
 14.9
 19.3
194.7
 13.8
 11.0

219.5
 23.7
  1.6

  1.3

  1.1
  6.0
  0.7
  5.1
 39.5

  0.6

 40.1

  5.4
 45.5
 60.9
100.0
a.  Basis
      New 500-MW plant (30-yr life); 198 klb/hr  (60%  solids)  sludge.
      Midwest plant location; average basis for  cost  scaling, mid-1979.
      Coal analysis (by wt) :  3.5% S (dry basis),  16% ash.
      Flyash removed with SOo.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based  on  S02 removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 193 acres at 30  ft  deep.
      Trucks used for transport of treated sludge  to  disposal area.
      Lime added at 4% of dry solids.
                                        278

-------
                              TABLE A-146.    IUCS  PROCESS

      TOTAL ANNUAL REVENUE REQUIREMENTS - REGULATED UTILITY ECONOMICS
(Base case)
Annual Unit
quantity cost, $
Direct costs
Delivered raw materials
Lime (ground) 16,216 tons 53.00/ton
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant 35,040 man-hr 12.50/man-hr
Solids disposal equipment 52,560 man-hr 17.00/man-hr
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance) 693,000 tons 0.06/ton
Earthmoving equipment (fuel and
maintenance) 693,000 tons 0.16/ton
Electricity 3,688 kkWh 0.029/kWh
Analyses 1,000 hr 17.00/man-hr
Subtotal conversion costs
Subtotal direct costs
Total
annual revenue
requirements, $
859,400
859,400
438,000
893,500
172,000
11,000
41,600
110,900
107,000
17,000
1,791,000
2,650,400
Percent
of total
annual revenue
requirements
16.2
16.2
8.3
16.9
3.3
0.2
0.8
2.1
2.0
0.3
33.0
50.1
Indirect costs

Capital charges
 Depreciation,  interim replacement,  and
  insurance at  7.83% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
 Plant, 50% of  conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit  revenue requirements
                                  744,100

                                  921,700


                                  842,000
                                  133,200
                                2,641,000

                                5,291,400

Dollars/dry ton   Dollars/wet ton   Mills/kWh
     12.55
                       7.63
                                     1.51
a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 482,571 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $10,717,000.
     Midwest plant location, mid-1980 operating costs.
 14.1

 17.4


 15.9
  2.5
 49.9

100.0
                                                279

-------
                          TABLE A-147.  IUCS PROCESS3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT  AND  INSTALLATION ANALYSIS


                 (Variation from base case:   200-MW plant)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks  and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 1,520
   126

    65

    94
   430
    56
   550
 2,841

	43_

 2,884

   400
 3,284

   311
    78
   602
   237
 4,512

   902
 5,414

   501
   650
 6,565

   280
   348

 7,193
          Percent of   Percent of
            direct    total  capital
          investment   investment
 46.3
  3.8

  2.0
 86.5
  1.3

 87.8

 12.2
100.0

  9.5
  2.4
 18.3
  7.2
137.4

 27.5
164.9

 15.3
 19.7
199.9

  8.5
 10.6

219.0
 21.1
  1.8

  0.9

  1.3
  6.0
  0.8
  7.6
 39.5

  Q.6

 40.1

  5.6
 45.7
100.0
a.  Basis
      New 200-MW plant  (30-yr life); 81  klb/hr  (60%  solids)  sludge.
      Midwest plant location; average basis  for  cost scaling,  mid-1979.
      Coal analysis (by wt):  3.5%  S  (dry  basis),  16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on 862  removed.
      Disposal in landfill  1 mi from scrubber facilities,  60%  solids  cake.
      Land required for disposal, 80 acres at 30 ft  deep.
      Trucks used for transport of  treated sludge  to disposal  area.
      Lime added at 4% of dry solids.
                                       280

-------
                           TABLE  A-148.   IUCS PROCESS

      TOTAL ANNUAL REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
	 	 — — 	 	 	
(Variation
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and. supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements
from base case: 200-MW plant)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements


6,633 tons 53.00/ton 351,500
351,500


26,280 man-hr 12.50/man-hr 328,500
43,800 man-hr 17.00/man-hr 744,600

115,400

5,000
283,500 tons 0.06/ton 17,000
283,500 tons 0.16/ton 45,400
2,141 kkWh 0.031/kWh 66,400
1,000 hr 17.00/man-hr 17,000
1,339,300
1,690,800





514,000

618,600


636,500
107,300
1,876,400
3,567,200
Dollars/dry ton Dollars/wet ton Mills/kWh
20.68 12.59 2.55


9.8
9.8


9.2
20.9

3.2

0.1
0.5
1.3
1.9
0.5
37.6
47.4





14.4

17.3


17.9
3.0
52.6
100.0


a.  Basis
    Remaining plant life,  30.yr.
    Coal burned, 175,238 Ib/hr, 9,200 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $7,193,000.
    Midwest plant location, mid-1980 operating costs.
                                             281

-------
                          TABLE A-149. IUCS PROCESS3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


  (Variation from base case:  existing 200-MW plant, 25-yr remaining life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 1,625
   127

    71

    97
   431
    56
   550
 2,957

	44_

 3,001

   451
 3,452

   322
    81
   622
   246
 4,723

   945
 5,668

   522
   680
 6,870

   207
   351

 7,428
          Percent of
            direct
          investment
           Percent of
          total  capital
           investment
 47.1
  3.7

  2.1

  2.8
 12.5
  1.6
 15.9
 85.7

  1.2

 86.9

 13.1
100.0
 27.4
164.2

 15.1
 19.7
199.0

  6.0
 10.2

215.2
 21.8
  1.7

  1.0

  1.3
  5.8
  0.8
  7.4
 39.8

  0.6

 40.4

  6.1
 46.5

  4.3
  1.1
  8.4
  3.3
 63.6

 12.7
 76.3
 92
  2.8
_ 4.7

100.0
a.  Basis
      Existing 200-MW plant  (25-yr remaining  life) ;  83 klb/hr  (60% solids)
       sludge .
      Midwest plant location; average basis for  cost scaling,  mid-1979.
      Coal analysis (by wt) :   3.5% S (dry basis), 16% ash.
      Flyash removed with  S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5  stoichiometry based on  S02  removed.
      Disposal in landfill 1 mi from scrubber facilities,  60%  solids  cake.
      Land required for disposal,  50 acres at 30 ft  deep.
      Trucks used for transport of treated sludge  to disposal  area.
      Lime added at 4% of  dry solids.
                                       282

-------
                              TABLE A-150.    IUCS PROCESS

      TOTAL ANNUAL  REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
(Variation from base
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
EarChraoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
case: existing 200-MW plant, 25-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements


6,846 tons



26,280 man-hr
43,800 man-hr




290,500 tons

290,500 tons
2,196 kkWh
1,000 hr



53.00/ton



12.50/man-hr
17.00/man-hr




0.06/ton

0.16/ton
0.031/kWh
17.00/man-hr



362,800
362,800


328,500
744,600

120,000

4,000
17,400

46,500
68,100
17,000
1,346,100


9.8
9.8


8.9
20.1

3.2

0.1
0.5

1.3
1.8
0.5
36.4
    Subtotal direct costs

Indirect  costs

Capital charges
  Depreciation, interim replacement, and
  insurance at 8.8% of total capital
  investment less land and working
  capital
  Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
  Plant,  50% of conversion costs less
  utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements
Equivalent unit revenue  requirements
                                1,708,900
                                  604,600

                                  638,800


                                  639,000
                                  107,300
                                1,989,700

                                3,698,600

Dollars/dry ton   Dollars/wet ton   Mills/kWh
                                             20.66
                                                              12.73
                                     2.64
   Basis
     Remaining  plant life, 25 yr.
     Coal burned, 180,952 Ib/hr,  9,500  Btu/kWh.
     Power plant on-stream time,  7,000  hr/yr.
     Total capital investment, $7,428,000.
     Midwest plant location,  mid-1980 operating costs.
                                                                                           46.2
 16.3

 17.3


 17.3
  2.9
 53.8

100.0
                                                283

-------
                          TABLE A-151.  IUCS PROCESS3

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case:  existing 200-MW plant, 20-yr remaining life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks  and  earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 1,625
   127

    71

    97
   431
    56
   550
 2,957

	44^

 3,001

   451
 3,452

   322
    81
   622
   246
 4,723

   945
 5,668

   522
   680
 6,870

   130
   351

 7,351
          Percent of
            direct
          investment
           Percent  of
          total capital
           investment
 47.0
  3.7

  2.1

  2.8
 12.5
  1.6
 15.9
 85.6

  1.3

 86.9

 13.1
100.0

  9.3
  2.3
 18.1
  7.1
136.8

 27.4
164.2

 15.1
 19.7
199.0

  3.8
 10.1

212.9
 22.0
  1.7

  1.0

  1.3
  5.9
  0.8
  7.5
 40.2

  0.6

 40.8

  6.2
 47.0

  4.4
  1.1
  8.4
  3.3
 64.2
100.0
a.  Basis
      Existing 200-MW plant (20-yr remaining life) ; 83  klb/hr  (60%  solids)
      sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt) :  3.5%. S  (dry basis),  16%  ash.
      Flyash removed with S02-
      S02 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on  862  removed.
      Disposal in landfill 1 mi from  scrubber facilities, 60% solids  cake.
      Land required for disposal, 37  acres at 30 ft deep.
      Trucks used for transport of treated sludge  to disposal area.
      Lime added at 4% of dry solids.
                                       284

-------
                            TABLE A-152.   IUCS PROCESS

      TOTAL  ANNUAL REVENUE REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: existing 200-MW plant, 20-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmotfing equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 9.3% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements


6,846 tons 53.00/ton 362
362


26,280 man-hr 12.50/man-hr 328
43,800 man-hr 17.00/man-hr 744

120

3
290,500 tons 0.06/ton 17

290,500 tons 0.16/ton 46
2,196 kkWh 0.031/kWh 68
1,000 hr 17.00/man-hr 17
1,345
1,708





638

632


638
107
2,017
3,725


,800
,800


,500
,600

,000

,100
,400

,500
,100
,000
,200
,000





,900

,000


,600
,300
,000
,000


9.8
9.8


8.8
20.0

3.2

0.1
0.5

1.2
1.8
0.5
36.1
45.9





17.1

17.0


17.1
2.9
54.1
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
20.80 12.82
2.66

a.  Basis
    Remaining plant life, 20 yr.
    Coal burned, 180,952 Ib/hr, 9,500 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $7,351,000.
    Midwest plant location, mid-1980 operating costs.
                                         285

-------
                          TABLE A-153. IUCS PROCESS3

    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case:  existing 200-MW plant,  15-yr remaining life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during constLUCtion
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                        1,625
                                           127

                                           71

                                           97
                                           431
                                           56
                                           550
                                        2,957

                                        	44

                                        3,001

                                          451
                                        3,452

                                          322
                                           81
                                          622
                                          246
                                        4,723

                                          945
                                        5,668

                                          522
                                          680
                                        6,870

                                           74
                                          351

                                        7,295
                                                 Percent of
                                                   direct
                                                 investment
           Percent of
          total capital
           investment
 47.0
  3.7

  2.1

  2.8
 12.5
  1.6
 15.9
 85.7

  1.2

 86.9

 13.1
100.0

  9.3
  2.3
 18.1
  7.1
136.8

 27.4
164,2
 15.1
 19.7
199.0
  2.1
 10.2

211,3
 22.3
  1.7

  1.0

  1.3
  5.9
  0.8
  7.5
 40.5

  0.6

 41.1

  6.2
 47.3

  4.4
  1.1
  8.5
__M
 64.7

 13.0
 77.7
100.0
a.
Basis
  Existing 200-MW plant (15-yr remaining life) 83 klb/hr  (60% solids)
  sludge.
  Midwest plant location; average basis for cost scaling, mid-1979.
  Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
  Flyash removed with S02.
  S02 and flyash removed to meet NSPS.
  Limestone process with 1.5 stoichiometry based on S02 removed.
  Disposal in landfill 1 mi from scrubber facilities, 60% solids cake,
  Land required for disposal, 21 acres at 30 ft deep.
  Trucks used for transport of treated sludge to disposal area.
  Lime added at 4% of dry solids.
                                       286

-------
                             TABLE  A-154.    IUCS  PROCESS

     TOTAL  ANNUAL REVENUE  REQUIREMENTS  - REGULATED UTILITY  ECONOMICS
(Variation from base case: existing 200-MW plant, 15-yr remaining life)
Total
Annual Unit annual revenue
quantity cost, $ requirements, $
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs


6,846 tons



26,280 man-hr
43,800 man-hr




290,500 tons

290,500 tons
2,196 kkWh
1,000 hr




53.00/ton



12.50/man-hr
17.00/man-hr




0.06/ton

0.16/ton
0.037/kWh
17.00/man-hr




362,800
362,800


328,500
744,600

120,000

2,400
17,, 400

46,500
68,100
17,000
1,344,500
1,707,300
Percent
of total
annual revenue
requirements


9.5
9.5


8.6
19.5

3.1

0.1
0.5

1.2
1.8
0.4
35.2
44.7
Indirect costs

Capital charges
 Depreciation, interim replacement, and
  insurance at 10.87, of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
 Plant, 50X of conversion costs  less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                                  742,000

                                  627,400


                                  638,200
                                  107,300
                                2,114,900

                                3,822,200

Dollars/dry ton   Dollars/wet ton   Mills/kWh
                                             21.35
                      13.16
                                     2.73-
a.  Basis
     Remaining plant life, 15 yr.
     Coal burned,  180,952 Ib/hr, 9,500 Btu/kWh.
     Power plant  on-stream time, 7,000 hr/yr.
     Total capital investment, $7,295,000.
     Midwest plant location, mid-1980 operating  costs.
 19.4

 16.4


 16.7
  2.8
 55.3

100.0
                                                  287

-------
                        TABLE A-155. IUCS PROCESS

    TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
   (Variation from base case:  existing 500-MW plant, 25-yr remaining life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving  equipment
     Subtotal direct investment

Engineering design arid supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,565
   176

   140

   116
   645
    70
   550
 4,262

	64

 4,326

   581
 4,907

   392
    98
   843
   322
 6,562

 1,312
 7,874

   729
   945
 9,548

   501
   542

10,591
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 52.3
  3.6

  2.9

  2.4
 13.1
  1.4
 11.2
 86.9

  1.3

 88.2

 11.8
100.0

  8.0
  2.0
 17.1
  6.6
133.7

 26.8
160.5

 14.9
 19.2
194.6
 10.2
 11.0

215.8
 24.1
  1.7

  1.3

  1,1
  6.1
  0.7
  5.2
 40.2

  0.6

 40.8
 46.3

  3.7
  0.9
  8.1
__3L0
 62.0
 90.2

  4.7
  5J.

100.0
a.  Basis
      Existing 500-MW plant (25-yr remaining life); 202klb/hr (60% solids)
      sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt);   3.5% S  (dry basis).  16%  ash.
      Flyash removed with S02.
      S02 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities, 60% solids cake.
      Land required for disposal,  143  acres  at  30 ft deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime added at 4% of dry solids.
                                       288

-------
                        TABLE  A-156.   IUCS PROCESS

  TOTAL  ANNUAL REVENUE REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: existing 500-MW plant, 25-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance— 'plant labor and material,
l\'J, of direct investment
landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 8.8% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements


16,576 tons 53.00/ton 878
878


35,040 man-hr 12.50/man-hr 438
52,560 man-hr 17.00/man-hr 893

173

9
707,000 tons 0.06/ton 42

707,000 tons 0.16/ton 113
3;,760 kkWh 0.029/kWh 109
1,000 hr 17.00/man-hr 17
1,795
2,674





840

910


843
133
2,727
5,401


,500
,500


,000
,500

,000

,700
,400

,100
,000
,000
,700
,200





,200

,800


,400
,200
,600
,800


16.3
16.3


8.1
16.5

3.2

0.2
0.8

2.1
2.0
0.3
33.2
49.5





15.6

16.8


15.6
2.5
50.5
100.0
Dollars /dry ton Dollars /wet ton Mill's /kWh
Equivalent unit revenue requirements
12.55 7.63
1.54

Basis
 Remaining plant  1-ife,  25 yr.
 Coal burned, 438,095 Ib/hr, 9,200 Btu/kWh.
 Power plant on-stream time, 7,000 hr/yr.
 Total capital investment, $10,591,000.
 Midwest plant location, mid-1980 operating costs.
                                         289

-------
                        TABLE A-157. IUCS PROCESS3

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


  (Variation from base case:  existing 500-MW plant, 20-yr remaining life)



Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
roads and railroads
Electrical
Instrumentation
Buildings
Subtotal
Services and miscellaneous
Subtotal excluding trucks and
equipment
Trucks and earthmoving equipment
Subtotal direct investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Subtotal
Contingency
Subtotal fixed investment
Allowance for startup and modifications
Interest during construction
Subtotal capital investment
Land
Working capital
Total capital investment


Total, k$
2,565
176
-
140

116
645
70
550
4,262
64

4,326
581
4,907
392
98
843
322
6,562
1,312
7,874
729
945
9,548
312
542
10,402
Percent of
direct
investment
52.3
3.6
—
2.9

2.4
13.1
1.4
11.2
86.9
1.3

88.2
11.8
100.0
8.0
2.0
17.1
6.6
133.7
26.8
160.5
14.9
19.2
194.6
6.4
11.0
212.0
Percent of
total capital
investment
24.7
1.7
-
1.3

1.1
6.2
0.7
5.3
41.0
0.6

41.6
5.6
47.2
3.8
0.9
8.1
3.1
63.1
12.6
75.7
7.0
9.1
91.8
3.0
5.2
100.0

a.  Basis
      Existing 500-MW plant (20-yr remaining life) ;  202 klb/hr  (60%  solids)
      sludge.
      Midwest plant location;  average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis;, 16% ash.
      Flyash removed with S02-
      S02 and flyash removed  to meet .NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 89 acres at 30 ft deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime added at 4% of dry solids.

                                     290

-------
                            TABLE A-158.   IUCS PROCESS

      TOTAL  ANNUAL REVENUE REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: existing 500-MW plant, 20-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material ,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 9.3% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


16,576 tons 53.00/ton 878,500
878,500


35,040 man-hr 12.50/man-hr 438,000
52,560 man-hr 17.00/man-hr 893,500

173,000

7,600
707,000 tons 0.06/ton 42,400

707,000 tons 0.16/ton 113,100
3,760 kkWh 0.029/kWh 109,000
1,000 hr 17.00/man-hr 17jOOO
1,793,600
2,672,100





888,000

894,600


842,300
133,200
2,758,100
5,430,200
Dollars/dry ton Dollars/wet ton Mills/kWh
12.62 7.68 1.55


16.2
16.2


8.1
16.4

3.2

0.1
0.8

2.1
2.0
0.3
33.0
49.2





16.4

16.5


15.5
2.4
50.8
100.0


a.  Basis
    Remaining plant life, 20 yr.
    Coal burned, 438,095 Ib/hr, 9,200 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $10,402,000.
    Midwest plant location, mid-1980 operating costs.
                                            291

-------
                        TABLE A-159. IUCS PROCESS3

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION  ANALYSIS


  (Variation from base case:  existing 500-MW plant,  15-yr  remaining life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,565
   176

   140

   116
   645
    70
   550
 4,262
 4,326

   581
 4,907

   392
    98
   843
   322
 6,562

 1,312
 7,874

   729
   945
 9,548

   179
   542

10,269
          Percent of
            direct
          investment
           Percent  of
          total capital
           investment
 52.3
  3.6

  2.9

  2.4
 13.1
  1.4
 11.2
 86.9

  1.3

 88.2

 11.8
100.0

  8.0
  2.0
 17.1
  6.6
133.7

 26.8
160.5

 14.9
 19.2
194.6

  3.6
 11.1
209.3
 24.9
  1.7

  1.4

  1.1
  6.3
  0.7
  5.4
 41.5

  0.6

 42.1

  5.7
 47.8

  3.8
  1.0
  8.2
  3.1
 63.9

 12.8
 76.7

  7.1
  9.2
 93.0
  1.7
  5.3

100.0
a.  Basis
      Existing 500-MW plant (15-yr remaining life);  202 klb/br  (60% solids)
      sludge*
      Midwest plant location; average basis for cost  scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based  on S02  removed.
      Disposal in landfill 1 mi from scrubber facilities,  60% solids  cake.
      Land required for disposal, 51 acres at 30 ft deep.
      Trucks used for transport of treated sludge to  disposal area.
      Lime added at 4% of dry solids.

                                       292

-------
                           TABLE A-160.   IUCS  PROCESS

     TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: existing 500-MW plant, 15-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 10.8% of total capital
investment less land and working
capital
Average cost of capital and taxes at
S.dZ of total capital investment
Overhead
Plant, 507, of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


16,576 tons 53.00/ton 878,500
878,500


35,040 man-hr 12.50/man-hr 438,000
52,560 man-hr 17.00/man-hr 893,500

173,000

5,800
707,000 tons 0.06/ton 42,400

707,000 tons 0.16/ton 113,100
3,760 kkWh 0.029/kWh 109,000
1,000 hr 17.00/man-hr 17,000
1,791,800
2,670,300





1,031,200

883,100


841,400
133,200
2,889,900
5,559,200
Dollars/dry ton Dollars/wet ton Mills/kWh
12.92 7.86 1.59


15.8
15.8


7.9
16.0

3.1

0.1
0.8

2.0
2.0
0.3
32.2
48.0





18.6

15.9


15.1
2.4
52.0
100.0


a.  Basis
    Remaining plant life, 15 yr.
    Coal burned,  438,095 Ib/hr, 9,200 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $10,269,000.
    Midwest plant location, mid-1980 operating  costs.
                                             293

-------
                          TABLE A-161. IUCS PROCESS

     TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
               (Variation from base case:  1500-MW plant)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 5,050
   287

   314

   180
 1,012
    74
 1,004
 7,921

   119

 8,040

 1,057
 9,097

   495
   124
 1,410
   514
11,640

 2,328
13,968

 1,291
 1,676
16,935

 2,030
 1,140

20,105
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 55.5
  3.2

  3.5

  2.0
 11.1
  0.8
 11.0
 87.1

  1.3

 88.4

 11.6
100.0

  5.4
  1.4
 15.5
  5.7
128.0

 25.5
153.5

 14.2
 18.5
186.2
 22.3
 12.5

221.0
 25.1
  1.4

  1.6

  0.9
  5.0
  0.4
  5.0
 39.4

  0.6

 40.0

  5.2
 45.2

  2.5
  0.6
  7.0
  2.6
 57.9

 11.6
 69.5
 84
100.0
a.  Basis
      New 1500-MW plant (30-yr life); 593 klb/hr  (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on 862 removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 580 acres at 30 ft deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime added at 4% of dry solids.
                                         294

-------
                           TABLE  A-162.   IUCS PROCESS

     TOTAL ANNUAL REVENUE REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: 1500-MW plant)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground) 49,000 tons 53.00/ton
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant 43,800 man-hr 12.50/man-hr
Solids disposal equipment 87,600 man-hr 17.00/man-hr
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance) 2,075,500 tons 0.06/ton
Earthmoving equipment (fuel and
maintenance) 2,075,500 tons 0.16/ton
Electricity 9,073 kkwh 0.027/kWh
Analyses 1,500 hr 17.00/man-hr
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8,6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Dollars/dry ton Dollars/wet
Equivalent unit revenue requirements 8.23 5.02


2,597,000
2,597,000


547,500
1,489,200

321,600

33,000
124,500

332,100
244,900
25,500
3,118,300
5,715,300





1,326,000

1,729,000


1,436,700
203,700
4,695,400
10,410,700
ton Mills/kWh
0.99


24.9
24.9


5.3
14.3

3.1

0.3
1.2

3.2
2.4
0.2
30.0
54.9





12.7

16.6


13.8
2.0
45.1
100.0


a.  Basis
    Remaining plant life, 30 yr.
    Coal burned,  1,285,714 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $20,105,000.
    Midwest plant location, mid-1980 operating  costs.
                                           295

-------
                          TABLE A-163. IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 1500-MW plant, 25-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 5,247
   287

   314

   183
 1,016
    74
 1,004
 8,125

   122

 8,247

 1,057
 9,304

   495
   124
 1,440
   523
11,886

 2,377
14,263

 1,321
 1,712
17,296

 1,505
 1,151

19,952
          Percent of   Percent of
            direct    total capital
          investment   investment
 56.3
  3.1

  3.4

  2.0
 10.9
  0.8
 10.8
 87.3

  1.3

 88.6

 11.4
100.0

  5,3
  1.3
 15.6
  5.6
127.8
 14.2
 18.4
185.9
214.4
 26.3
  1,4

  1.6

  0.9
  5.1
  0.4
  5.0
 40.7

  0.6

 41.3

  5.3
 46.6

  2.5
  0.6
  7.3
  2.6
 59.6

 11.9
 71.5
  6.6
  8.6
 86.7
  7.5
  5.8

100.0
a.  Basis
      Existing 1500-MW plant (25-yr remaining life) ; 606  klb/hr (60%  solids)
      sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5%  S  (dry basis),  16%  ash.
      Flyash removed with S02-
      S0£ and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from  scrubber facilities, 60% solids  cake.
      Land required for disposal, 430 acres at  30  ft deep.
      Trucks used for transport of treated sludge  to disposal area.
      Lime added at 4% of dry solids.
                                       296

-------
                         TABLE  A-164.   IUCS  PROCESS

   TOTAL ANNUAL  REVENUE  REQUIREMENTS - REGULATED UTILITY ECONOMICS
(Variation from base case: existing
Annual
quantity
Direct costs
.Delivered raw materials
Lime (ground) 49,728 tons
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant 43,800 man-hr
Solids disposal equipment 87,600 man-hr
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance) 2,121,000 tons
Earthmoving equipment (fuel and
maintenance) 2,121,000 tons
Electricity 9,152 kkWh
Analyses 1,500 hr
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 8.8% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Dollars /dry
Equivalent unit revenue requirements 8.24
1500-MW plant, 25-yr remaining life)
Total
Unit annual revenue
cost, $ requirements, $


53.00/ton 2,635,600
2,635,600


12.50/man-hr 547,500
17.00/man-hr 1,489,200

329,900

29,200
0.06/ton 127,300

0.16/ton 339,400
0.027/kWh 247,100
17.00/man-hr 25,500
3,135,100
5,770,700





1,522,000

1,715,900


1,444,000
203,700
4,885,600
10,656,300
ton Dollars /wet ton Mills /kWh
5.02 1.01
Percent
of total
annual revenue
requirements


24.7
24.7


5.1
14.1

3.1

0.3
1.2

3.2
2.3
0.2
29.5
54.2





14.3

16.0


13.6
1.9
45.8
100.0


Basis
 Remaining plant life, 25 yr.
 Coal burned, 1,314,286 Ib/hr, 9,000 Btu/fcWh.
 Power plant on-stream time,  7,000 hr/yr.
 Total capital investment, $19,952,000.
 Midwest plant location, mid-1980 operating costs.
                                          297

-------
                          TABLE A-165. IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 1500-MW plant, 20-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 5,247
   287

   314

   183
 1,016
    74
 1,004
 8,125

   122

 8,247

 1,057
 9,304

   495
   124
 1,440
   523
11,886

 2,377
14,263

 1,321
 1,712
17,296

   935
 1,151

19,382
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 56.3
  3.1
  3.4

  2.0
 10.9
  0.8
 10.8
 87.3

  1.3

 88.6

 11.4
100.0

  5.3
  1.3
 15.6
  5.6
127.8

 25.5
153.3

 14.2
 18.4
185.9

 10.0
 12.4

208.3
 27.1
  1.5

  1.6

  0.9
  5.2
  0.4
  5.2
 41.9

  0.6

 42.5

  5.5
 48.0

  2.6
  0.6
  7.4
  2.7
 61.3
 89.2

  4.8
  6.0

100.0
a.  Basis
      Existing 1500-MW plant (20-yr remaining life) ; 606 klb/hr  (60% solids
      sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S  (dry basis),  16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 267 acres at 30  ft deep.
      Trucks used for transport of treated sludge  to disposal area.
      Lime added at 4% of dry solids.
                                         298

-------
                           TABLE A-166.   IUCS  PROCESS

     TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: existing
Annual
quantity
Direct costs
Delivered raw materials
Lime (ground) 49,728 tons
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant _ 43,800 man-hr
Solids disposal equipment 87,600 man-hr
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance) 2,121,000 tons
Earthmoving equipment (fuel and
maintenance) 2,121,000 tons
Electricity 9 ,152 kkwh
Analyses 1,500 hr
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 9.3% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 507, of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Dollars/dry
Equivalent unit revenue requirements 3.26
1500-MW plant, 20-yr remaining life)
Total
Unit annual revenue
cost, $ requirements, $


53.00/ton 2,635,600
2,635,600


12.50/man-hr 547,500
17.00/man-hr 1,489,200

329,900

22,700
0.06/ton 127,300

0.16/ton 339,400
0.027/kWh 247,100
17.00/man-hr 25,500
3,128,600
5,764,200





1,608,500

1,666,900


1,440,800
203,700
4,919,500
10,684,100
ton Dollars /wet ton Mills /kWh
5.04 1.02
Percent
of total
annual revenue
requirements


24.7
24.7


5.1
14.0

3.1

0.2
1.2

3.2
2.3
0.2
29.3
54.0





15.0

15.6


13.5
1.9
46.0
100.0


a.  Basis
    Remaining plant life, 20 yr.
    Coal burned,  1,314,286 Ib/hr, 9,200 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $19,382,000.
    Midwest plant location, mid-1980 operating  costs.
                                             299

-------
                          TABLE A-167. IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 1500-MW plant, 15-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 5,247
   287

   314

   183
 1,016
    74
 1,004
 8,125

   122

 8,247

 1,057
 9,304

   495
   124
 1,440
   523
11,886

 2,377
14,263

 1,321
 .1,712
17,296

   529
 1.151

18,976
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 56.3
  3.1

  3.4

  2.0
 10.9
  0.8
 10.8
 87.3

  1.3

 88.6

 11.4
100.0

  5.3
  1.3
 15.6
  5.6
127.8

 25.5
153.3

 14.2
 18.4
185.9
  5.7
 12.4

204.0
 27.6
  1.5

  1.6
  0.4
  5.3
 42.8
  0.7
 43.5
  5.5
 49.0

  2.6
  0.7
  7.5
  2.8
 62.6
 12.5
 75.2

  6.9
  9.0
 91.1
  2.8
  6.1

100.0
a.  Basis
      Existing 200-MW plant (15-yr remaining life); 606 klb/hr  (60% solids)
      sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with 502-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 151 acres at 30 ft deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime added at 4% of dry solids.
                                         300

-------
                         TABLE A-168.    IUCS  PROCESS

   TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: existing 1500-MW plant, 15-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground) 49,728 tons 53.00/ton
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant 43,800 man-hr 12.50/man-hr
Solids disposal equipment 87,600 man-hr 17 .00/man-hr
Maintenance — plant labor and material,
n of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance) 2,121,000 tons 0.06 /ton
Earthmoving equipment (fuel and
maintenance; 2,121,000 tons 0.16/ton
Electricity 9,152 kkWh 0.027/kWh
Analyses 1,500 hr 17. 00/man-hr
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 10.8% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Dollars /dry ton Dollars /wet
Equivalent unit revenue requirements 8.43 5.14


2^635,600
2,635,600


547,500
1,489,200

329,900

17,100
127,300

339,400
247,100
25,500
3,123,000
5,758,600





1,868,000

1,632,000


1,438,000
203,700
5,141,700
10,900,300
ton Mills /kWh
1.04


24.2
24.2


5.0
13.6

3.0

0.2
1.2

3.1
2.3
0.2
28.6
52.8





17.1

15.0


13.2
1.9
47.2
100.0


Basis
  Remaining plant life, 15  yr.
  Coal burned, 1,314,286 Ib/hr, 9,200 Btu/kWh.
  Power plant on-stream time, 7,000 hr/yr.
  Total capital investment, $18,876,000.
  Midwest plant location, mid-1980 operating costs.
                                         301

-------
                          TABLE A-169. IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
              (Variation from base case:  12% flyash in coal)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks  and  earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,225
   141

   106

   107
   452
    66
   550
 3,647

	55_

 3,702

   581
 4,283

   334
    84
   741
   290
 5,732

 1,146
 6,878

   630
   825
 8,333

   557
   455

 9,345
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 51.9
  3.3

  2.5

  2.5
 10.6
  1.5
 12.8
 85.1

  1.3

 86.4

 13.6
100.0

  7.8
  2.0
 17.2
  6.8
133.8

 26.8
160.6

 14.7
 19.3
194.6

 13.0
 10.6

218.2
 23.9
  1.5

  1.1

  1.1
  4.8
  0.7
  5.9
 39.0

  0.6

 39.6

  6.2
 45.8

  3.6
  0.9
  7.9
  3.1
 61.3

 12.3
 73.6

  6.7
  8.9
 89.2

  5.9
  4.9

100.0
a.  Basis
      New 500-MW plant (30-yr life); 163 klb/hr  (60%  solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5%  S (dry basis), 12%  ash,  11,100  Btu/lb HV.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 159 acres at 30 ft  deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime added at 4% of dry solids.
                                         302

-------
                           TABLE A-170.   IUCS  PROCESS

     TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: 12% ash in coal)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Ea.rthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements


13,395 tons 53.00/ton 709
709


35,040 man-hr 12.50/man-hr 438
52,560 man-hr 17. 00 /man-hr 893

148

9
570,500 tons 0.06/ton 34

570,500 tons 0.16/ton 91
3,000 kkWh 0.029/kWh 87
1,000 hr 17. 00 /man-hr 17
1,718
2,428





652

803


515
133
2,105
4,533


,900
,900


,000
,500

,100

,000
,200

,300
,000
,000
,100
,000





,500

.700


,600
,200
,000
,000


15.7
15.7


9.7
19.7

3.3

0.2
0.7

2.0
1.9
0.4
37.9
53.6





14.4

17.7


11.4
2.9
46.4
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
13.05 7.94
1.30

a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 405,405 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $9,345,000.
     Midwest plant location, mid-1980 operating costs.
                                             303

-------
                          TABLE A-171. IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
               (Variation from base case:  20% flyash in coal)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,886
   192

   141

   118
   704
    70
   550
 4,661

	70_

 4,731

   698
 5,429

   392
    98
   908
   347
 7,174

 1,435
 8,609

   791
 1,033
10,433

   809
   615

11,857
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 53.2
  3.5

  2.6

  2.2
 13.0
  1.3
 10.1
 85.9

  1.2

 87.1

 12.9
100.0

  7.2
  1.8
 16.7
  6.4
132.1

 26.5
158.6

 14.6
 19.0
192.2

 14.9
 11.3

218.4
 24.4
  1.6

  1.2

  1.0
  5.9
  0.6
  4.6
 39.3

  0.6

 39.9

  5.9
 45.8
 12.1
 72.6

  6.7
  8.7
 88.0

  6.8
  5.2

100.0
a.  Basis
      New 500-MW plant (30-yr life); 236 klb/hr  (60% solids) sludge.
      Midwest plant location; average basis for  cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 20% ash, 9,900 Btu/lb HV.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on  S0£  removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 231 acres at 30 ft deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime added at 4% of dry solids.
                                          304

-------
                               TABLE A-172.   IUCS  PROCESS

      TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED UTILITY ECONOMICS
(Variation from base case: 20% ash in coal)
Total
Annual Unit annual revenue
quantity cost, $ requirements, $
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance-rplant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs


19,376 tons



35,040 man-hr
61,320 man-hr




826,000 tons

826,000 tons
4,424 kkWh
1,000 hr




53.00/ton



12. 50 /man-hr
17.00/man-hr




0.06/ton

0.16/ton
0.029/kWh
17.00/man-hr




1.026.900
1,026,900


438,000
1,042,400

189,200

13,000
49,600

132,200
12,8,300
17,000
2,009,700
3,036,600
Percent
of total
annual revenue
requirements


17
17


7
17

3

0
0

2
2
0
33
50


.2
.2


.3
.5

.2

.2
.8

.2
.2
.3
.7
.9
Indirect costs

Capital charges
  Depreciation, interim replacement, and
  insurance at 7.83% of total capital
  investment less land and working
  capital
  Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
  utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements
 quivalent  unit revenue requirements
                                  816,900           13.7

                                1,028,300           17.2
                                 940,700           15.7
                                 148,000            2.5
                                2,933,900           49.1

                                5,970,500          100.0

Dollars/dry  ton   Dollars/wet ton  Mills/kWh
     11.84             7.23          1.71
a.  Basis
     Remaining plant life,  30 yr.
     Coal burned, 454,545 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment, $11,957,000.
     Midwest plant location, mid-1980 operating  costs.
                                               305

-------
                          TABLE A-173.  IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
          (Variation from base case:  2% S content in coal)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,128
   140

   105

   104
   542
    58
   550
 3,627

	5_4

 3,681

   505
 4,186

   334
    84
   737
   285
 5,626

 1,125
 6,751

   625
   810
 8,186

   469
   470

 9,125
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 50.9
  3.3

  2.5

  2.5
 12.9
  1.4
 13.1
 86.6

  1.3

 87.9

 12.1
100.0

  8.0
  2.0
 17.6
  6.8
134.4

 26.9
161.3

 14.9
 19.4
195.6
 11.2
 11.2

218.0
 23.4
  1.5

  1.2

  1.1
  5.9
  0.6
  6.0
 39.7

  0.6

 40.3

  5.6
 45.9

  3.7
  0.9
  8.1
  3.1
 61.7
 89.7

  5.1
  5.2

100.0
a.  Basis
      New 500-MW plant (30-yr life); 137 klb/hr  (60%  solids)  sludge.
      Midwest plant location; average basis for cost  scaling, mid-1979.
      Coal analysis (by wt):   2% S  (dry basis),  16% ash,  10,700  Btu/lb  HV.
      Flyash removed with SO?.
      SC>2 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based  on SC>2 removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 193 acres at 30  ft  deep.
      Trucks used for transport of treated sludge to  disposal area.
      Lime added at 4% of dry solids.
                                          306

-------
                          TABLE A-I74.   IUCS  PROCESS

    TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: 27, S in coal)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
k'/. of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


11,274 tons 53.00/ton 597,500
597,500


35,040 man-hr 12.50/man-hr 438,000
52,560 man-hr 17.00/man-hr 893,500

147,200

8,000
479,500 tons 0.06/ton 28,800

479,500 tons 0.16/ton 76,700
3,172 kkWh 0.029/kWh 92,000
1,000 hr 17.00/man-hr 17,000
1,701,200
2,298,700





641,000

776,200


804,600
133,200
2,355,000
4,653,700
Dollars/dry ton Dollars/wet ton Mills/kWh
15.57 9.71 1.33


12.8
12.8


9.4
19.2

3.2

0.2
0.6

1.6
2.0
0.4
36.6
49.4





13.8

16.6


17.3
2.9
50.6
100.0


a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 420,561 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $9,025,000.
     Midwest plant location,  mid-1980 operating costs.
                                             307

-------
                          TABLE A-175. IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
              (Variation from base case:  5% S  in coal)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks  and earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 3,078
   186

   147

   122
   691
    70
   550
 4,844

	73

 4,917

   698
 5,615

   392
    98
   938
   356
 7,399

 1,480
 8,879

   818
 1,065
10,762

   879
   642

12,283
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 54.9
  3.3

  2.6

  2.2
 12.3
  1.2
  9.8
 86.3

  1.3

 87.6

 12.4
100.0

  7.0
  1.7
 16.8
  6.3
131.8

 26.3
158.1

 14.6
 19.0
191.7

 15.7
 11.4

218.8
 25.0
  1.5

  1.2

  1.0
  5.6
  0.6
  4.5
 39.4

  0.6

 40.0

  5.7
 45.7

  3.2
  0.8
  7.6
  2.9
 60.2

 12.1
 72.3

  6.6
  8.7
 87.6

  7.2
  5.2

100.0
a.  Basis
      New 500-MW plant (30-yr life); 257 klb/hr  (60% solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   5g S  (dry  basis),  16% ash,  10,400 Btu/lb HV.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids  cake.
      Land required for disposal,  251 acres at 30 ft deep.
      Trucks used for transport of treated sludge  to disposal area.
      Lime added at 4% of dry solids.
                                         308

-------
                          TABLE  A-176.   IUCS  PROCESS3

    TOTAL ANNUAL  REVENUE  REQUIREMENTS - REGULATED UTILITY ECONOMICS
(Variation from base case: 5% S in coal)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83/S of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6Z of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


21,088 tons 53.00/ton 1,117,700
1,117,700


35,040 man-hr 12 . 50/man-hr 438,000
61,320 man-hr 17.00/man-hr 1,042,400

224,600

14,000
889,500 tons 0.06/ton 53,400

889,500 tons 0.16/ton 142,300
4,320 kkWh 0.029/kWh 125,300
1,000 hr 17.00/man-hr 17,000'
2,057,000
3,174,700





842,700

1,056,300


965,900
148,000
3,012,900
6,187,600
Dollars/dry ton Dollars/wet ton Mills/kWh
11.29 6.88 1.77


18.1
18.1


7.1
16.8

3.6

0.2
0.9

2.3
2.0
0.3
33.2
51.3





13.6

17.1


15.6
2.4
48.7
100.0


a.  Basis
    Remaining plant life, 30 yr.
    Coal burned, 432,692 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment,  $12,283,000.
    Midwest plant location,  mid-1980 operating costs.
                                             309

-------
                          TABLE A-177. IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
              (Variation from base case:  200 MW with flyash
                       removed independently of 802)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                            1,435
                                              114

                                               95

                                               89
                                              581
                                               64
                                              550
                                            2,928
                                            2,972

                                              340
                                            3,312

                                              392
                                               98
                                              617
                                              239
                                            4,658

                                              932
                                            5,590

                                              525
                                              671
                                            6,786

                                              203
                                              312

                                            7,301
                                                     Percent of
                                                       direct
                                                     investment
           Percent  of
          total capital
           inves tment
 43.4
  3.4

  2.9

  2.7
 17.5
  1.9
 16.6
 88.4

  1.3

 89.7

 10.3
100.0

 11.8
  3.0
 18.6
  7.2
140.6

 28.2
168.8
 15.9
 20.2
204.9
  6.1
  9.4

220.4
 19.6
  1.6

  1.3

  1.2
  8.0
  0.9
  7.5
 40.1

  0.6

 40.7

  4.7
 45.4
 12.7
 76.5
100.0
a.  Basis
      New 200-MW plant (30-yr life); 59 klb/hr  (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5%  s (dry basis), 16% ash.
      Flyash removed independently of S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on SO
      Disposal in landfill 1  mi from scrubber facilities,
      Land required for disposal, 59 acres at 30 ft deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime and flyash added at 4% of dry  solids.
                                          310
                                                            removed.
                                                           0% solids cake.

-------
                        TABLE  A-178.   IUCS PROCESS

  TOTAL ANNUAL REVENUE REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: 200-MW plant)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


3,518 tons 53.00/ton 186,500
186,500


26,280 man-hr 12.50/man-hr 328,500
43,800 man-hr 17.00/man-hr 744,600

118,900

3,000
206,500 tons 0.06/ton 12,400

206,500 tons 0.16/ton 33,000
1,834 kkWh 0.031/kWh 56,900
1,000 hr 17.00/man-hr 17,000
1,314,300
1,500,800





531,300

627,900


628,700
107,300
1,895,200
3,396,000
Dollars/dry ton Dollars/wet ton Mills/kWh
37.03 16.45 2.43


5.5
5.5


9.7
21.8

3.5

0.1
0.4

1.0
1.7
0.5
38.7
44.2





15.6

18.5


18.5
3.2
55.8
100.0


Basis
 Remaining plant life,  30 yr.
 Coal burned, 175,238 Ib/hr, 9,200 Btu/kWh.
 Power plant on-stream time, 7,000 hr/yr.
 Total capital investment, $7,301,000.
 Midwest plant location, mid-1980 operating costs.
                                          311

-------
                          TABLE  A-179. IUCS PROCESS3

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
     (Variation from base case:  flyash removed independently of 802)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
2,230
  141

  154

   99
  763
   66
  550
4,003

	60

4,063

  441
4,504

  403
  101
  800
  301
6,109
  689
  880
8,900

  494
  445

9,839
         Percent of
           direct
         investment
           Percent of
          total  capital
           investment
 49.6
  3.1

  3.4

  2.2
 16.9
  1.5
 12.2
 88.9

  1.3

 90.2

  9.8
100.0

  8.9
  2.2
 17.8
  6.7
135.6

 27.2
162.8

 15.3
 19.5
197.6

 11.0
  9.9

218.5
 22.6
  1.4

  1.6

  1.0
  7.8
  0.7
  5.6
 40.7

  0.6

 41.3
 62.1
 90.5

  5.0
  4.5

100.0
a.  Basis
      New 500-MW plant (30-yr life);  144 klb/hr (60% solids) sludge.
      Midwest plant location; average basis  for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S  (dry basis), 16% ash.
      Flyash removed independently of S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on  S02  removed.
      Disposal in landfill  1 mi from  scrubber facilities,  60% solids cake.
      Land required for disposal, 141 acres  at 30 ft deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime and flyash both added at 4% of dry solids.
                                     312

-------
                                TABLE A-180.    IUCS PROCESS

        TOTAL  ANNUAL REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
(Variation from base case: no flyash)
Annual Unit
quantity cost, $
Direct costs
Delivered raw materials
Lime (ground) 8,600 tons
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant 35,040 man-hr
Solids disposal equipment 52,560 man-hr
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance) 504,000 tons
Earthmoving equipment (fuel and
maintenance) 504,000 tons
Electricity 2,577 kkWh
Analyses 1,000 hr
Subtotal conversion costs
Subtotal direct costs


53.00/ton



12.50/man-hr
17.00/man-hr




0.06/ton

0.16/ton
0.029/kWh
17.00/man-hr


Total
annual revenue
requirements, $


455
455


438
893

161

8
30

80
74
17
1,703
2,159


,800
,800


,000
,500

,700

,000
,200

,600
,700
,000
,700
,500
Percent
of total
annual revenue
requirements


9.8
9.8


9.4
19.3

3.4

0.2
0.6

1.7
1.6
0.4
36.6
46.4
Indirect  costs

Capital charges
  Depreciation, interim  replacement, and
  insurance at 7.83%  of total capital
  investment less land  and working
  capital
  Average cost of capital and taxes at
  8.63! of total capital investment
Overhead
  Plant,  50% of conversion costs less
  utilities
  Administrative, 10%  of operating labor
    Subtotal indirect costs

    Total annual revenue requirements
Equivalent unit revenue  requirements
                                 696,900

                                 846,200


                                 814,500
                                 133,200
                                2,490,800

                                4,650,300

Dollars/dry  ton   Dollars/wet ton   Mills/kWh
                                              20.87
                                                               9.23
                                                                             1.33
   Basis
     Remaining plant life, 30 yr.
     Coal burned, 482,571 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment, $9,839,000.
     Midwest plant location, mid-1980 operating costs.
 15.0

 18.2


 17.5
  2.9
 53.6

100.0
                                                313

-------
                          TABLE  A-181.IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
             (Variation from base case:  1500-MW plant, flyash
                       removed independently of 802)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding pond

Pond construction
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
                                        4,422
                                          202

                                          359

                                          135
                                        1,274
                                           73
                                        1,004
                                        7,469

                                          112
                                        7,581

                                          766
                                        8,347

                                          587
                                          147
                                        1,343
                                          482
                                       10,906

                                        2,181
                                       13,087

                                        1,232
                                        1,570
                                       15,889

                                        1,414
                                          800

                                       18,103
                                                 Percent of
                                                   direct
                                                 investment
           Percent of
          total capital
           investment
 53.0
  2.4

  4.3

  1.6
 15.3
  0.9
 12.0
 89.5

  1.3
 90.8

  9.2
100.0

  7.0
  1.8
 16.1
  5.8
130.7
 14.8
 18.8
190.4
 16.9
  9.6

216.9
 24.6
  1.1

  2.0

  0.7
  7.0
  0.4
  5.5
 41.3

  0.6
 41.9

  4.2
 46.1

  3.2
  0.8
  7.4
  2.7
 60.2

 12.1
 72.3
  6.8
  8.7
 87.8
  7.8
  4.4

100.0
a.
Basis
  New 1500-MW plant (30-yr life); 430 klb/hr (60% solids) sludge.
  Midwest plant location; average basis for cost scaling, mid-1979.
  Coal analysis (by wt) :   3.5%S (dry basis),  16% ash.
  Flyash removed independently of 862.
  S02 and flyash removed to meet NSPS.
  Limestone process with 1.5 stoichiometry based on S02  removed.
  Disposal in landfill 1 mi from scrubber facilities, 60% solids cake,
  Land required for disposal,  404 acres at 30  ft deep.
  Trucks used for transport of treated sludge to disposal area.
  Lime and  flyash both  added  at  4% of dry  solids.
                                       314

-------
                              TABLE A-182.    IUCS  PROCESS

      TOTAL ANNUAL  REVENUE REQUIREMENTS - REGULATED UTILITY ECONOMICS
(Variation from base case




Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material.
n of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs


Annual
quantity


25,799 tons



43,800 man-hr
70,080 man-hr




1,505,000 tons

1,505,000 tons
6,356 kkWh
1,500 hr

: 1500-MW plant)


Unit
cost, $


53.00/ton



12 . 50/man-hr
17.00/man-hr




0.06/ton

0.16/ton
0.027/kWh
17.00/man-hr


Total
annual revenue
requirements, $


1,367,300
1,367,300


547,500
1,191,400

313,400

23,000
90,300

240,800
171,600
25,500
2,603,500
Percent
of total
annual revenue
requirements


16.8
16.8


6.7
14.6

3.8

0.3
1.1

3.0
2.1
0.3
31.9
    Subtotal direct costs

Indirect costs

Capital charges
 Depreciation,  interim replacement,  and
  insurance at  7.83% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
 Plant, 50% of  conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit  revenue requirements
                                3,970,800
Dollars/dry ton   Dollars/wet
   1,244,100

   1,556,900


   1,216,000
     173,900
   4,190,900

   8,161,700

ton   Mills/kWh
                                            12.17
                                                               5.42
                                                                             0.78
a.  Basis
    Remaining plant life,  30 yr.
    Coal burned, 1,285,714 Ib/hr,  9,000 Btu/kWh.
    Power plant on-stream time,  7,000 hr/yr.
    Total capital investment,  $18,103,000.
    Midwest plant location,  mid-1980 operating costs.
                                                    48.7
                                                    15.2

                                                    19.1


                                                    14.9
                                                     2.1
                                                    51.3

                                                   100.0
                                                 315

-------
                          TABLE A-183.  IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT  AND  INSTALLATION ANALYSIS
            (Variation from base case:   truck  5 mi  to  disposal)
                                          Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding  trucks  and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,551
   176

   136

   115
   650
    70
   550
 4,248

	64_

 4,312

   923
 5,235

   392
    98
   841
   338
 6,904

 1,381
 8,285

   736
   994
10,015

   676
   686

11,377
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 48.8
  3.4

  2.6

  2.2
 12.4
  1.3
 10.5
 81.2

  1.2

 82.4

 17.6
100.0

  7.5
  1.9
 16.0
  6.5
131.9

 26.4
158.3

 14.1
 18.9
191.3

 12.9
 13.1

217.3
 22.5
  1.5

  1.2
  0.6
 37.9
  8.1
 46.0

  3.4
  0.9
  7.4
  3.0
 60.7
 12.1
 72.8

  6.5
  8.7
 88.0

  6.0
  6.0

100.0
a.  Basis
      New 500-MW plant  (30-yr life);  198 klb/hr  (60% solids) sludge.
      Midwest plant location; average basis  for  cost  scaling,  mid-1979.
      Coal analysis (by wt) :  3.5% S  (dry basis), 16% ash.
      Flyash removed with  S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5  stoichiometry based  on SOo removed.
      Disposal in landfill  5 mi from  scrubber facilities,  60%  solids  cake.
      Land required for disposals 193 acres  at 30 ft deep.
      Trucks used for transport of treated sludge  to  disposal  area.
      Lime added at 4% of  dry solids.
                                       316

-------
                        TABLE  A-184.   IUCS  PROCESS

  TOTAL ANNUAL REVENUE  REQUIREMENTS - REGULATED  UTILITY  ECONOMICS
(Variation from base case: disposal area 5 mi from scrubber facilities)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements


16,216 tons 53.00/ton 859
859


35,040 man-hr 12.50/man-hr 439
87,600 man-hr 17.00/man-hr 1,489

172

11
693,000 tons 0.20/ton 138

693,000 tons 0.16/ton 110
3,688 kkWh 0.029/kWh 107
1,000 hr 17.00/man-hr 17
2,486
3,345





784

978


1,189
192
3,145
6,490


,400
,400


,800
,200

,500

,000
,600

,900
,000
,000
,000
,400





,200

,400


,500
,900
,000
,400


13.2
13.2


6.8
22.9

2.7

0.2
2.1

1.7
1.6
0.3
38.3
51.5





12.1

15.1


18.3
3.0
48.5
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
15.40 9.37
1.85

Basis
 Remaining plant life,  30 yr.
 Coal burned, 482,571 Ib/hr, 9,000 Btu/kWh.
 Power plant on-stream time, 7,000 hr/yr.
 Total capital investment, $11,377,000.
 Midwest plant location, mid-1980 operating costs.
                                        317

-------
                          TABLE  A-185. IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
           (Variation from base case:  truck 10 mi to disposal)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,551
   176

   136

   115
   650
    70
   550
 4,248

	6_4

 4,312

 1,197
 5,509

   392
    98
   841
   351
 7,191

 1,438
 8,629

   743
 1,035
10,407

   676
   808

11,891
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 46.2
  3.2

  2.5
  1.2
 78.3
 21.7
100.0

  7.1
  1.8
 15.2
  6.4
130.5
 13.5
 18.8
188.9
 12.3
 14.6

215.8
 21.4
  1.5

  1.1

  1.0
  5.5
  0.6
  4.6
 35.7

  0.6

 36.3

 10.0
 46.3

  3.3
  0.8
  7.1
  3.0
 60.5

 12.1
 72.6

  6.2
  8.7
 87.5
  5.7
  6.8

100.0
a.  Basis
      New 500-MW plant (30-yr life); 198 klb/hr (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5%  S (dry basis), 16%-ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on  S02 removed.
      Disposal in landfill  10 mi from scrubber facilities,  60%  solids  cake.
      Land required for disposal, 198 acres at 30  ft deep.
      Trucks used for transport of  treated sludge to disposal area.
      Lime added at 4% of dry solids.
                                         318

-------
                        TABLE A-186.   IUCS  PROCESS

  TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: disposal area 10 mi from scrubber facilities)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
455 of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements


16,216 tons 53.00/ton 859
859


35,040 man-hr 12.50/man-hr 438
113,880 man-hr 17.00/man-hr 1,936

172

11
693,000 tons 0.39/ton 270

693,000 tons 0.16/ton 110
3,688 kkWh 0.029/kWh 107
1,000 hr 17.00/man-hr 17
3,062
3,922





814

1,022


1,477
237
3,552
7,475


,500
,500


,000
,000

,500

,000
,300

,900
,000
,000
,700
,200





,900

,600


,900
,400
,800
,000


11.5
11.5


5.9
25.9

2.3

3.6
3.6

1.5
1.4
0.2
41.0
52.5





10.9

13.7


19.7
3.2
47.5
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
17.73 10.78
2.14

Basis
 Remaining plant life,  30 yr.
 Coal burned, 482,571 Ib/hr, 9,000 Btu/kWh.
 Power plant on-stream time, 7,000 hr/yr.
 Total capital investment, $11,891,000.
 Midwest plant location, mid-1980 operating costs.
                                          319

-------
                          TABLE  A-187.IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
         (Variation from base case:  lime added for stabilization
                         at 5% of dry solids rate)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,584
   176

   137

   115
   639
    70
   550
 4,271

	63_

 4,334

   581
 4,915

   449
   112
   828
   317
 6,621

 1,304
 7,925

   725
   939
 9,589

   679
   579

10,847
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 52.6
  3.6

  2.8

  2.3
 13.0
  1.4
 11.2
 86.9

  1.3

 88.2

 11.8
100.0

  9.3
  2.3
 17.2
  6.6
135.4

 27.1
162.5

 15.1
 19.5
197.1

 13.8
 11.8

220.7
 23.8
  1.6

  1.3

  1.1
  5.9
  0.6
  5.1
 39.4

  0.6

 40.0

  5.3
 45.3

  4.1
  1.0
  7.7
  2.9
 61.0

 12.1
 73.1

  6.7
  8.6
 88.4

  6.3
  5.3

100.0
a.  Basis
      New 500-MW plant (30-yr life); 199 klb/hr  (60%  solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5%  S  (dry basis),  16%  ash.
      Flyash removed with SO^.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on 862 removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 194 acres at 30 ft deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime added at 5% of dry solids.
                                         320

-------
                           TABLE  A-188.   IUCS  PROCESS

     TOTAL ANNUAL REVENUE  REQUIREMENTS - REGULATED  UTILITY  ECONOMIC?
(Variation from base case: 5% lime, solid, added to mixing bin)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance— plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation , interim replacement , and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6^ of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


20,269 tons 53.00/ton 1,074,300
1,074,300


35,040 man-hr 12.50/man-hr 438,000
52,560 man-hr 17.00/man-hr 893,500

169,400

11,000
696,500 tons 0.06/ton 41,800

696,500 tons 0.16/ton 111,400
3,890 kkWh 0.029/kWh 112,800
1,000 hr 17.00/man-hr 17,000
1,794,900
2,869,200





743,100

924,300


841,100
133,200
2,641,700
5,510,900
Dollars/dry ton Dollars/wet ton Mills/kWh
12.95 7.91 1.57


19.5
19.5


8.0
16.2

3.1

0.2
0.8

2.0
2.0
0.3
32.6
52.1





13.5

16.7


15.3
2.4
47.9
100.0


a.  Basis
    Remaining plant  life, 30 yr.
    Coal burned, 482,571 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,,000 hr/yr.
    Total capital investment, $10,748,000.
    Midwest plant location, mid-1980 operating costs.
                                             321

-------
                          TABLE A-189.  IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
         (Variation from base case:  lime added for stabilization
                         at 3% of dry solid rate)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,479
   176

   109

   114
   575
    66
   550
 4,069
 4,130

   581
 4,711

   357
    89
   811
   312
 6,280

 1,256
 7,536

   696
   908
 9,140

   672
   494

10,306
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 52.7
  3.7

  2.3

  2.4
 12.2
  1.4
 11.7
 86.4

  1.3

 87.7

 12.3
100.0

  7.6
  1.9
 17.2
  6.6
133.3

 26.7
160.0

 14.8
 19.1
194.0

 14.3
 10.5

218.8
 24.1
  1.7

  1.1

  1.1
  5.6
  0.6
  5.3
 39.5

  0.6

 40.1

  5.6
 45.7

  3.5
  0.9
  7.8
  3.0
 60.9

 12.2
 73.1

  6.8
  8.8
 88.7

  6.5
  4.8

100.0
a.  Basis
      New 500-MW plant (30-yr life); 196 klb/hr (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16%.ash.
      Flyash removed with S0£.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
      Land required for disposal, 192 acres at 30 ft deep.
      Trucks used for transport of treated sludge to disposal area.
      Lime added at 3% of dry solids.
                                        322

-------
                        TABLE  A-190.   IUCS PROCESS

  TOTAL  ANNUAL REVENUE REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: 37, lime — solid — added to mixing bin)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, ? requirements, $ requirements
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
n of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6? of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


12,163 tons 53.00/ton 644,600
644,600


35,040 man-hr 12.50/man-hr 438,000
52,560 man-hr 17.00/man-hr 893,500

165,200

11,000
686,000 tons 0.06/ton 41,200

686,000 tons 0.16/ton 109,800
3,484 kkWh 0.029/kWh 101,000
1,000 hr 17.00/man-hr 17,000
1,776,700
2,421,300





715,300

886,000


837,900
133,200
2,572,400
4,993,700
Dollars/dry ton Dollars/wet ton Mills/kWh
11.96 7.28 1.43


12.9
12.9


8.8
17.9

3.3

0.2
0.8

2.2
2.0
0.4
35.6
48.5





14.3

17.7


16.8
2.7
51.5
100.0


Basis
 Remaining plant  life, 30 yr.
 Coal burned, 482,571 Ib/hr, 9,000 Btu/kWh.
 Power plant on-stream time, 7,000 hr/yr.
 Total capital investment, $10,302,000.
 Midwest plant location, mid-1980 operating costs.
                                          323

-------
                          TABLE A-191. IUCS PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
     (Variation from base case:  lime process with 1.1 stoichiometry)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                        2,499
                                          168

                                          137

                                          120
                                          587
                                           66
                                          550
                                        4,127

                                       	62

                                        4,189

                                          581
                                        4,770

                                          380
                                           95
                                          821
                                          315
                                        6,381

                                        1,276
                                        7,657

                                          708
                                          919
                                        9,284

                                          588
                                          511

                                       10,383
                                                 Percent of
                                                   direct
                                                 investment
           Percent of
          total capital
           investment
 52.4
  3.5

  2.9

  2.5
 12.3
  1.4
 11.5
 86.5

  1.3

 87.8

 12.2
100.0

  8.0
  2.0
 17.2
  6.6
133.8

 26.7
160.5

 14.8
 19.3
194.6
 12.4
 10.7

217.7
 24.1
  1.6

  1.3

  1.1
  5.7
  0.6
  5.3
 39.7

  0.6

 40.3

  5.6
 45.9

  3.7
  0.9
  7.9
  3.0
 61.4
 89.4

  5.7
  4.9

100.0
a.
Basis
  New 500-MW plant (30-yr life); 172 klb/hr  (60% solids)  sludge.
  Midwest plant location; average basis for cost scaling, mid-1979.
  Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
  Flyash removed with SOo.
  S02 and flyash removed to meet NSPS.
  Lime process with 1.1 stoichiometry based on S02 removed.  Scrubber
  effluent (10% solids).
  Disposal in landfill 1 mi from scrubber facilities, 60% solids cake.
  Land required for disposal, 168 acres at 30 ft deep.
  Trucks used for transport of treated sludge to disposal area.
  Lime added at 4% of dry solids.
                                     324

-------
                            TABLE A-192.   IUCS PROCESS

      TOTAL  ANNUAL REVENUE REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: lime process with 1.1 stoichiometry)
Total
Annual Unit annual revenue
quantity cost, $ requirements, $
Direct costs
Delivered raw materials
Lime (ground)
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


14,116 tons 53.00/ton 748,100
748,100


35,040 man-hr 12.50/man-hr 438,000
52,560 man-hr 17.00/man-hr 893,500

167,600

10,000
602,000 tons 0.06/ton 36,100

602,000 tons 0.16/ton 96,300
3,600 kkWh 0.029/kWh 104,400
1,000 hr 17.00/man-hr 17,000
1,762,900
2,511,000





726,900

892,900


829,300
133,200
2,582,300
5,093,300
Dollars/dry ton Dollars/wet ton Mills/kWh
13.88 8.46 1.46
Percent
of total
annual revenue
requirements


14.7
14.7


8.6
17.5

3.3

0.2
0.7

1.9
2.1
0.3
34.6
49.3





14.3

17.5


16.3
2.6
50.7
100.0


a.  Basis
    Remaining plant life,  30 yr.
    Coal burned, 482,571 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $10,383,000.
    Midwest plant location, mid-1980 operating costs.
                                           325

-------
                       TABLE A-193. CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                                (Base case)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,885
   227
   697
   209

   162
   853
   107
   550
 5,690

	85.

 5,775

   442
 6,217

   472
   118
 1,072
   385
 8,264

 1,653
 9,917

   948
 1,190
12,055

   693
   783

13,531
          Percent of
            direct
          investment
           Percent  of
          total capital
           investment
 46.5
  3.6
 11.2
  3.4

  2.6
 13.7
  1.7
  8.8
 91.5

  1.4

 92.9

  7.1
100.0

  7.6
  1.9
 17.2
  6.2
132.9

 26.6
159.5

 15.2
 19.2
193.9
 11.1
 12.6

217.6
 21.3
  1.7
  5.2
  1.5

  1.2
  6.3
  0.8
  4.1
 42.1

  0.6

 42.7

  3.2
 45.9

  3.5
  0.9
  8.0
  2.8
 61.1

 12.2
 73.3

  7.0
  8.8
 89.1

  5.1
  5.8

100.0
a.  Basis
      New 500-MW plant (30-yr life); 203 klb/hr  (60% solids') sludge.
      Midwest plant location; average basis for  cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on  S02  removed.
      Disposal in landfill  1 mi from scrubber facilities.
      Land required for disposal, 198 acres at 30 ft deep.
      Clarified sludge (35% solids) transported  by pipeline  to  disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement -  7%,  sodium
      silicate - 4%.                      00,
                                          J/D

-------
                            TABLE A-194.    CHEMFIX PROCESS*

      TOTAL  ANNUAL REVENUE  REQUIREMENTS  - REGULATED  UTILITY ECONOMICS
(Base case)
Annual Unit
quantity cost, $
erials
(38% so In)

1 materials cost
• and supervision

:al equipment
.ant labor and material,
.nvestment
:ion
:ion
and maintenance)
equipment (fuel and



[version costs

7,357 tons
28,000 tons


35,040 man-hr
43,800 man-hr






710,500 tons
3,551 kkWh
1,000 hr


98.00/ton
52.00/ton


12.50/man-hr
17. 00 /man-hr






0.30/ton
0.029/kWh
17. 00 /man-hr

Total
annual revenue
requirements, $

721
1,456
2,177

438
744

231

11


213
103
17
1,757

,000
,000
,000

,000
,600

,000

,000


,200
,000
,000
,800
Percent
of total
annual revenue
requirements

10.3
20.9
31.2

6.3
10.7

3.3

0.1


3.0
1.5
0.2
25.1
Direct costs

Delivered raw materials
  Sodium sili
  Cement
Conversion costs
  Operating labo
   Plant
   Solids dispo
  Maintenance — p
   4% of direct
  Landfill operation
   Land preparation
   Trucks (fuel
   Earthmoving e
    maintenance)
  Electricity
  Analyses
    Subtotal direct costs

Indirect costs

Capital charges
 Depreciation,  interim replacement, and
  insurance at  7.83% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6? of total capital investment
Overhead
 Plant, 50% of  conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit  revenue requirements
                                                                           3,934,800
                                                                             943,900

                                                                           1,163,700


                                                                             827,400
                                                                             118,300
                                                                           3,053,300

                                                                           6,988,100
Dollars/dry ton
      16.51
Dollars/wet ton
     10.08
                                                                              Mills/kWh
                                                                                2.00
   Basis
     Remaining plant  life,  30 yr.
     Coal burned,  428,571 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment,  $13,531,000.
     Midwest plant location, mid-1980 operating costs.
                                                                                              56.3
                                   13.5

                                   16.7
                                  100.0
                                                    327

-------
                       TABLE A-195.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                 (Variation from base case:  200-MW plant)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 1,709
   173
   487
    77

   138
   587
    87
   550
 3,808

	57_

 3,865

   423
 4,288

   392
    98
   768
   290
 5,836

 1,167
 7,003

   658
   840
 8,501

   284
   464

 9,249
          Percent  of
            direct
          investment
           Percent  of
          total capital
           investment
 39.9
  4.0
 11.4
  1.8

  3.2
 13.7
  2.0
 12.8
  1.3

 90.1

  9.9
100.0

  9.1
  2.3
 17.9
  6.8
136.1

 27.2
163.3

 15.3
 19.7
198.3

  6.6
 10.8

215.7
 18.6
  1.9
  5.3
  0.8

  1.5
  6.3
  0.9
  5.9
 41.2

  0.6

 41.8

  4.6
 46.4

  4.2
  1.1
  8.3
  3.1
 63.1

 12.6
 75.7

  7.1
  9.1
 91.9

  3.1
  5.0

100.0
a.  Basis
      New 200-MW plant (30-yr life); 83 klb/hr (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal,  81 acres  at 30 ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                         328

-------
                            TABLE  A-196.   CHEMFIX PROCESS3

    TOTAL ANNUAL REVENUE  REQUIREMENTS  -  REGULATED UTILITY ECONOMICS
                                (Variation from base case:  200-MW plant)
                                          Annual
                                         quantity
                   Unit
                  cost,  $
                   Total
               annual  revenue
               requirements, $
                 Percent
                of  total
             annual revenue
              requirements
Direct costs

Delivered raw materials
 Sodium silicate (38% soln)
 Cement
    Subtotal raw materials  cost

Conversion costs
 Operating labor and supervision
   Plant
   Solids disposal equipment
 Maintenance—plant labor and  material,
  k'l, of direct investment
 Landfill operation
   Land preparation
   Trucks (fuel and maintenance)
   Earthmoving equipment  (fuel arid
    maintenance)
 Electricity
 Analyses
    Subtotal conversion costs

    Subtotal direct costs

Indirect costs
 3,010 tons
11,431 tons
98.00/ton
52.00/ton
295,000
594.400
889,400
26,280 man-hr
43,800 man-hr


290,500 tons
2,097 kkWh
1,000 hr
12. 50 /man-hr
17.00/man-hr


0.30/ton
0.031/kWh
17.00/man-hr
328,500
744,600
154,600
5,000
87,200
65,000
17,000
                                  1,401,900

                                  2,291,300
a.  Basis
       Remaining plant life,  30 yr.
       Coal burned, 175,238  Ib/hr,  9,200  Btu/kWh.
       Power plant on-stream time,  7,000  hr/yr.
       Total capital investment, $9,259,000.
       Midwest plant location,  mid-1980 operating  costs.
 6.5
13.1
19.6
                                                      7.3
                                                     16.5
                                                      3.4

                                                      0.1
                                                      1.9
                                                      1.4
                                                      0.4
                                                     31.0
                                     50.6
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.62 of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


665,600

796,300


668,500
107,300
2,237,700
4,529,000
Dollars/drv ton Dollars/wet ton Mills/kWh
26.14 15.59 3.24


14.

17.


14.
2.
49.
100.




7

6


1
4
4
0


                                                   329

-------
                       TABLE A-197. CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 200-MW plant, 25-yr remaining life)
                                         Total, k$
         Percent of   Percent of
           direct    total capital
         investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and  earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
1,836
  175
  487
   78

  143
  596
   87
  550
3,952
4,011

  423
4,434

  392
   98
  792
  298
6,014
  679
  866
8,762

  214
  472

9,448
 41.4
  3.9
 11.0
  1.8

  3.2
 13.4
  2.0
 12.4
 89.1

  1.4

 90.5

  9.5
100.0

  8.8
  2.2
 17.9
  6.7
135.6

 27.2
162.8

 15.3
 19.5
197.6

  4.8
 10.7

213.1
 19.4
  1.9
  5.2
  0.8

  1.5
  6.3
  0.9
  5.8
 41.8

  0.6

 42.4

  4.5
 46.9

  4.2
  1.0
  8.4
  3.2
 63.7

 12.7
 76.4

  7.2
  9.1
 92.7

  2.3
  5.0

100.0
a.  Basis
      Existing 200-MW plant (25-yr remaining life); 86 klb/hr  (60% solids)
      sludge;  Midwest plant location;  average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal, 61 acres at 30 ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                        330

-------
                       TABLE A-198.   CHEMFIX PROCESS

  TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED UTILITY ECONOMICS
(Variation from base case: existing 200-MW plant, 25-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
« of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 8.8% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8,6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


3,115 tons 98.00/ton 305,300
11,806 tons 52.00/ton 613,900
919,200


26,280 man-hr 12.50/man-hr 328,500
43,800 man-hr 17.00/man-hr 744,600

160,400

4,100


301,000 tons 0.30/ton 90,300
2,175 kkWh 0.031/kWh 67,400
1,000 hr 17.00/man-hr 17,000
1,412,300
2,331,500





771,100

812,500


672,500
107,300
2,363,400
4,694,900
Dollars/dry ton Dollars/wet ton Mills/kWh
26.11 15.60 3.35


6.5
13.1
19.6


7.0
15.9

3.4

0.1


1.9
1.4
0.4
30.1
49.7





16.4

17.3


14.3
2.3
50.3
100.0


a.  Basis
     Remaining plant life, 25 yr.
     Coal burned,  180,952 Ib/hr, 9,500 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $9,448,000.
     Midwest plant location, mid-1980 operating costs.
                                           331

-------
                       TABLE A-199.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT -  PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 200-MW plant, 20-yr remaining life)
                                                     Percent of   Percent of
                                                       direct    total capital
                                         Total, k$   investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks  and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
1,836
  175
  487
   78

  143
  596
   87
  550
3,952

	59

4,011

  423
4,434

  392
   98
  792
  298
6,014
  679
  866
8,762

  133
  472

9,367
 41.4
  3.9
 11.0
  1.8

  3.2
 13.4
  2.0
 12.4
 89.1

  1.4

 90.5

  9.5
100.0

  8.8
  2.2
 17.9
  6.7
135.6

 27.2
162.8

 15.3
 19.5
197.6
 19.6
  1.9
  5.2
  0.8

  1.5
  6.4
  0.9
  5.9
 42.2

  0.6

 42.8

  4.5
 47.3

  4.2
  1.0
  8.5
  3.2
 64.2

 12.8
 77.0
211.3
100.0
a.  Basis
      Existing 200-MW plant (20-yr remaining life); 86 klb/hr (60% solids)
      sludge; Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 16% ash.
      Flyash removed with S0£.
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal, 38 acres at 30 ft deep.
      Clarified sludge (35% solids)  transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                         332

-------
                       TABLE A-200.   CHEMFIX PROCESS

   TOTAL ANNUAL REVENUE REQUIREMENTS - REGULATED  UTILITY  ECONOMICS
(Variation from base case: existing 200-MW plant, 20-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmovins equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 9.3% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costa less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


3,115 tons 98.00/ton 305,300
11,806 tons 52.00/ton 613,900
919,200


26,280 man-hr 12.50/man-hr 328,500
43,800 man-hr 17.00/man-hr 744,600

160,400

3,200


301,000 tons 0.30/ton 90,300
2,175 kkWh 0.031/kWh 67,400
1,000 hr 17.00/man-hr 17,000
1,411,400
2,330,600





814,900

805,600


672,000
107,300
2,399,800
4,730,400
Dollars/dry ton Dollars/wet ton Mills/kWh
26.31 15.72 3.38


6.5
13.0
19.5


6.9
15.7

3.4

0.1


1.9
1.4
0.4
29.8
49.3





17.2

17.0


14.2
2.3
50.7
100.0


a.  Basis
    Remaining plant life, 20 yr.
    Coal burned, 180,952 Ib/hr, 9,500 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment,  $9,367,000.
    Midwest plant location,  mid-1980 operating costs.
                                           333

-------
                       TABLE A-201. CHEMFIX PROCESS3

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 200-MW plant, 15-yr remaining life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
1,836
  175
  487
   78

  143
  596
   87
  550
3,952
4,011

  423
4.434

  392
   98
  792
  298
6,014
  679
  866
8,762

   77
  472

9,311
         Percent of
           direct
         investment
           Percent of
          total capital
           investment
 41.4
  4.0
 11.0
  1.8

  3.2
 13.4
  2.0
 12.4
 89.2

  1.3

 90.5

  9.5
100.0

  8.8
  2.2
 17.9
  6.7
135.6

 27.2
162.8

 15.3
 19.5
197.6
  1.7
 10.7

210.0
 19.8
  1.9
  5.2
  0.8

  1.5
  6.4
  0.9
  5.9
 42.4
  4.5
 47.6

  4.2
  1.1
  8.5
  3.2
 64.6
 12.9
 77.5

  7.3
  9.3
 94.1
  0.8
  5.1

100.0
a.  Basis
      Existing 200-MW plant (15-yr remaining life) 86 klb/hr  (60% solids)
      sludge; Midwest plant location; average basis for cost scaling, mid-1979
      Coal analysis (by wt):   3.5% S  (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal, 22 acres at 30  ft deep.
      Clarified sludge (35% solids)  transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of  dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                        334

-------
                       TABLE A-202.   CHEMFIX  PROCESS

  TOTAL ANNUAL REVENUE REQUIREMENTS  - REGULATED UTILITY  ECONOMICS
(Variation from base




Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
case: existing 200-MW plant, 15-yr remaining life)


Annual
quantity


3,115 tons
11,806 tons



26,280 man-hr
43,800 man-hr






301,000 tons
2,175 kkWh
1,000 hr



Unit
cost, $


98.00/ton
52.00/ton



12. 50 /man-hr
17 . 00/man-hr






0.30/ton
0.031/kWh
17. 00 /man-hr


Total
annual revenue
requirements , $


305,300
613,900
919,200


328,500
744,600

160,400

2,500


90,300
67,400
17,000
1,410,700
Percent
of total
annual revenue
requirements


6.3
12.6
18.9


6.8
15.3

3.3

0.1


1.9
1.4
0.3
29.1
    Subtotal direct costs

Indirect costs
2,329,900
a.  Basis
    Remaining plant life, 15 yr.
    Coal burned, 180,952 Ib/hr,  9,500 Btu/kWh
    Power plant on-stream time,  7,000 hr/yr.
    Total capital investment, $9,311,000.
    Midwest plant location, mid-1980 operating costs.
                 48.0
Capital charges
Depreciation, interim replacement, and
insurance at 10.8% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


946,300

800,700


671,700
107,300
2,526,000
4,855,900
Pollars/dry ton Dollars/wet ton Mills/kWh
27.01 16.13 3.47


19.

16.


13.
2.
52.
100.




5

5


8
2
0
0


                                            335

-------
                       TABLE A-203. CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 500-MW plant, 25-yr remaining life)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,904
   227
   697
   210

   162
   855
   107
   550
 5,712
 5,798

   441
 6,239

   472
   118
 1,075
   386
 8,290

 1,658
 9,948

   951
 1,194
12,093

   515
   792

13,400
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 46.5
  3.6
 11.2
  3.4

  2.6
 13.7
  1.7
  8.8
 91.5

  1.4

 92.9

  7.1
100.0

  7.6
  1.9
 17.2
  6.2
132.9

 26.5
159.4

 15.2
 19.2
193.8
  8.3
 12.7

214.8
 21.6
  1.7
  5.2
  1.6

  1.2
  6.4
  0.8
  4.1
 42.6

  0.7

 43.3
 61.9
 12.4
 74.3

  7.1
  8.9
 90.3
  3.8
  5.9

100.0
a.  Basis
      Existing 500-MW plant (25-yr remaining life) ; 207 klb/hr  (60% solids)
      sludge; Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S  (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal, 147 acres at 30 ft deep.
      Clarified sludge (35% solids)  transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                          336

-------
                        TABLE A-204.   CHEMFIX PROCESS

     TOTAL ANNUAL REVENUE REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: existing 500-MW plant, 25-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
n of direct, investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 8.8% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


7,525 tons 98.00/ton 737,500
28,574 tons 52.00/ton 1^485,800
2,223,300


35,040 man-hr 12.50/man-hr 438,000
43,800 man-hr 17.00/man-hr 744,600

231,900

10,000


724,500 tons 0.30/ton 217,400
3,603 kkWh 0.029/kWh 104,500
1,000 hr 17.00/man-hr 17,000
1,763,400
3,986,700





1,064,200

1,152,400


829,500
118,300
3,165,000
7,151,700
Dollars/dry ton Dollars/wet ton Hills/'kWh
16.55 9.87 2.04


10.3
20.8
31.1


6.1
10.4

3.3

0.1


3.0
1.5
0.2
24.6
55.7





14.9

16.1


11.6
1.7
44.3
100.0


a.  Basis
    Remaining plant life, 25 yr.
    Coal burned,  438,095 Ib/hr, 9,200 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $13,400,000.
    Midwest plant location, mid-1980 operating  costs.
                                            337

-------
                       TABLE A-205. CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 500-MW plant, 20-yr remaining life)
                                                     Percent of   Percent of
                                                       direct    total capital
                                         Total, k$   investment   investment
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks  and earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,904
   227
   697
   210

   162
   855
   107
   550
 5,712

	86

 5,798

   441
 6,239

   472
   118
 1,075
   386
 8,290

 1,658
 9,948

   951
 1,194
12,093

   319
   792

13,204
 46.5
  3.6
 11.2
  3.4

  2.6
 13.7
  1.7
  8.8
 91.5

  1.4

 92.9

  7.1
100.0

  7.6
  1.9
 17.2
  6.2
132.9

 26.5
159.4

 15.2
 19.2
193.8
  5.1
 12.7

211.6
 22.0
  1.7
  5.3
  1.6

  1.2
  6.5
  0.8
  4.2
 43.3

  0.6

 43.9

  3.4
 47.3

  3.6
  0.9
  8.1
  2.9
 62.8

 12.5
 75.3
  7.2
  9.1
 91.6

  2.4
  6.0

100.0
a.  Basis
      Existing 500-MW plant (20-yr remaining life); 207  klb/hr  (60% solids)
      sludge; Midwest plant location; average basis for  cost  scaling, mid-1979.
      Coal analysis (by wt):   3.5% S  (dry basis), 16%  ash.
      Flyash removed with S02.
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal , 91 acres  at 30  ft deep.
      Clarified sludge (35% solids)  transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):   Portland cement - 7%, sodium
      silicate - 4%.
                                         338

-------
                           TABLE  A-206.   CHEMFIX  PROCESS

     TOTAL ANNUAL  REVENUE REQUIREMENTS - REGULATED  UTILITY  ECONOMICS
(Variation from base
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material.
If/, of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmpving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
case: existing
Annual
quantity


7,525 tons
28,574 tons



35,040 man-hr
43,800 man-hr






724,500 tons
3,603 kkWh
1,000 hr

500-MW plant, 20-yr remaining life)
Total
Unit annual revenue
cost, $ requirements, $


98.00/ton
52.00/ton



12. 50 /man-hr
17. 00/man-hr






0.30/ton
0.029/kWh
17 . 00/man-hr



737,500
1,485,800
2,223,300


438,000
744,600

231,900

7,700


217,400
164,500
17,000
1,761,100
Percent
of total
annual revenue
requirements


10.3
20.6
30.9


6.1
10.4

3.2

0.1


3.0
1.5
0.2
24.5
    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 9,3% of total  capital
   investment less land and working
   capital
  Average cost of capital and  taxes at
   8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements
Equivalent unit revenue requirements
                                3,984,400
                                1,124,600

                                1,135,500


                                  828,300
                                  118,300
                                3,206,700

                                7,191,100

ppllars/dry  ton   Dollars/wet ton  Mills/'kWh
     16.64             9.92          2.05
   Basis
     Remaining plant life, 20 yr.
     Coal burned,  438,095 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $13,204,000.
     Midwest plant location, mid-1980 operating costs.
                                                   55.4
 15.6

 15.8


 11.5
  1.7
 44.6

100.0
                                                339

-------
                       TABLE A-207. CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 500-MW plant, 15-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and  earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
2,904
227
697
210
162
855
107
550
5,712
86
5,798
441
6,239
472
118
1,075
386
8,290
1,658
9,948
951
1,194
12,093
182
792
Percent of
direct
investment
46.5
3.6
11.2
3.4
2.6
13.7
1.7
8.8
91.5
1.4
92.9
7.1
100.0
7.6
1.9
17.2
6.2
132.9
26.5
159.4
15.2
19.2
193.8
2.9
12.7
Percent of
total capital
investment
22.4
1.7
5.3
1.6
1.2
6.5
0.8
4.2
43.7
0.7
44.4
3.4
47.8
3.6
0.9
8.2
2.9
63.4
12.7
76.1
7.3
9.1
92.5
1.4
6.1
13,067
209.4
100.0
a.  Basis
      Existing 500-MW plant (15-yr remaining life) ; 207 klb/hr  (60% solids)
      sludge; Midwest plant location; average basis for cost scaling, mid-1979
      Coal analysis (by wt) :   3.5% S  (dry basis), 16% ash,,
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal, 52 acres at 30  ft deep.
      Clarified sludge (35% solids)  transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                        340

-------
                         TABLE A-208.   CHEMFIX PROCESS

     TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material ,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 10.8% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements
case: existing 500-MW plant, 15-yr remaining life)
Total
Annual Unit annual revenue
quantity cost, $ requirements, $


7,525 tons 98.00/ton 737,500
28,574 tons 52.00/ton 1,485,800
2,223,300


35,040 man-hr 12.50/man-hr 438,000
43,800 man-hr 17.00/man-hr 744,600

231,900

5,900


724,500 tons 0.30/ton 217,400
3,603 kkWh 0.029/kWh 104,500
1,000 hr 17.00/man-hr 17,000
1,759,300
3,982,600





1,306,000

1,124,600


827,400
118,300
3,376,300
7,358,900
Dollars/dry ton Dollars/wet ton Mills/kWh
17.03 10.16 2.10
Percent
of total
annual revenue
requirements


10.0
20.2
30.2


5.9
10.1

3.2

0.1


3.0
1.4
0.2
23.9
54.1





17.8

15.3


11.2
1.6
45.9
100.0

	
a. Basis
    Remaining plant life, 15 yr.
    Coal burned, 438,095 Ib/hr, 9,200 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $13,077,000.
    Midwest plant location, mid-1980 operating costs.
                                            341

-------
                       TABLE A-209. CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
               (Variation from base case:  1500-MW plant)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks  and earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total,
 5,499
   367
 1,027
   394

   239
 1,274
   119
 1,004
 9,923

   149

10,072

   789
10,861

   564
   141
 1,700
   588
13,854

 2,771
16,625

 1,584
 1,995
20,204

 2,083
 1,817

24,104
          Percent of
            direct
          investment
           Percent of
          total capital
           inves tment
 50.7
  3.4
  9.5
  3.6

  2.2
 11.7
  1.1
  9.2
 91.4

  1.3

 92.7

  7.3
100.0

  5.2
  1.3
 15.7
  5.4
127.6

 25.5
153.1

 14.6
 18.3
186.0

 19.2
 16.7

221.9
 22.8
  1.5
  4.3
  1.6

  1.0
  5.3
  0.5
  4.2
 41.2

  0.6

 41.8
 57.5
 83.8

  8.6
  7.6

100.0
a.  Basis
      New 1500-MW plant (30-yr life); 609  klb/hr  (60%  solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5%  S  (dry  basis),  16%  ash.
      Flyash removed with S02.
      S02 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal ,  595 acres at  30  ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                        342

-------
                          TABLE A-210.   CHEMFIX  PROCESS

       TOTAL  ANNUAL REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: 1500-MW plant)
Total
Annual Unit annual revenue
quantity cost, $ requirements, $
Direct costs
Delivered raw materials
Sodium silicate (38% soln) 22,050 tons
Cement 83,860 tons
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant 43,800 man-hr
Solids disposal equipment 52,560 man-hr
Maintenance — plant labor and material,
4!? of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance) 2,131,300 tons
Electricity 8,419 kkwh
Analyses 1,500 hr
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6X of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Dollars/dry
Equivalent unit revenue requirements 11.31


98.00/ton 2,160,900
52.00/ton 4,360,700
6,521,600


12.50/man-hr 547,500
17. 00 /man-hr 893,500

402,900

34,000


0.30/ton 639,400
0.027/kWh 227,300
17.00/man-hr 25,500
2,770,100
9,291,700





1,582,000

2,072,900


1,271,400
144,100
5,070,400
14,362,100
ton Dollars/wet ton Mills/kWh
6.74 1.37
Percent
of total
annual revenue
requirements


15.0
30.4
45.4


3.8
6.2

2.8

0.2


4.5
1.6
0.2
19.3
64.7





11.0

14.4


8.9
1.0
35.3
100.0


a. Basis
    Remaining plant life,  30 yr.
    Coal burned, 1,285,714 Ib/hr,  9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $24,104,000.
    Midwest plant location, mid-1980 operating costs.
                                               343

-------
                       TABLE A-211. CHEMFIX PROCESS3

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 1500-MW plant, 25-yr remaining life)

                                                     Percent of   Percent of
                                                       direct    total capita;
                                         Total, k$   investment   investment
Process equipment                           5,660       51.2
Piping and insulation                         377        3.4
Transport lines                             1,027        9.3
Foundation and structural                     397        3.6
Excavation, site preparation,
 roads and railroads                          240        2.2
Electrical                                  1,281       11.6
Instrumentation                               119        1.1
Buildings                                   1.004        9.1
     Subtotal                              10,105       91.5

Services and miscellaneous                    152        1.4
     Subtotal excluding trucks and
     equipment                             10,257       92.9

Trucks and earthmoving equipment              789        7.1
     Subtotal direct investment            11,046      100.0

Engineering design and supervision            564        5.1
Architect and engineering contractor          141        1.3
Construction expense                        1,726       15.6
Contractor fees                               596        5.4
     Subtotal                              14,073      127.4

Contingency                                 2,815       25.5
     Subtotal fixed investment             16,888      152.9

Allowance for startup and modifications     1,610       14.6
Interest during construction                2,027       18.3
     Subtotal capital investment           20,525      185.8

Land                                        1,547       14.0
Working capital                             1,850       16.8

     Total capital investment              23,922      216.6
 23.6
  1.6
  4.3
  1.7

  1.0
  5.4
  0.5
  4.2
 42.3

  0.6

 42.9
 85.8

  6.5
  7.7

100.0
a.  Basis
      Existing 1500-MW plant (25-yr remaining life); 623 klb/hr (60% solids)
      sludge; Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis, 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal, 442 acres at 30 ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                        344

-------
                          TABLE  A-212.   CHEMFIX  PROCESS

       TOTAL ANNUAL  REVENUE REQUIREMENTS  -  REGULATED UTILITY  ECONOMICS
(Variation from base case: existing 1500-MW plant, 25-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost , $ requirements , $ requirements
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
C6ni6iit
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance— plant labor and material,
4Z of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity '
Analyses
Subtotal conversion costs


22,579 tons
85,719 tona


43,800 man-hr
52,560 man-hr


180,500 tons
8,497 kkWh
1,500 hr


98.00/ton
52.00/ton


12.50/man-hr
17.00/man-hr


0.30/ton
0.027/kWh
17.00/man-hr


2,212,700
4,457,400
6,670,100


547,500
893,500
410,300
29,900
654,200
229,400
25,500
2,790,300


15.0
30.2
45.2


3.7
6.0
2.8
0.2
4.4
1.6
0.2
18.9
    Subtotal direct costs

 Indirect costs_

 CaPital charges
  Depreciation, interim replacement,  and
  insurance at 8.8% of total capital

  capital61" lESS land 3nd workinS

  Ar«86 C°St of coital and taxes at
Overhead"' t0tal CaPltal invest">e"'
  pl
-------
                       TABLE A-21J.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  existing 1500-MW plant, 20-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks  and  earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 5,660
   377
 1,027
   397

   240
 1,281
   119
 1,004
10,105

   152

10,257

   789
11,046

   564
   141
 1,726
   596
14,073

 2,815
16,888

 1,610
 2,027
20,525

   963
 1,849

23,337
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 51.2
  3.4
  9.3
  3.6

  2.2
 11.6
  1.1
  9.1
 91.5

  1.4

 92.9

  7.1
100.0
 25.5
152.9

 14.6
 18.3
185.8

  8.7
 16.8

211.3
24.3
 1.6
 4.4
 1.7

 1.0
 5.5
 0.5
 4.3
43.3

 0.6

43.9

 3.4
47.3

 2.4
 0.6
 7.4
 2.6
60.3

12.1
72.4

 6.9
 8.7
88.0

 4.1
 7.9
              100.0
a.  Basis
      Existing 1500-MW plant (20-yr remaining life); 623 klb/hr  (60% solids)
      sludge; Midwest  plant location;  average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis),  16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal,  275  acres at 30  ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate -  4%.
                                        346

-------
                            TABLE  A-214.    CHEMFIX  PROCESS

      TOTAL  ANNUAL REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
(Variation from base case: existing 1500-MW plant, 20-yr remaining life)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
n of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance) 2
Electricity
Analyses
Subtotal conversion costs


22,579 tons
85,719 tons



43,800 man-hr
52,560 man-hr






,180,500 tons
8,497 kkWh
1,500 hr



98.00/ton
52.00/ton



12. 50 /man-hr
17.00/man-hr






0.30/ton
0.027/kWh
17 . 00/man-hr



2,212,700
4,457,400
6,670,100


547,500
893,500

410,300

23,300


654,200
229,400
25,500
2,783,700


15.0
30.1
45.1


3.7
6.0

2.8

0.2


4.4
1.5
0.2
18.8
    Subtotal direct costs

Indirect  costs

Capital charges
 Depreciation, interim replacement, and
  insurance at 9.3% of total capital
  investment less land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
 Plant,  50% of conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                               9,453,800
                               1,908,800

                               2,007,000


                               1,277,200
                                 144,100
                               5,337,100

                               14,790,900

Dollars/dry  ton   Dollars/wet ton   Mills/kWh
                                              11,39
                                                               6.78
                                     1.41
   Basis
     Remaining plant life,  20 yr.
     Coal burned, 1,314,286 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment, $23,337,000.
     Midwest plant location, mid-1980 operating costs.
                                                  63.9
 12.9

 13.6


  8.6
  1.0
 36.1

100.0
                                                 347

-------
                       TABLE A-215.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


  (Variation from base case:  existing 1500-MW plant, 15-yr remaining life)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks  and  earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, K$
 5,660
   377
 1,027
   297

   240
 1,281
   119
 1,004
10,105

   152

10,257

   789
11,046

   564
   141
 1,726
   596
14,073

 2,815
16,888

 1,610
 2,027
20,525

   543
 1,847

22,915
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 51.2
  3.4
  9.3
  3.6

  2.2
 11.6
  1.1
  9.1
 91.5

  1.4

 92.9

  7.1
100.0

  5.1
  1.3
 15.6
  5.4
127.4

 25.5
152.9

 14.6
 18.3
185.8

  4.9
 16.7

207.4
 24.7
  1.6
  4.5
  1.7

  1.1
  5.6
  0.5
  4.4
 44.1

  0.7

 44.8

  3.4
 48.2

  2.5
  0.6
  7.5
  2.6
 61.4

 12.3
 73.7

  7.0
  8.9
 89.6
  2.4
  8.0

100.0
a.  Basis
      Existing 1500-MW plant (15-yr remaining life); 623 klb/hr  (60%  solids)
      sludge; "Midwest plant location; average basis for eost scaling, mid-1979
      Coal analysis (by wt):  3.5% S  (dry basis), 16% ash.
      Flyash removed with S02-
      S02 and flyash removed to meet   NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal, 155 acres at 30 ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):   Portland cement - 7%, sodium
      silicate - 4%.
                                        348

-------
                             TABLE  A-216.    CHEMFIX  PROCESS

       TOTAL ANNUAL REVENUE REQUIREMENTS  -  REGULATED UTILITY ECONOMICS
(Variation from base




Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
case: existing 1500-MW plant, 15-yr remaining life)


Annual
quantity


22,579 tons
85,719 tons



43,800 man-hr
52, 560' man-hr






2,180,500 tons
8,497 kkWh
1,500 hr



Unit
cost, $


98.00/ton
52.00/ton



12. 50 /man-hr
17. 00 /man-hr






0.30/ton
0.027/kWh
17.00/man-hr


Total
annual revenue
requirements, $


2,212,700
4^457,400
6,670,100


547,500
893,500

410,300

17,500


654,200
229,400
25,500
2,777,900
Percent
of total
annual revenue
requirements


14.7
29.6
44.3


3.6
6.0

2.7

0.1


4.4
1.5
0.2
18.5
    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation,  interim replacement,  and
   insurance at  10.8% of total capital
   investment less land and working
   capital
  Average cost of capital and taxes  at
   8.6% of total capital investment
Overhead
  Plant, 50% of  conversion costs less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit  revenue requirements
                               9,448,000
Dollars/dry  ton   Dollars/wet
   2,216,700

   1,970,700


   1,274,300
    144,100
   5,605,800

  15,053,800

ton  Mills/kWh
                                                  14.7

                                                  13.0


                                                   8.5
                                                   1.0
                                                  37.2

                                                 100.0
                                              11.59
                                                               6.90
                                    1.43
   Basis
     Remaining plant life,  15  yr.
     Coal burned, 1,314,286 Ib/hr, 9,200 Btu/kWh.
     Power plant on-stream  time, 7,000 hr/yr.
     Total capital investment,  $22,915,000.
     Midwest plant location, mid-1980 operating costs.
                                               349

-------
                       TABLE A-217.  CHEMFIX PROCESS3

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


               (Variation from base case:  12% ash in ceal)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks  and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
2,508
191
487
159
154
764
107
550
4,920
74
4,994
441
5,435
438
110
950
348
Percent of
direct
investment
46.1
3.5
9.0
2.9
2.8
14.1
2.0
10.1
90.5
1.4
91.9
8.1
100.0
8.1
2.0
17.5
6.4
Percent of
total capital
investment
21.2
1.6
4.1
1.3
1.3
6.4
0.9
4.6
41.4
0.7
42.1
3.7
45.8
3.7
0.9
8.0
2.9
 7,281

 1,456
 8,737

   830
 1,048
10,615

   571
   693

11,879
134.0
 26.8
160.8

 15.3
 19.2
195.3
 10.5
 12.8

218.6
 61.3
 12.3
 73.6

  7.0
  8.8
 89.4
  4.8
  5.8

100.0
a.  Basis
      New 500-MW plant (30-yr life); 167 klb/hr (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis), 12% ash, 11,100 Btu/lb HV.
      Flyash removed with S02.
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal, 163 acres at 30 ft deep.
      Clarified sludge (35% solids)  transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                        350

-------
                           TABLE  A-218.   CHEMFIX PROCESS

       TOTAL  ANNUAL REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case:
Annual
quantity
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor- and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs


6
23



35
43





584
2
1



,076 tons
,093 tons



,040 man-hr
,800 man-hr





,500 tons
,948 kkWh
,000 hr



98
52



12
17





0
0.
17

12% ash in coal)
Total
Unit annual revenue
cost, $ requirements, $


.00/ton
.00/ton



,50/man-hr
.00 /man-hr





,30/ton
029/kWh
. 00/man-hr



595
1,200
1,796


438
744

199

9

175
85
17
1,669


,400
,800
,200


,000
,600

,800

,000

,400
,500
,000
,300
Percent
of total
annual revenue
requirements


9
19
28


7
12

3

0

2
1
0
26


.5
.3
.8


.0
.0

.2

.1

.8
.4
.3
.8
    Subtotal direct costs

Indirect costs
3,465,500
    Remaining plant life, 30 yr.
    Coal burned, 405,405 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $11,879,000.
    Midwest plant location, mid-1980 operating  costs.
                 55.6
Capital charges
Depreciation, interim replacement., and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
831
1,021
791
118
,200
,600
,900
,300
2,763,000
6,228,500
Dollars/dry ton Dollars/wet ton Mills/kWh
17.86 10.66
1:78
13.4
16.4
12.7
1.9
44.4
100.0
                                             351

-------
                       TABLE A-219.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
               (Variation from base case:  20% ash in coal)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
3,037
250
697
225
166
878
107
550
5,910
89
5,999
468
6,467
472
118
1,106
397
8,560
1,712
10,272
980
1,233
12,485
830
877
Percent of
direct
investment
46.9
3.9
10.8
3.5
2.6
13.6
1.6
8.5
91.4
1.4
92.8
7.2
100.0
7.3
1.8
17.2
6.1
132.4
26.4
158.8
15.2
19.1
193.1
12.8
13.6
Percent of
total capital
investment
21.4
1.8
4.9
1.6
1.2
6.2
0.7
3.9
41.7
0.6
42.3
3.3
45.6
3.3
0.8
7.8
2.8
60.3
12.1
72.4
6.9
8.7
88.0
5.8
6.2
14,192
219.5
100.0
a.  Basis
      New 500-MW plant (30-yr life); 243 klb/hr (60% solids)  sludge.
      Midwest location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis),  20% ash, 9,900 Btu/lb HV,
      Flyash removed with S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removal.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal,  237 acres at 30  ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%,  sodium
      silicate - 4%.
                                       352

-------
                          TABLE  A-220.   CHEMFIX  PROCESS

       TOTAL ANNUAL  REVENUE REQUIREMENTS  - REGULATED UTILITY ECONOMICS
(Variation from base case: 207, ash in coal)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Sodium silicate (387. soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance—plant labor and material,
It'/, of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6X of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements


8,796 tons 98.00/ton 862,000
33,415 tons 52.00/ton 1,737,600
2,599,600


35,040 man-hr 12.50/man-hr 438,000
43,800 man-hr 17.00/man-hr 744,600

240,000

13,000


850,500 tons 0.30/ton 255,200
4,204 kkWh 0.029/kWh 121,900
1,000 hr 17.00/man-hr 17,000
1,829,700
4,429,300





977,600

1,220,500


853,900
118,300
3,170,300
7,599,600
Dollars/dry ton Dollars/wet ton Mills/kWh
15.00 8.93 2.17


11.3
22.9
34.2


5.7
9.8

3.2

0.2


3.4
1.6
0.2
24.1
58.3





12.9

16.0


11.2
1.6
41.7
100.0


a.  Basis
     Remaining plant life, 30 yr.
     Coal burned, 454,545 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment,  $14,192,000.
     Midwest plant location,  mid-1980 operating costs.
                                              353

-------
                       TABLE A-221.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT -  PROCESS  EQUIPMENT AND  INSTALLATION  ANALYSIS
(Variation from base case:


Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
roads and railroads
Electrical
Instrumentation
Buildings
Subtotal
Services and miscellaneous
Subtotal excluding trucks and
equipment
Trucks and earthmoving equipment
Subtotal direct investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Subtotal
Contingency
Subtotal fixed investment
Allowance for startup and modifications
Interest during construction
Subtotal capital investment
Land
Working capital
Total capital investment
2% S in


Total, k$
2,282
190
487
148
150
707
89
550
4,603
69

4,672
423
5,095
415
104
899
331
6,844
1,369
8,213
779
986
9,978
483
662
11,123
coal)
Percent of
direct
investment
44.8
3.7
9.6
2.9
2.9
13.9
1.7
10.8
90.3
1.4

91.7
8.3
100.0
8.1
2.0
17.7
6.5
134.3
26.9
161.2
15.3
19.3
195.8
9.5
13.0
218.3

Percent of
total capital
investment
20.5
1.7
4.4
1.3
1.4
6.4
0.8
4.9
41.4
0.6

42.0
3.8
45.8
3.7
0.9
8.1
3.0
61.5
12.3
73.8
7.0
8.9
89.7
4.3
6.0
100.0

a.  Basis
      New 500-MW plant  (30-yr life);  141  klb/hr  (60%  solids)  sludge.
      Midwest plant location; average basis  for  cost  scaling,  mid-1979.
      Coal analysis (by wt):   2.0% S  (dry basis),  16% ash,  10,700 Btu/lb HV.
      Flyash removed with S0£.
      S02 and flyash removed  to  meet  NSPS.
      Limestone process with  1.5 stoichiometry based  on S02 removed.
      Disposal in landfill 1  mi  from  scrubber facilities.
      Land required for disposal,  138 acces  at 30  ft  deep.
      Clarified sludge  (35% solids) transported  by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):   Portland cement - 7%, sodium
      silicate -  4%.
                                       354

-------
                         TABLE  A-222.   CHEMFIX  PROCESS

     TOTAL  ANNUAL REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case



Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maint enan ce )
Electricity
Analyses
Subtotal conversion costs

Annual
quantity


5,660 tons
21,540 tons



35,040 man-hr
43,800 man-hr






493,500 tons
3,104 kkWh
1,000 hr

: 2% S in coal)

Unit
cost, $


98.00/ton
52.00/ton



12. 50 /man-hr
17.00/man-hr






0.30/ton
0.029/kWh
17.00/man-hr

Total
annual revenue
requirements, $


554,700
1,120,100
1,674,800


438,000
744,600

186,900

8,000


148,000
90,000
17,000
1,632,500
Percent
of total
annual revenue
requirements


9.3
18.9
28.2


7.4
12.5

3.2

0.1


2.5
1.5
0.3
27.5
    Subtotal direct costs

Indirect costs
3,307,300
a.  Basis
    Remaining plant life,  30 yr.
    Coal burned,  420,561 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $11,123,000.
    Midwest plant location, mid-1980 operating costs.
                 55.7
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.67, of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements




781

956


771
118
2,627
5,934




,300

,600


,300
,300
,500
,800




13.2

16.1


13.0
2.0
44.3
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
20.19 12.02
1.70

                                            355

-------
                       TABLE A-223.  CHEMFIX PROCESS3

   TOTAL CAPITAL INVESTMENT -  PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
              (Variation from base case:  5%  S  in  coal)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Ins trumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks  and  earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
Percent of
direct
investment
Percent of
total capital
investment
 3,198
   244
   697
   254

   169
   929
   118
   550
 6,159

	92_

 6,251

   468
 6,719

   495
   124
 1,144
   408
 8,890

 1,778
10,668

 1,020
 1,280
12,968

   903
   983

14,854
 47.6
  3.6
 10.4
  3.8

  2.5
 13.8
  1.8
  8.2
 91.7

  1.3

 93.0

  7.0
100.0

  7.4
  1.8
 17.0
  6.1
132.3

 26.5
158.8

 15.2
 19.0
193.0
 13.5
 14.6

221.1
 21.5
  1.6
  4.7
  1.7

  1.1
  6.4
  0.8
  3.7
 41.5

  0.6

 42.1
 59.8
 12.0
 71.8

  6.9
  8.6
 87.3
  6.1
  6.6

100.0
a.  Basis
      New 500-MW plant (30-yr life); 264 klb/hr  (60% solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt) :   5%  S  (dry basis), 16% ash,  10,400  Btu/lb  HV.
      Flyash removed with S0£.
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal,  258 acres at 30 ft deep.
      Clarified sludge (35% solids)  transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                        356

-------
                           TABLE A-224.   CHEMFIX PROCESS

    TOTAL  ANNUAL REVENUE REQUIREMENTS - REGULATED  UTILITY  ECONOMICS
(Variation



Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
from base case:


Annual
quantity

10,520 tons
40,040 tons


35,040 man-hr
43,800 man-hr


924,000 tons
4,355 kkWh
1,000 hr
57, S in coal)


Unit
cost, $

98.00/ton
52.00/ton


12.50/man-hr
17. 00 /man-hr


0.30/ton
0.029/kWh
17.00/man-hr


Total
annual revenue
requirements, $

1,031,000
2,082,100
3,113,100


438,000
744,600
250,000
15,000
277,200
126,300
17,000
1,868,100

Percent
of total
annual revenue
requirements

12.5
25.2
37.7


5.3
9.0
3.0
0.2
3.4
1.5
0.2
22.6
    Subtotal direct  costs

Indirect costs

Capital charges
 Depreciation, interim replacement, and
  insurance at 7.83% of total capital
  investment less  land and working
  capital
 Average cost of capital and taxes at
  8.6% of total capital investment
Overhead
 Plant, 50% of conversion costs less
  utilities
 Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements
 Equivalent unit revenue  requirements
                                4,981,200
                                1,015,400

                                1,277,400


                                 870,900
                                 118,300
                                3,282,000

                                8,263,200

Dollars/dry ton   Dollars/wet ton   Mills/kWh
     15.01             8.94           2.36
   Basis
    Remaining plant life, 30 yr.
    Coal burned, 432,692 Ib/hr,  9,000  Btu/kWh.
    Power plant on-stream time,  7,000  hr/yr.
    Total capital investment, $14,854,000.
    Midwest  plant location, mid-1980 operating costs.
                                                   60.3
 12.3

 15.5


 10.5
  1.4
 39.7

100.0
                                                  357

-------
                       TABLE A-225. CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
           (Variation from base case:  200-MW plant, no flyash)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks and earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
1,364
  155
  326
   86

  130
  515
   82
  550
3,593

  369
   92
  666
  254
4,974

  995
5,969

  563
  716
7,248
7,767
         Percent of
           direct
         investment
           Percent of
          total capital
           investment
 38.0
  4.3
  9.1
  2.4

  3.6
 14.3
  2.3
 15.3
 89.3

  1.3

 90.6

  9.4
100.0

 10.3
  2.6
 18.4
  7.1
138.4

 27.7
166.1

 15.7
 19.9
201.7
  4.2
 10.3

216.2
 17.5
  2.0
  4.2
  1.1

  1.7
  6.6
  1.1
  7.1
 41.3

  0.6

 41.9

  4.3
 46.2
 93.3

  1.9
  4.7

100.0
a.  Basis
      New 200-MW plant (30-yr life); 44 klb/hr (60% solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis),  16% asb.
      Flyash removed independently of S02.
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based on S02  removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal,  43 acres at 30  ft deep.
      Clarified sludge (35%  solids) transported by pipeline  to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%
                                       358

-------
                         TABLE A-226.   CHEMFIX PROCESS

     TOTAL ANNUAL  REVENUE  REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation from base case: 200-MW plant, separate system for disposal/removal




Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs


Annual
quantity


1,596 tons
6,062 tons



26,280 man-hr
43,800 man-hr






154,000 tons
1,794 kkWh
1,000 hr



Unit
cost, $


98,00/ton
52.00/ton



12.50/man-hr
17.00/man-hr






0.30/ton
0.031/kWh
17.00/man-hr


Total
annual revenue
requirements, $


156,400
315^200
471,600


328,500
744,600

125,800

2,000


46,200
55,600
17,000
1,319,700
of flyash)
Percent
of total
annual revenue
requirements


4.1
8.4
12.5


8.7
19.8

3.3

0.1


1.2
1.5
0.5
35.1
    Subtotal direct costs

Indirect costs
1,791,300
   Basis
    Remaining plant life, 30 yr.
    Coal burned, 175,238 Ib/hr, 9,200 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $7,767,000.
    Midwest plant location, mid-1980 operating  costs.
                 47.6
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Equivalent unit revenue requirements
567
668
632
107
,500
,000
,100
,300
1,974,900
3,766,200
Dollars /dry ton Dollars /wet ton Mills /kWh
40.89 24.45
2.69
15.1
17.7
16.8
2.8
52.4
100.0
                                            359

-------
                       TABLE A-227. CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
                  (Variation from base case:   no flyash)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment
Trucks and earthmoving equipment
     Subtotal direct investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
2,083
188
487
105
140
600
87
550
4,240
64
4,304
441
4,745
392
98
840
313
6,388
1,278
7,666
723
920
9,309
547
447
Percent of
direct
investment
43.9
4.0
10.3
2.2
3.0
12.6
1.8
11.6
89.4
1.3
90.7
9.3
100.0
8.3
2.1
17.6
6.6
134.6
27.0
161.6
15.2
19.4
196.2
11.5
9.4
Percent of
total capital
investment
20.2
1.8
4.7
0.2
1.4
5.8
0.8
5.3
41.2
0.6
41.8
4.3
46.1
3.8
0.9
8.2
3.0
62.0
12.4
74.4
7.0
9.0
90.4
5.3
4.3
10,303
217.1
100.0
a.  Basis
      New 500-MW plant (30-yr life); 107 klb/hr (60% solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis),  16% ash.
      Flyash removed independently of S02-
      S02 and flyash removed  to meet NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal,  105 acres at 30  ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                        360

-------
                           TABLE A-228.   CHEMFIX PROCESS

      TOTAL ANNUAL  REVENUE  REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: no flyash)




Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs


Annual
quantity


3,899 tons
14,826 tons



35,040 man-hr
43,800 man-hr






374,500 tons
2,415 kkWh
1,000 hr



Unit
cost, $


98.00/ton
52.00/ton



12. 50 /man-hr
17.00/man-hr






0.30/ton
0.029/kWh
17.00/man-hr


Total
annual revenue
requirements, $


382,100
771,000
1,153,100


438,000
744,600

167,000

6,000


112,400
70,000
17,000
1,555,000
Percent
of total
annual revenue
requirements


7.4
14.8
22.2


8.4
14.4

3.2

0.1


2.2
1.4
0.3
30.0
    Subtotal direct costs

Indirect costs
2,708,100
   Basis
     Remaining plant  life,  30 yr.
     Coal burned, 482,571 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $10,124,000.
     Midwest plant location, mid-1980 operating costs.
                 52.2
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.67. of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements




728

886


742
118
2,475
5,183




,900

,100


,500
,300
,800
,900




14.1

17.1


14.3
2.3
47.8
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
23.17 13.84
1.48

                                           361

-------
                       TABLE A-229.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
           (Variation from base case:  1500-MW plant, no flyash)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 3,873
   264
   854
   297

   178
   961
   118
 1,004
 7,549

   113
 7,662
 7,662

   789
 8,451

   495
   124
 1,355
   486
10,911

 2,182
13,093

 1,230
 1,571
15,894

 1,106
 1,133

18,133
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 45.8
  3.1
 10.1
  3.5

  2.1
 11.4
  1.4
 11.9
 89.3

  1.4
 90.7
 90.7

  9.3
100.0

  5.9
  1.5
 15.9
  5.8
129.1

 25.8
154.9

 14.6
 18.6
188.1

 13.1
 13.4

214.6
 21.4
  1.5
  4.7
  1.6

  1.0
  5.3
  0.7
  5.5
 41.6

  0.6
 42.3
 42.3

  4.4
 46.6

  2.7
  0.7
  7.5
  2.7
 60.2

 12.0
 72.2

  6.8
  8.7
 87.7

  6.1
  6.3

100.0
a.  Basis
      New 1500-MW plant (30-yr life); 323 klb/hr (60% solids)  sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis),  16% ash.
      Flyash removed independently of S02-
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal,  316 acres at 30  ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                         362

-------
                               TABLE A-230.   CHEMFIX PROCESS

           TOTAL  ANNUAL REVENUE REQUIREMENTS  -  REGULATED UTILITY ECONOMICS
(Variation




Direct costs
Delivered raw materials
Sodium silicate (38% soln) n
Cement 44
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant 43
Solids disposal equipment 52
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance) 1,130
Electricity 5
Analyses 1
Subtotal conversion costs
from base case :


Annual
quantity


,711 tons 98
,464 tons 52



,800 man-hr 12
,560 man-hr 17






,500 tons 0
,535 kkWh 0.
,500 hr 17

1500-MW plf


Unit
cost, $


.00/ton
.00/ton



. 50/man-hr
.00 /man-hr






.30/ton
027/kWh
. 00/man-hr

mt)

Total
annual revenue
requirements , $


1,147,700
2,312,100
3,459,800


547,500
893,500

298,900

18,000


339,200
149,400
25,500
2,272,000

Percent
of total
annual revenue
requirements


11.9
24.0
35.9


5.7
9.3

3.1

0.2


3.5
1.5
0.3
23.6
    Subtotal direct costs

Indirect costs

Capital charges
  Depreciation, interim replacement, and
   insurance at 7.83% of total  capital
   investment less land and working
   capital
  Average cost of capital and taxes at
   8.6% of total capital investment
Overhead
  Plant, 50% of conversion costs  less
   utilities
  Administrative, 10% of operating labor
    Subtotal indirect costs

    Total annual revenue requirements


Equivalent unit revenue requirements
                               5,731,800
Dollars/dry  ton   Dollars/wet
  1,244,500

  1,444,700


  1,061,300
    144,100
  3,894,600

  9,626,400

ton    Mills/kWh
                                              14.30
                                                               8.52
                                                                              0.93
a.  Basis
     Remaining plant  life, 30 yr.
     Coal burned,  1,285,714 Ib/hr, 9,000 Btu/kWh.
     Power plant on-stream time, 7,000 hr/yr.
     Total capital investment, $18,313,000.
     Midwest plant location, mid-1980 operating costs.
                                                  59.5
                                                  13.0

                                                  15.0


                                                  10.0
                                                   1.5
                                                  40.5

                                                 100.0
                                                 363

-------
                       TABLE A-231.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
  (Variation from base case:  disposal area 5 mi from scrubber facilities)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

 Trucks  and  earthmoving  equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                         Total, k$
 3,575
   229
 3,484
   216

   309
   971
   106
   550
 9,440

   142

 9,582

   442
10,024

   461
   115
 1,631
   553
12,784

 2,557
15,341

 1,490
 1,841
18,672

   693
   862

20,227
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 35.7
  2.3
 34.7
  2.1

  3.1
  9.7
  1.1
  5.5
 94.2

  1.4

 95.6

  4.4
100.0

  4.6
  1.1
 16.3
  5.5
127.5

 25.0
153.0

 14.9
 18.4
186.3
  6.9
  8.6

201.8
 17.8
  1.1
 17.2
  1.1

  1.5
  4.8
  0.5
  2.7
 46.7

  0.7

 47.4
 63.2
 12.6
 75.8

  7.4
  9.1
 92.3
  3.4
  4.3

100.0
a.  Basis.
      New 500-MW plant (30-yr life);  203 klb/hr (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S  (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed  to meet  NSPS.
      Limestone process with  1.5 stoichiometry based on S02 removal.
      Disposal in landfill 5  mi from  scrubber facilities.
      Land required for disposal, 198 acres at 30 ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of  dry solids):   Portland cement - 7%, sodium
      silicate - 4%.
                                         364

-------
                        TABLE A-232.   CHEMFIX PROCESS

      TOTAL ANNUAL  REVENUE REQUIREMENTS  - REGULATED UTILITY ECONOMICS
(Variation from base case: disposal over 5 mi from scrubber facilities)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
455 of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements'


7,357 tons 98.00/ton 721
28,000 tons 52.00/ton 1,456
2,177


43,800 man-hr 12.50/man-hr 547
43,800 man-hr 17.00/man-hr 744

383

11


710,500 tons 0.30/ton 213
10,078 kkWh 0.029/kWh 292
1,000 hr 17.00/man-hr 17
2,208
4,385





1,462

1,739


958
129
4,289
8,674


,000
,000
,000


,500
,600

,300

,000


,200
,300
,000
,900
,900





,000

,500


,300
,200
,000
,900


8.3
16.8
25.1


6.3
8.6

4.4

0.1


2.5
3.4
0.2
25.5
50.6





16.8

20.1


11.0
1.5
49.4
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
20.49 12.52
2.48

a.  Basis
    Remaining plant life, 30 yr.
    Coal burned, 482,571 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment $20,227,000.
    Midwest plant location,  mid-1980 operating costs.
                                             365

-------
                       TABLE A-233.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS


   (Variation from base case:  disposal area 10 mi from scrubber facilities)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
3,598
225
6,969
216
499
1,008
106
550
13,171
198
13,369
442
13,811
461
115
2,151
706
17,244
3,449
20,693
2,025
2,483
25,201
693
894
Percent of
direct
investment
26.0
1.6
50.5
1.6
3.6
7.3
0.8
4.0
95.4
1.4
96.8
3.2
100.0
3.3
0.8
15.7
5.1
124.9
24.9
149.8
14.7
18.0
182.5
5.0
6.5
Percent of
total capital
investment
13.4
0.9
26.0
0.8
1.9
3.8
0.4
2.0
49.2
0.7
49.9
1.7
51.6
1.7
0.4
8.1
2.6
64.4
12.9
77.3
7.5
9.3
94.1
2.6
3.3
                                       26,788
194.0
100.0
a.
Basis
  New 500-MW plant (30-yr life); 203 klb/hr (60% solids)  sludge.
  Midwest plant location; average basis for cost scaling, mid-1979.
  Coal analysis (by wt):   3.5% S (dry basis),  16% ash,
  Flyash removed with S02.
  S02 and flyash removed  to meet NSPS.
  Limestone process with  1.5 stoichiometry based on S02 removed.
  Disposal in landfill 10 mi from scrubber facilities.
  Land required for disposal,  198 acres at 30  ft deep.
  Clarified sludge (35% solids) transported by pipeline to disposal/
  treatment area.
  Fixation additives (% of dry solids):  Portland cement - 7%, sodium
  silicate  -  4%.
                                     366

-------
                          TABLE A-234.   CHEMFIX PROCESS

      TOTAL  ANNUAL REVENUE REQUIREMENTS  - REGULATED  UTILITY ECONOMICS
(Variation from base case: disposal
Annual
quantity
Direct costs
Delivered raw materials
Sodium silicate (38% soln) 7,357 tons
Cement 28,000 tons
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant 43,800 man-hr
Solids disposal equipment 43,800 man-hr
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance) 710,500 tons
Electricity 10,340 kkWh
Analyses 1,000 hr
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements
Dollars/dry
Equivalent unit revenue requirements 23 63
area 10 mi from scrubber facilities)
Total
Unit annual revenue
cost, $ requirements, $


98.00/ton 721,000
52.00/ton 1,456,000
2,177,000


12.50/man-hr 547,500
17.00/man-hr 744,600

534,800

11,000


0.30/ton 213,200
0.029/kWh 299,900
17.00 man-hr 17,000
2,368,000
4,545,000





1,973,200

2,321,000


1,034,100
129,200
5,457,500
10,002,500
ton Dollars/wet ton Mills/kWh
14.43 2.86
Percent
of total
annual revenue
requirements


7.2
14.5
21.7


5.5
7.4

5.4

0.1


2.1
3.0
0.2
23.7
45.4





19.7

23.2


10.4
1.3
54.6
100.0


a.  Basis
    Remaining plant life, 30 yr.
    Coal burned, 482,571 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $26,988,000.
    Midwest plant location, mid-1980 operating costs.
                                            367

-------
                       TABLE A-2J5.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT -  PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
      (Variation from base case:  50% solids being pumped to filter;
                    increased fixation additive rates)
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
Total, k$
3,378
228
657
388
163
848
107
550
6,319
95
6,414
585
6,999
472
118
1,169
421
9,179
1,836
11,015
1,043
1,322
13,380
914
1,976
Percent of
direct
investment
48.3
3.3
9.4
5.5
2.3
12.1
1.5
7.9
90.3
1.3
91.6
8.4
100.0
6.7
1.7
16.7
6.0
131.1
26.3
157.4
14.9
18.9
191.2
13.1
28.2
Percent of
total capital
investment
20.7
1.4
4.0
2.4
1.0
5.2
0.7
3.4
38.8
0.6
39.4
3.6
43.0
2.9
0.7
7.2
2.6
56.4
11.3
67.7
6.4
8.1
82.2
5.6
12.2
16,270
232.5
100.0
a.  Basis
      New 500-MW plant (30-yr life); 267 klb/hr  (50% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt) :   3.5%  §  (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet  NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removal.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal,  261 acres at 30 ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement -  22%  sodium
      silicate --8%.
                                        368

-------
                        TABLE A-236.   CHEMFIX PROCESS

    TOTAL ANNUAL  REVENUE  REQUIREMENTS -  REGULATED UTILITY ECONOMICS
(Variation



Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4X of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
from base case:


Annual
quantity

35,889 tons
88,256 tons


35,040 man-hr
52,560 man-hr


934,500 tons
3,932 kkWh
1,000 hr
50% solids from


Unit
cost, $

98.00/ton
52.00/ton


12. 50 /man-hr
17.00/man-hr


0.30/ton
0.029/kWh
17.00/man-hr
filter)

Total
annual revenue
requirements, $

3,517,100
4,589,300
8,106,400


438,000
893,500
256,600
15,000
280,400
114,000
17,000
2,014,500

Percent
of total
annual revenue
requirements

25.7
33.6
59.3


3.2
6.6
1.9
0.1
2.1
0.8
0.1
14.8
    Subtotal direct costs

Indirect costs
                                                               10,120,900
Basis
 Remaining plant life, 30 yr.
 Coal burned,  482,571 Ib/hr,  9,000 Btu/kWh.
 Power plant on-stream time,  7,000 hr/yr.
 Total capital investment, $16,270,000.
 Midwest plant location, mid-1980 operating costs.
                                                                                 74.1
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements


1,047

1,399


950
133
3,530
13,651


,700

,200


,300
,200
,400
,300


7.7

10.2


7.0
1.0
25.9
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
28.71 14.61
3.90

                                          369

-------
                       TABLE A-237. CHEMFIX PROCESS3

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
       (Variation from base case:   55% solids being pumped to filter;
                      increased fixation additive rates)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 3,120
   228
   657
   306

   162
   853
   107
   550
 5,983

	90

 6,073

   468
 6,541

   472
   118
 1,117
   400
 8,648

 1,730
10,378

   991
 1.245
12,614

   795
 1,348

14,757
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 47.8
  3.5
 10.0
  4.7

  2.5
 13.0
  1.6
  8.4
 91.5

  1.4

 92.9

  7.1
100.0

  7.2
  1.8
 17.1
  6.1
132.2

 26.5
158.7

 15.2
 18.9
192.8

 12.2
 20.6

225.6
 21.1
  1.5
  4.5
  2.1

  1.1
  5.8
  0.7
  3.7
 40.5

  0.6

 40.1

  3.2
 44.3

  3.2
  0.8
  7.6
  2.7
 58.6

 11.7
 70.3

  6.7
  8.5
 85.5
  5.4
  9.1

100.0
a.  Basis
      New 500-MW plant (30-yr life); 232 klb/hr (55% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):  3.5% S (dry basis), 16% ash.
      Flyash removed with S02.
      S02 and flyash removed to meet NSPS.
      Limestone process with 1.5 stoichiometry based on S02 removed.
      Disposal in landfill 1 mi from scrubber facilities.
      Land required for disposal, 227 acres at 30 ft deep.
      Clarified sludge (35% solids) transported by pipeline to disposal/
      treatment area.
      Fixation additives (% of dry solids):  Portland cement -  12%   sodium
      silicate - 6%.

-------
                        TABLE A-238.   CHEMFIX PROCESS

     TOTAL  ANNUAL REVENUE REQUIREMENTS -  REGULATED  UTILITY  ECONOMICS
(Variation
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 507. of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements
from base case: 55% solids from filter)
Total
Annual Unit annual revenue
quantity cost, $ requirements, $


24,843 tons 98.00/ton 2,434,600
50,313 tons 52.00/ton 2,616,300
5,050,900


35,040 man-hr 12.50/man-hr 438,000
43,800 man-hr 17.00/man-hr 744,600

242,900

13,000


812,000 tons 0.30/ton 243,600
3,953 kkWi 0.029/kWh 114,600
1,000 hr 17.00/man-hr 17,000
1,813,700
6,864,600





987,700

1,269,100


849,600
118,300
3,224,700
10,089,300
Dollars/dry ton Dollars/wet ton Mills/kWh
20.99 12.42 2.89
Percent
of total
annual revenue
requirements


24.1
25.9
50.0


4.4
7.4

2.4

0.1


2.4
1.1
0.2
18.0
68.0





9.8

12.6


8.4
1.2
32.0
100.0


a.  Basis
     Remaining plant life,  30 yr.
     Coal burned, 482,571 Ib/hr,  9,000 Btu/kWh.
     Power plant on-stream time,  7,000 hr/yr.
     Total capital investment $14,757,000.
     Midwest plant location, mid-1980 operating  costs.
                                            371

-------
                       TABLE A-239.  CHEMFIX PROCESS

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
      (Variation from base case:  lime process with 1.1 stoichiometry)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
 2,542
   219
   657
   243

   164
   727
   103
   550
 5,205

	78_

 5,283

   441
 5,724

   449
   112
   995
   362
 7,642

 1,528
 9,170

   873
 1,100
11,143

   606
   682

12,431
          Percent of
            direct
          investment
           Percent of
          total capital
           investment
 44.4
  3.8
 11.5
  4.2

  2.9
 12.7
  1.8
  9.6
 90.9

  1.4

 92.3

  7.7
100.0

  7.8
  2.0
 17.4
  6.3
133.5

 26.7
160,2

 15.3
 19.2
194.7

 10.6
 11.9

217.2
 20.5
  1.8
  5.3
  1.9

  1.3
  5.9
  0.8
  4.4
 41.9

  0.6

 42.5

  3.6
 46.1

  3.6
  0.9
  8.0
  2.9
 61.5

 12.3
 73.8

  7.0
  8.8
 89.6

  4.9
  5.5

100.0
a.  Basis
      New 500-MW plant (30-yr life); 177 klb/hr (60% solids) sludge.
      Midwest plant location; average basis for cost scaling, mid-1979.
      Coal analysis (by wt):   3.5% S (dry basis),  16% ash.
      Flyash removed with S02.
      S02 and flyash removed  to meet NSPS.
      Lime process with 1.1  stoichiometry based on S02 removed.
      Disposal in landfill 1  mi from scrubber facilities.
      Land required for disposal, 173 acres at 30  ft deep.
      Clarified sludge (35%  solids)  transported by pipeline to disposal/
      treatment area.
      Fixation additives (%  of dry solids):  Portland cement - 7%, sodium
      silicate - 4%.
                                         372

-------
                          TABLE A-240.   CHEMFIX  PROCESS

      TOTAL  ANNUAL REVENUE REQUIREMENTS  - REGULATED  UTILITY  ECONOMICS
(Variation from base case: lime process with 1.1



Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating liabor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs


Annual
quantity

6,412 tons
24,332 tons


35,040 man-hr
43,800 man-hr




619,500 tons
3,368 kkWh
1,000 hr


Unit
cost, $

98.00/ton
52.00/ton


12. 50 /man-hr
17.00/man-hr




0.30/ton
0.029/kWh
17.00/man-hr
stoichiometry)

Total
annual revenue
requirements, $

628,400
1,265,300
1,893,700


438,000
744,600
211,300

10,000

11,200
97,700
17,000
1,529,800

Percent
of total
annual revenue
requirements

10.1
20.4
30.5


7.1
12.0
3.4

0.1

0.2
1.6
0.3
24.7
    Subtotal direct  costs

Indirect costs
3,423,500
a.  Basis
    Remaining plant life, 30 yr.
    Coal burned, 482,571 Ib/hr,  9,000 Btu/kWh.
    Power plant on-stream time,  7,000 hr/yr.
    Total capital investment, $12,431,000.
    Midwest plant location, mid-1980 operating  costs.
                 55.2
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements




872

1,069


716
118
2,776
6,199




,500

,100


,100
,300
,000
,500




14.1

17.2


11.6
1.9
44.8
100.0
Dollars/dry ton Dollars/wet ton Mills/kWh
Equivalent unit revenue requirements
16.83 10.01
1.77

                                              373

-------
                       TABLE A-2^1.  CHEMFIX PROCESS3

   TOTAL CAPITAL INVESTMENT - PROCESS EQUIPMENT AND INSTALLATION ANALYSIS
          (Variation from base case:   Trucks used for transport of
                      treated sludge  to disposal area)
                                         Total, k$
Process equipment
Piping and insulation
Transport lines
Foundation and structural
Excavation, site preparation,
 roads and railroads
Electrical
Instrumentation
Buildings
     Subtotal

Services and miscellaneous
     Subtotal excluding trucks and
     equipment

Trucks and earthmoving equipment
     Subtotal direct investment

Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
     Subtotal

Contingency
     Subtotal fixed investment

Allowance for startup and modifications
Interest during construction
     Subtotal capital investment

Land
Working capital

     Total capital investment
                                        2,813
                                          207

                                          211

                                          117
                                          725
                                           92
                                          550
                                        4,715
                                        4,786

                                          423
                                        5,209

                                          461
                                          115
                                          917
                                          337
                                        7,039

                                        1,408
                                        8,447

                                          802
                                        1,014
                                       10,263

                                          693
                                          784

                                       11,740
                                                 Percent of
                                                   direct
                                                 investment
           Percent of
          total capital
           inves tment
 54.0
  4.0

  4.1

  2.2
 13.9
  1.8
 10.5
 90.5

  1.4

 91.9

  8.1
100.0

  8.9
  2.2
 17.5
  6.5
135.1

 27.1
162.2
225.4
 23.9
  1.8

  1.8

  1.0
  6.2
  0.8
  4.7
 40.2

  0.6

 40.8

  3.6
 44.4

  3.9
  1.0
  7.8
  2.9
 60.0

 12.0
 72.0

  6.8
  8.6
 87.4
  5.9
  6.7

100.0
a.
Basis
  New 500-MW plant (30-yr life); 203 klb/hr (60% solids) sludge.
  Midwest plant location; average basis for cost scaling, mid-1979.
  Coal analysis (by wt):   3,5% S (dry basis), 16% ash.
  Flyash removed with S02-
  S02 and flyash removed to meet NBPS.
  Limestone process with 1.5 stoichiometry based on S02 removed.
  Disposal in landfill 1  mi from scrubber facilities.
  Land required for disposal, 198 acres at 30 ft deep.
  Trucks used for transport of treated sludge to disposal area.
  Fixation additives (%  of  dry solids):  Portland cement - 7%, sodium
  silicate - 4%.
                                    374

-------
                          TABLE  A-242.   CHEMFIX  PROCESS

      TOTAL ANNUAL  REVENUE REQUIREMENTS  - REGULATED UTILITY ECONOMICS
(Variation from base
Direct costs
Delivered raw materials
Sodium silicate (38% soln)
Cement
Subtotal raw materials cost
Conversion costs
Operating labor and supervision
Plant
Solids disposal equipment
Maintenance — plant labor and material,
4% of direct investment
Landfill operation
Land preparation
Trucks (fuel and maintenance)
Earthmoving equipment (fuel and
maintenance)
Electricity
Analyses
Subtotal conversion costs
Subtotal direct costs
Indirect costs
Capital charges
Depreciation, interim replacement, and
insurance at 7.83% of total capital
investment less land and working
capital
Average cost of capital and taxes at
8.6% of total capital investment
Overhead
Plant, 50% of conversion costs less
utilities
Administrative, 10% of operating labor
Subtotal indirect costs
Total annual revenue requirements

Equivalent unit revenue requirements
case: intermediate ponding, transport by truck)
Percent
Total of total
Annual Unit annual revenue annual revenue
quantity cost, $ requirements, $ requirements


7,357 tons 98.00/ton 721,000
28,000 tons 52.00/ton 1,456,000
2,177,000


35,040 man-hr 12.50/man-hr 438,000
43,800 man-hr 17.00/man-hr 744,600

191,400

11,000
710,500 tons 0.06/ton 42,600

710,500 tons 0.30/ton 213,200
3,551 kkWh 0.029/kWh 103,000
1,000 hr 17.00/man-hr 17,000
1,760,800
3,937,800





803,600

1,009,600


828,900
118,300
2,760,400
6,698,200
Dollars/dry ton Dollars/wet ton Mills/kWh
15.82 9.66 1.91


10.8
21.7
32.5


6.5
11.1

2.9

0.2
0.6

3.2
1.5
0.3
26.3
58.8





12.0

15.0


12.4
1.8
41.2
100.0


a.  Basis
    Remaining plant life,  30 yr.
    Coal burned, 482,571 Ib/hr, 9,000 Btu/kWh.
    Power plant on-stream time, 7,000 hr/yr.
    Total capital investment, $11,740,000.
    Midwest plant location, mid-1980 operating  costs.
                                            375

-------
                        APPENDIX B




DECLINING OPERATING PROFILE - LIFETIME REVENUE REQUIREMENTS
                             377

-------
                                                         TABLE B-l
L 1VE/L1MESTCNE SLUDGF  DISPOSAL  - UNTREATED, ZOO MW NEW UNIT, 3.5*  5,  16*  ASH  IN  CC.AL • REGULATED CD. ECONOMICS
                                                 FIXED  INVESTMENT:
                                                                          V8COOOO
TOTAL
SULFUR BY-PRODUCT OP. COST
REMOVED RATE, INCLUDING
YEARS ANNUAL POWER UNIT POKER UN 11 BY EQUIVALENT NET REVENUE, REGULATED TOTAL
AFTER PPERA- HFAT FUEL POLLUTION TONS/YEAR S/TON ROI FOR NET
POWER TIHN, REQUIREMENT, CflNSUMPT 1'JM , CONTROL POWER SALES
UNIT KW-HR/ MILLION BTU TONS COAL PROCESS, WASTE WASTE COMPANY, REVENUE,
START KW /YEAR /YEAR TONS/YEAR StlLIDS SOLIDS WYEAR $/YEAR
1 7000 12H80000 613300 14600 332500 0.0
2 7000 12880000 613300 14600 332500 0.0
3 7000 12E80000 613300 14600 332500 0.0
4 7000 12880000 613300 14600 332500 0.0
	 5 	 20.0.0 	 12BB.0000 	 613300 	 14600 	 332500 	 0*0 	
6 7000 12880000 613300 14600 332500 0.0
7 7000 12880000 613300 14600 332500 0.0
8 7000 12880000 613300 14600 332500 0.0
9 7000 12880000 613300 14600 332500 0.0
10 7000 IZflflODQQ 6J3300 146()0 	 132500 	 . .0.0 	
11 5000 9200000 438100 10400 237500 0.0
12 5000 9200000 43P100 10400 237500 0.0
13 5000 9200000 438100 10400 237500 0.0
14 5000 9200000 43E100 104.00 237500 0.0
<_.•> 15 50.00 9?nOOOO 4.38100 104-[)0 	 ?375.f)0 0.0
^ 16 35CO 6440000 306700 7300 166300 0.0
17 35CO 6440000 306700 7300 166300 0.0
18 3500 6440000 306700 7300 166300 0.0
19 3500 6440000 306700 7300 166300 0.0
_20 	 3500 	 6441)000 	 206200 	 2300 	 166300 	 C*0 	
21 1500 2760000 131400 3100 71300 0.0
22 1500 2760000 131400 3100 71300 0.0
23 1500 2760000 131400 3100 71300 0.0
24 1500 2760000 131400 3100 71300 0.0
_25 	 1500 	 2260000 	 131400 	 3100 	 21300 	 0*0 	
26 1500 2760000 131400 3100 71300 0.0
27 1500 2760000 131400 3100 71300 0.0
28 1500 2760000 131400 3100 71300 0.0
29 1500 2760000 131400 3100 71300 0.0
»30 	 1500. 	 2260000 	 131400 	 3100 	 21300 	 0*0 	
TOT 127500 234600000 11171000 265500 6057000
LIFETIME AVERAGE INCREASE (DECREASEI IN UNIT OPERATING COST
DOLLARS PER TON OF CPAt BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PEf> TUN OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT 11.61 TO INITIAL YEAR, DOLLARS
LtVELIZED INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO DISCOUNTED P
DOLLARS PEP TUN HF CtlAL BURNED
MILLS PER KIL(!WATT-HtlUR
CENTS PER MLLION BTU HEAT INPUT
DOLLARS PbR TON OF SULFUR REMOVED
2881000 0
2829400 0
2777700 0
2726100 0
	 2624500 	 Q_
2622800 0
2571200 0
2519600 0
2467900 0
2255100 0
2203400 0
2151800 0
2100200 0
1902100 0
1650400 0
1798800 0
1747200 0
	 1635500 	 D_
1483400 0
1431800 0
1380100 0
1328500 0
	 12262X10 	 Q_
1225200 0
1173600 0
1122000 0
1070300 0
._ 	 10ia20.0_ Q_
58750000 0
5.26 0.0
2.30 0.0
25.04 0.0
221.28 0.0
20204800 0
ROCESS COST OVER LIFE OF
4.64 0.0
2.03 0.0
22.10 0.0
195.03 0.0
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASEI (DECREASE)
IN COST OF IN COST OF
POWER, POWER,
» $
2881000
2829400
2777700
2726100
2622800
2571200
2519600
2467900
2*1630.0.
2881000
5710400
8488100
11214200
16511500
19082700
21602300
24070200
76486500
2255100 28741600
2203400 30945000
2151800 33096800
2100200 35197000
	 .204^500 	 32245500
1902100 39147600
1R50400 40998000
1798800 42796800
1747200 44544000
	 1625500 	 4623250 0
1483400 47722900
1431800 49154700
1380100 50534800
1328500 51863300
__ 1226200 _ -53140200
1225200
1173600
1122000
1070300
1Q187QQ.
58750000
5.26
2.30
25.04
221.28
20204800
POWER UNIT
4 .64
2.03
22.10
195.03
54365400
55539000
56661000
57731300
.-5*250000

-------
                                                              TABLE  B-2




LIME/LIMESTONE SLUDGE DISPOSAL  - UNTRlATfD,  SOD HW  NEW UNIT, 3.5*  S,  16* ASH  IN CC'AL, REGULATED CD.  ECONOMICS
                                                    FIXED  INVESTMENT:   $
                                                                             17211000

YEARS ANNUAL
AFTER OPERA-
POWER TION,
UNIT KW-HR/
START KW
1 7000
2 7000
3 7000
4 7000
SULFUR BY-PRODUCT
REMOVED RATE,
POWER UNIT POKFR UNIT BY EQUIVALENT
HEAT FUEL POLLUTION TONS/YEAR
REQUIREMENT, CONSUMPTION, CONTROL
MILLION BTU TONS COAL PROCESS, WASTE
/YEAR /YEAR TONS/YEAR SOLIDS
31500000 1500000 35600 812000
31500000 1500000 35600 812000
31500000 1500000 35600 812000
31500000 1500000 35600 812000

TOTAL
OP. COST
INCLUDING
NET REVENUE, REGULATED
i/TON

WASTE
ROI FOR
POWER
COMPANY,
SOLIDS $/YEAR
0.0
0.0
0.0
0.0
4807200
4717300
4627500
4537600
5 ^7000™ 3i"5nnnnn iinnnnn ^i*.nn Bi?oon n.o 4447HOO
6 7000
7 7000
8 7000
9 7000
in 	 2QDQ__
11 5000
12 5000
13 5000
14 5000
IS 	 5.0.QQ-
16 3500
17 3500
18 3500
19 3500
_20 	 350Q_.
21 1500
22 1500
23 1500
24 1500
•> C 1C QQ
26 1500
27 1500
28 1500
29 1500
3.Q 	 15.QQ 	
TOT 127500
31500000 1500000 35600 812000
31500000 1500000 35600 812000
31500000 1500000 35600 812000
31500000 1500000 35600 812000
0.0
0.0
0.0
0.0
4357900
4268100
4178200
4088400

TOTAL
NET
SALES
REVENUE,
*/YEAR
0
0
0
0
n
0
0
0
0
NET ANNUAL
INCREASE
(DECREASE}
IN COST OF
POWER,
1
4807200
4717300
4627500
4537600
&6&7 BQQ
4357900
4268100
4178200
4088400
CUMULATIVE
NET INCREASE
(DECREASE)
IN COST OF
POWER,
$
4807200
9524500
14152000
18689600
?31 37400
27495300
31763400
35941600
40030000
^i^OQOnQ 	 ..TjOQDOp 35600 , (n?nnQ n.n ^Qpa-jnn n 3 1 1 7f\f\f\
2047800
1957900
1868100
1778200
1 ft ft fi 4 f)D
97757800
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST




PROCESS COST
LEVEL1ZED




DOLLARS PER TON OF COAL BURNED
MILLS PER KILCWATT-HtlUR
CENTS PER HILLION BTU HEAT INPUT
DCLLARS PER TUN OF SULFUR RFMPVED
DISCOUNTED AT 11.6% TO INITIAL YEAR, DOLLARS
INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO
DOLLARS PER TUN OF CdAl BURNED
HILLS PER K1LOHATT-HTUR
CENTS PER MILLION BTi' HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED





DISCOUNTED




3.58
1.53
17.04
150.86
33612100
PROCESS COST OVER
3.16
1.35
15.03
133.01
0
0
0
0
o_
0
0
0
0
o_
0
0
0
0
n
0
0
0
0
n
0

0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
3751600
3661700
3571900
3482000
3TSJPOO
3168300
3078400
2988600
2898700
?nnn
-------
                                                           TABLE  B-3
 LIME/LIMESTONE  SLUDGE  DISPOSAL  - UNjRtftTfD,  15CC  HW  NEW  UMT,  3.5*  S,  16% ASH  IN COAL, REGULATED CO. ECONOMICS.
                                                 FIXED  INVESTMENT:
                                                                        36455 COO


YEARS ANNUAL
AFTER OPERA-
POWER T10N,
UNIT KW-HR/
START Kh
1 7000
2 7000
3 7000
4 7000
	 5 	 2OQO_
6 7000
7 7000
8 7000
9 7000
_10 	 ZOQO 	
11 5000
12 5000
13 5000
14 5000
15 _50QO
16 3500
17 3500
18 3500
19 3500
21 1500
22 1500
23 1500
24 1500
_25 	 1500 	
26 1500
27 1500
28 1500
29 1500
_3Q 	 1500 	


POWER UNIT
HEAT
REQUIREMENT
MILLION BTU
/YEAR
94500000
94500000
94500000
94500000
	 2 &_500000_
94500000
94500000
94500000
94500000
	 94500000-
67500000
67500000
67500000
67500000

47250000
47250000
47250000
47250000
"~ 20250000
20250000
20250000
20250000
JfiyiQ Qp Q 	
20250000
20250000
20250000
20250000
	 2025QQQQ-.


POWER UNIT
FUEL
, CONSUMPTION.
TONS COAL
/YEAR
4500000
4500000
4500000
4500000
	 450QQ0Q 	
4500000
4500000
4500000
4500000
	 i5QQQOO 	
3214300
3214300
3214300
3214300
3?i4^fin
2250000
2250000
2250000
2250000
964300
964300
964300
964300

964300
964300
964300
964300
Q&4qno
SULFUR
REMOVED
BY
POLLUTION
CONTROL
PROCESS,
TONS/YEAR
106800
106800
106800
106800
	 lUfifi.0.0.
106800
106800
106800
106800
	 L0£.aao.
76300
76300
76300
76300
	 _It30.Q.
53400
53400
53400
53400
22900
22900
22900
22900
22400-
22900
22900
22900
22900
22100-
TOT  127500   1721250000     81964500       1945500
   LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
                    DOLLARS PER TON Of COAL BURNED
                    HILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DULLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6* TO INITIAL YFAR, DOLLARS
   LEVELUED INCREASE (DECREASE) IN UNIT OPERATING CO!
                    DULLARS PER TON UF COAL BURNED
                    MILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
BY-PRODUCT
RATE,
EQUIVALENT
TONS/YEAR

WASTE
SOLIDS
2432500
2432500
2432500
2432.500


NET REVENUE,
$/TON

WASTE
SOLIDS
0.0
0.0
0.0
0.0
TOTAL
OP. COST
INCLUDING
REGULATED
ROI FOR
POWER
COMPANY,
$/YEAR
9988400
9799900
9611400
9422900


TOTAL
NET
SALES
REVENUE,
t/YEAR
0
0
0
0

NET ANNUAL
INCREASE
(DECREASE)
IN COST OF
POWER,
$
9988400
9799900
9611400
9422900
	 p_4325GO n .0 Q?^44nn n o?^44flft
2432500
2432500
2432500
2432500
	 2432500-
1737500
1737500
1737500
1737500
	 LI32500-
1216300
1216300
1216300
1216300
1216.300
521300
521300
521300
521300
	 5213.00 	
521300
521300
521300
521300
	 5213 QD 	
44307000
G COST




RS
EQUIVALENT TO




0.0
0.0
0.0
0.0
O.Q
0.0
0.0
0.0
0.0
	 O..Q
0.0
0.0
0.0
0.0
o.n
0.0
0.0
0.0
0.0
_— __ 	 n .n
0.0
0.0
0.0
0.0
_— _—« O.»0







9045900
8857400
8668900
8480400
fl? 9 1 9.00
7794600
7606300
7417800
7229300
704080^1
6591600
6403100
6214600
6026200
^fl ^77nft 	
5222800
5034300
4845800
4657300
	 44t££LQQ 	
4280300
4091800
3903300
3714800
^52630.0.
203309200

2.48
1.06
11.61
104.50
69819400
DISCOUNTED PROCESS COST OVER




2.19
0.94
10.41
92.07
0
0
0
0
ft
0
0
0
0
Q
0
0
0
0
n
0
0
0
0
n
0
0
0
0

0

0.0
0.0
o.o
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
9045900
8857400
8668900
8480400
A P
-------
                                                                  TABLE  B—4



    L IHf/L IMFSTCNE SLUDGE DISPOSAL - DRAVD PROCESS.  2OO  «h  NEW  UNIT,  3.5*  S,  Ifc* ASH IN COAL, RFGULATED CO. ECONOMICS
00
                                                     FIXED  INVESTMENT:
                                                                            13942000
SULFUR BY-PRODUCT
REMOVED RATE,
YEARS ANNUAL POWER UNIT POKER UNIT BY EQUIVALENT
AFTER PPERA- HEAT FUEL POLLUTION TONS/YEAR
POWER TION, REQUIREMENT, CONSUMPTION. CONTROL
UNIT KW-HR/ MILLION BTU TUNS COAL PROCESS, WASTE
START KW /YEAR /YEAR TONS/YEAR SOLIDS
1 7000 12P80000 613300 14600 357000
2 7000 12880000 613300 14600 357000
3 7000 12880000 613300 14600 357000
4 7000 12880000 613300 14600 357000
5 7QQD. ,.^mi2B8DDDQ . 6133nn. . , I4f.no 3"i7f)nn
6 7000 12680000 613300 14600 357000
7 7000 12860000 613300 14600 357000
8 7000 12880000 613300 14600 357000
9 7000 12880000 613300 14600 357000
lpT 	 70IJO 1PRROQQQ 613300 14&QQ 35.7QPQ
11 5000 9200000 43«100 10400 255000
12 5000 9200000 438100 10400 255000
13 5000 9200000 438100 10400 255000
14 5000 9200000 43B100 1040C 255000
J5 -_T5QQD 9?DOpoq ,438100 	 10400. 	 	 255QOD ,
16 3500 6440000 306700 7300 178500
17 3500 6440000 306700 7300 178500
IE 3500 6440000 306700 7300 178500
19 3500 6440000 306700 7300 178500
70 35OO 6440.000 306700 	 7300 	 17B5QQ
21 1500 2760000 131400 3100 76500
22 1500 2760000 131400 3100 76500
23 1500 2760000 131400 3100 76500
24 1500 2760000 131400 3100 76500

NET REVENUE
S/TON

WASTE
SOLIDS
0.0
0.0
0.0
0.0
fl 0
0.0
c.o
0.0
0.0
0.0
0.0
0.0
O.D
0.0
	 _ O.Q 	
0.0
0.0
0.0
0.0
. _ D-0
0.0
0.0
0.0
c.o
TOTAL
DP. COST
INCLUDING
, REGULATED
ROI FOR
POWER
COMPANY,
*/YEAR
4773900
4699400
4624800
4550300
46 717nfl
4401200
4326700
4252100
4177600
fcioinnn
3655300
3580700
3506200
3431600
•^q 571 nn
2984700
2910100
2835600
2761000
?fr flft "inn
2165300
2090800
2016200
1941700
25 _15_CiQ. 27hflJDDD J.314QO 31C10 .. 7650Q 	 fi»Q.. iRfi7inn
26 1500 2760000 131400 3100 76500
27 1500 2760000 131400 3100 76500
26 1500 2760000 131400 3100 76500
29 1500 2760000 131400 3100 76500
_3D 15Q1 2JtUDfJD 1314.00..-. 	 ,.,.3100 	 7fe5Qn
TOT K7500 234600000 11171000 265500 6502500
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
HILLS PER KILDWATT-HPUR
CENTS PER PILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
PROCESS CTST DISCOUNTED AT 11.6* TO INITIAL YEAR, DOLLARS
LEVELIZED INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER PILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
0.0
0.0
0.0
0.0
1792600
1718100
1643500
1569000

TOTAL
NET
SALES
REVENUE,
t/YEAR
0
0
0
0
fl_
0
0
0
0

0
0
0
0
n
0
0
0
0
n
0
0
0
0
n
0
0
0
0
NET ANNUAL
CUMULATIVE
INCREASE NET INCREASE
(DECREASE)
IN COST OF
POWER,
i
4773900
4699400
4624800
4550300
	 S425.2fln_
4401200
4326700
4252100
4177600
&1Q3.0Q0
3655300
3580700
3506200
3431600
3357100
2984700
2910100
2835600
2761000
2&&A.5.QQ
2165300
2090800
2016200
1941700
11(^7100
1792600
1718100
1643500
1569000
n,f) i&Q&tnn n i<.Q&&nn







94392200

8.45
3.70
40.24
355.53
33368200
DISCOUNTED P*OCESS COST OVER




7.66
3.36
36 .49
322.09
0

0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
o.o
94392200

8.45
3.70
40.24
355.53
33368200
POWER UNIT
7.66
3.36
36.49
322.09
(DtCREASE)
IN COST OF
POWER,
i
4773900
9473300
14098100
18648400
•> -a i ?&inn
27525300
31852000
36104100
40281700
44.384700
48040000
51620700
55126900
58558500
6.19. 1 56QO
64900300
67810400
70646000
73407000
. 	 76093500
78258800
80349600
82365800
84307500
8 61Z46.0.0
87967200
89685300
91328800
92897800
94332200












    DATA  SETUP NEEDS CHECKING.



    XHEAD CARD IS INCORRECT Of. ORDfR OF SfcTUP  IS  INCORRECT.

-------
                                                             TABLE  B-5
    LIKE/LIMESTONE SLUDGE  DISPOSAL  - DRAVU PROCESS, 500 MW, NEW UNIT, 3.5* S, 16!; AJH  IN COAL,  REGULATED CD. ECONOMICS
00
                                                     MXED INVESTMENT:  *
                                                                            24114000

YEARS ANNUAL
AFTER (iPERA-
PCKER TIUN,
UNIT KW-HR/
START KW
1 70CO
2 7000
3 7000
4 7COO
	 5 	 J.Q.tlC._.
6 7000
7 7000
» 7000
9 7000
ID -10.00
11 5000
12 5000
13 5000
14 5000
-IS 	 5000—
16 3500
17 3500
18 3500
19 3500
_20 	 3iua_.
21 1500
22 1500
23 1500
24 1500
£.5. I.5.Q.G.
2fc 1500
27 1500
28 1500
29 1500
_3Q 	 15.£lQ_-
TOT 127500
SULFUR
REMOVED
POWER UNIT POWER UNIT BY
HEAT FUEL POLLUTION
RECUIREMENT, CCiNSUMPT I OK , CONTROL
MILLION BTU TONS COAL PROCESS,
/YEAR /YEAR TONS/YEAR
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
	 315aQMD 	 ISOflOaa 	 25.60,0. 	
31500000 1500000 35600
31500000 1500000 356CO
31500000 15000DO 35600
31500000 1500000 35600
31500*000 1500DOO 35.6.QQ
22500000 1071400 25400
22500000 1071400 25400
22500000 1071400 25400
22500000 1071400 25400
	 225.0.0000. 	 1QZL4IH1 	 2i 4,0.0 	
15750000 750000 17600
15750000 750000 17800
J5750000 750000 17800
15750000 750000 17BOO
J525iinnn 75nnon i7snn
6750000 321400 7600
6750000 321400 7600
6750000 321400 7600
6750000 321400 7600
	 6750000. 	 .,3214.00 	 ,. 	 -26.00. 	
6750000 321400 7600
6750000 321400 7600
6750000 321400 7600
6750000 321400 7600
6.250QOQ • 321400 _. 76.0.Q
573750000 27321000 648000
BY-PRODUCT
RATE,

TOTAL
OP. COST
INCLUDING
EOUIVALENT NET REVENUE, REGULATED
TONS/YEAR

WASTE
SOL IDS
875000
875000
875000
875000
	 £25C QO 	
875000
875000
875000
8750CO
,17^000
625000
625000
625000
625000
	 6.250 DD 	
437500
437500
437500
437500
i/TON

WASTE
SOLIDS
0.0
o.o
0.0
0.0
	 C^Q 	
0.0
0.0
0.0
0.0
Q n
0.0
0.0
0.0
0.0
	 0^0 	
0.0
0.0
0.0
0.0
ROl FUR
POWER
COMPANY,
i/YEAR
8P35600
8708800
8582000
8455300
	 8^?Hsnn
8201700
8074900
7948100
7821400
76 94. 6DQ
6776300
6649500
6522700
6396000
	 62,i22fiO_
5521500
5394700
5267900
5141100

TOTAL
NET
SALES
REVENUE,
i/YEAR
0
0
0
0
	 Q_
0
0
0
0
0
0
c
0
0
	 Q_
0
0
0
0
NFT ANNUAL
INCREASE
(DECREASE)
IN COST DF
POWER ,
i
8835600
8708800
8582000
8455300
	 £3.2fi50fl 	
8201700
8074900
7948100
7821400
. r 76 94 ton ^
6776300
6649500
6522700
6396000
CUMULATIVE
NET INCREASE
(DECREASE)
IN COST OF
POWER,
i
8835600
17544400
26126400
34581700
	 4PQiQ?nn
51111900
59186800
67134900
74956300
B.26 5. Q9.00
89427200
96076700
102599400
108995400
	 6.2k22QQ 	 1I52&A.MO
5521500
5394700
5267900
5141100
120786100
126180800
131448700
136589800
4^75nn o^n 5m*.&nn n «;m/.tnn i£i>,n£.:>nn
187500
187500
1B7500
187500
X&25 QQ
187500
187500
187500
187500
0.0
0.0
0.0
0.0
_ _ 0-0 _
0.0
0.0
0.0
u.o
3986600
3859800
3733000
3606200
34.7950(1
3352700
3225900
3099100
2972300
0
0
0
0
0
0
0
0
0
3986600
3859800
3733000
3606200
1&7Q *ifln
3352700
3225900
3099100
2972300
145590800
149450600
153183600
156789800
i t\fty K Q^nn
163622000
166B47900
169947000
172919300
	 , _1B75QQ . fl-ft >«£«;fcnn i\ -xj/.tinn » -jt->«./.onn
15937500

175764900
0
175764900
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST




PROCESS COST
LEVEL1ZED




DOLLARS PER TON OF CI'AL BURNED
MILLS PER KILOWATT-HL.UR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED








DISCOUNTED AT 11.6% TO INITIAL Yf AR , DOLLARS
INCREASE (DECREASE) U UNIT OPERATING COST
DOLLARS PER TON OF CCAL BURNED
MILLS PER KILOKATT-W'UR
CE.NTS PER MILLION BTU HEAT INPUT
DOLLARS PER TUN OF SULFUR REMOVED
EOUIVALENT TO DISCOUNTED








6.43
2.76
30.63
271.24
62052600
0.0
0.0
u.o
0.0
0
PROCESS COST OVER LIFE OF
5.83
2.50
27.75
245.56
0.0
0.0
0.0
0.0
6 .43
2.76
30.63
271.24
62052600
POWER UNIT
5.83
2.50
27.75
245.56











-------
                                                                     TABLE B—6




L IME/L JwESTOM  SLUDGE  DISPOSAL  - ORAVD  PROCESS.  1500  HV  NEW UNIT 3.5*  S,  lfc% ASH  IN COAL.  REGULATED CD.  ECONOMICS
                                                      FIXtD  INVESTMENT:.
                                                                                48235000
SULFUR
REMOVED
YEARS ANNUAL POWER UNIT POWER UNIT Bv
AFTER OPERA- HEAT FUEL POLLUTION
POWER TICN, REQUIREMENT, CONSUMPTION, CONTROL
UNIT KW-HR/ MILLION BTU TONS COAL PROCESS,
START KW /YEAR /YEAR TONS/YEAR
1 7000 94500000 4500000 106800
2 7000 94500000 4500000 106800
3 7000 94500000 4500000 106800
4 7000 94500000 4500000 1C6POO
...5 	 7000 	 34500000 . . . 4500000 1068.00
6 7000 94500000 4500000 106800
7 7000 94500000 4500000 106800
8 7000 94500000 4500000 1C6800
9 7000 94500000 4500000 106800
in 7000 94500000 45QQOOO 106800
11 5000 67500000 3214300 76300
12 5000 67500000 3214300 76300
13 5000 67500000 3214300 76300
14 5000 67500000 3214300 76300
15 5000 675.00000 32143.00 26^0.0.
16 3500 47250000 2250000 53400
17 3500 47250000 2250000 53400
18 3500 47250000 2250000 53400
19 3500 47250000 2250000 53400
?n ^infl A"7p*>nnflo ppsnonn s^f* no
21 1500 20250000 964300 22900
22 1500 20250000 964300 22900
23 1500 20250000 964300 22900
24 15CO 20250000 964300 22900
25_ 1500. _2Q?5.0Q0Q. 964300 224QQ
26 1500 20250000 964300 22900
27 1500 20250000 964300 22900
28 1500 20250000 964300 22900
29 1500 20250000 964300 22900
30 1500 20250000 96.4300 ??9.00.
TOT 127500 1721250000 81964500 1945500
BY-PRODUCT
RATF,
EOUlVAl ENT
TONS/YEAR

WASTE
SOLIDS
2625000
2625000
2625000
2625000
262 50 QQ
2625000
2625000
2625000
2625000
	 26250 00_
1875000
1875000
1875000
1875000
1 Q 75.000
1312500
1312500
1312500
1312500
1 ^ 1 ?*> flfi
562500
562500
562500
562500
562500
562500
562500
562500
562500
5.£25QU_
47812500

NET REVENUE,
»/TON

WASTE
5CLIDS
0.0
0.0
0.0
0.0
0^0
0.0
0.0
0.0
0.0
fl-0
0.0
c.o
0.0
0.0
o.O
0.0
0.0
0.0
0.0
n.o
0.0
0.0
0.0
0.0
Q «Q
0.0
0.0
0.0
0.0
	 _n^o

TOTAL
DP. CDST
INCLUDING
REGULATED
ROl FOR
POWER
COMPANY,
i/YEAR
18986900
18737900
18488900
18239900
i 70 QQBOO
17741800
17492800
17243800
16994700
1.^245700
14462200
14213200
13964200
13715100

TOTAL
NET
SALES
REVENUE,
i/YEAR
0
0
0
0
0
0
0
0
0
a
0
0
0
0
NET ANNUAL
INCREASE
(DECREASE)
IN COST OF
POWER,
*
18986900
18737900
18488900
18239900
1 79100 24B4R4000
11648600
11399600
11150600
10901500
0
0
0
0
1065? 50q . 0
8197200
7948200
7699100
7450100
2201100-
6952100
6703100
6454000
6205000
595.6000
375002700
0
0
0
0
0
0
0
0
(1
Q 	
0
11648600
11399600
11150600
10901500
10652500
8197200
7948200
7699100
7450100
7201100
6952100
6703100
6454000
6205000
59560QO
375002700
260132600
271532200
282682800
293584300
•=IO4?3fcBOO
312434000
320382200
328081300
335531400
34.2232500
349684600
356387700
362841700
369046700
375flfl?7ftO

LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
DOLLARS PER TON OF CUAL BURNED
HILLS PER KILUWATT-HflUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED








PROCESS CDST DISCOUNTED AT 11.6% TO INITIAL YEAR, DOLLARS
LEVELUED INCREASE (DECREASE) IN UNIT OPERATING COST
DOLLARS PER TON OF CUAL BURNED
MILLS PER KILOWATT-HfUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
EQUIVALENT TO




4.58
1.96
21.79
192.75
133456200
DISCOUNTED PROCESS COST OVER




4.18
1.79
19.89
175.99
0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
4.58
1 .96
21.79
192.75
133456200
POWER UNIT
4.18
1 .79
19.89
175.99











-------
                                                             TABLE  B-7

 LIME/LIMESTONE  SLUDGE  DISPOSAL-1UCS  PROCESS,  200  HW  NEW  UNITi  3.5X  S»  16* ASH  IN COAL REGULATED Cfl. ECONOMICS.
                                                 FIXED  INVESTMENT:
                                                                         7193000
YEARS ANNUAL POWER UNIT POKER UNIT
AFTER OPERA- HEAT FUEL
POKER TION, REQUIREMENT, CONSUMPTION,
UNIT KW-HR/ MILLION BTU
START KW
1 7000
2 7000
3 7000
4 7000
	 5_ _ZQQa_
6 7000
7 7000
8 7000
9 7000
it) 7nno
11 5000
12 5000
13 5000
14 5000
15 5(100
16 3500
17 3500
18 3500
19 3500
-?£) 3500
21 1500
22 1500
23 1500
24 1500
25. 150.0
26 1500
27 1500
28 1500
29 1500
3D. 15.0.0.-
/YEAR
12880000
12880000
12880000
12680000
12flBOnnQ . ,
12880000
12880000
12860000
12880000
12fiB.OQ.OQ
9200000
9200000
9200000
9200000
9200000
6440000
6440000
6440000
6440000
f»44 QO.OO
2760000
2760000
2760000
2760000
276POnn
2760000
2760000
2760000
2760000
-2260000...
TONS COAL
/YEAR
613300
613300
613300
61330C
6 133QO.
613300
613300
613300
613300
Alison
438100
438100
438100
438100
438100.
306700
306700
306700
306700
306700
131400
131400
131400
131400
1314.00
131400
131400
131400
131400
] ii&nn
SULFUR
REMOVED
BY
POLLUTION
CONTROL
PROCESS,
TONS/YEAR
14600
14600
14600
14600
J ££ QQ
14600
14600
14600
14600
Lit 00
10400
10400
10400
10400
	 JpfcflO. . 	
7300
7300
7300
7300
-J2QD
3100
3100
3100
3100
31QQ
3100
3100
3100
3100
	 310X)
BY-PRODUCT
RATE,
EQUIVALENT NET REVENUE,
TUNS/YEAR »/TON
WASTE
SOLIDS
283500
28?500
283500
283500
26.35 QD
283500
283500
283500
283500
28.3^00
202500
202500
202500
202500
20.2500—
141KOO
141600
141800
141800
itienn
60800
60800
60800
60800
608.00.
60800
60800
60800
40800
f>nnnn
WASTE
SOLIDS
G.O
0.0
0.0
0.0
Q.O
C.O
C.O
0.0
G.O
O.Q
G.O
0.0
0.0
0.0
Q^D
C.O
1.0
0.0
0.0
D.n
0.0
0.0
0.0
0.0
_ CUQ 	
0.0
0.0
0.0
0.0
"Q«Q
TOTAL
OP. COST
INCLUDING
REGULATED
R01 FOR
POWER
COMPANY,
S/YFAR
4216000
4178400
4140700
4103100
4065500
4027800
3990200
3952600
3914900
"?fl TT\C\ 0
3383000
3345300
3307700
3270100
^23^^00
2811700
2774100
2736400
2698800
?fif>i pnn
2001900
1964300
1926700
1889000
1 8 5 1 4QQ
1813800
1776100
1738500
1700900
if>f>i?nn
TOTAL
NET
SALES
REVENUE,
*/YEAR
0
0
0
0
U
0
0
0
0
n
0
0
0
0
n
0
0
0
0
n
0
0
0
0
a_
0
0
0
0

NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE) (DECREASE)
IN COST OF IN COST OF
POWER,
*
4216000
4178400
4140700
4103100
4Q65^5f]Q
4027800
3990200
3952600
3914900
3B 771QQ
3383000
3345300
3307700
3270100
POWER,
*
4216000
8394400
12535100
16638200
20703. 7QO
24731500
28721700
32674300
36589200
& n& i* A*»nn
43849500
47194800
50502500
53772600
3.212AD.O_ 57005000
2811700
2774100
2736400
2698800
2hfcj ?nn
2001900
1964300
1926700
1889000
1 B 5 1 4. QQ
1813800
1776100
1738500
1700900
	 1663 2 OQ 	
59816700
62590800
65327200
68026000
7068. 22Q()
72689100
74653400
76580100
78469100
^Q^2Q5f)f)
82134300
83910400
85648900
87349800
	 B9013QQO
TOT  127500    234600000     11171000        265500        5164500
   LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
                    DOLLARS PER TON OF CC'AL BURNED
                    HILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6* TO INITIAL YEAR, DL'LLARS
 89013000

    7.97
    3.49
   37.94
  335.27
30584100
   0
0.0
0.0
0.0
0.0
   LEVELIZED INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO D1SCCUNTED PROCESS COST OVER LIFE OF
                    DOLLARS PER TON OF COAL BURNED                                        7.02       0.0
                    MILLS PER KILOWATT-Hl'UR                                               3.08       0.0
                    CENTS PER MILLION BTU HEAT INPUT                                     33.45       0.0
                    DOLLARS PER TON OF SULFUR REMOVED                                   295.21       0.0
  89013000

      7.97
      3.49
     37.94
    335.27
  30584100
POWER UNIT
      7.02
      3.08
     33.45
    295.21

-------
                                                             TABLE B-S

 LIME/LIMESTONE SLUDGE DISPOSAL - 1UC5 PROCESS. 50O HH NEW UNIT, 3.5*  S, 16% ASH  IN  COAL,  REGULATED  CO.  ECONOMICS
                                                 FIXED  INVESTMENT:
                                                                         10717COO


YEARS ANNUAL
AFTER OPERA-
POWER TION,
UNIT KW-HR/
START KW
1 7000
2 7000
3 7000
4 7000
5 7Q f)fi
6 7000
7 7000
8 70UO
9 7000
1Q 7QQ(1
11 5000
12 5000
13 5000
14 5000
15 5QQG
oS *6 3500
ui 17 3500
IB 3500
19 3500
20 3.500
21 15CO
22 1500
23 1500
24 1500
25. _15QD_
26 1500
27 1500
28 1500
29 1500
30 15CJO


POWER UNIT
HEAT
REQUIREMENT,
MILLION BTU
/YEAR
31500000
31500000
31500000
31500000
3 11 "500. 000
31500000
31500000
31500000
31500000
3.15QQ QO Q
22500000
22500000
22500000
22500000
7?5f>OQO Q
15750000
15750000
15750000
15750000
1 575 OOO D
6750000
6750000
6750000
6750000
fc75DOQO
6750000
6750000
6750000
6750000
6J5_QHflfl 	


POWER UNIT
FUEL
CONSUMPTION,
TONS COAL
/YEAR
1500000
1500000
1500000
1500000
i«innnno
1500000
1500000
1500000
1500000
i nn I4fl«jpn


NET REVENUE,
i/TON

WASTE
SOLIDS
0.0
0.0
0.0
0.0
n.o
0.0
0.0
0.0
0.0
Q.Q
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
_0~Q_
0.0
c.o
0.0
0.0
D .&Q
0.0
0.0
0.0
0.0
0Tn
TOTAL
OP. COST
INCLUDING
REGULATED
RD1 FOR
POWER
COMPANY,
$/YEAR
6271000
6216500
6162000
6107600
tniaiQo,
5998600
5944100
5889600
5835100
57Bnf,nn
4969800
4935300
4880800
4826400
422J.SflO_
4114300
4059800
4005300
3950800


TOTAL
NET
SALES
REVENUE,
J/YEAR
0
0
0
0
fl
0
0
0
0
n
0
0
0
0
a 	
0
0
0
0

NET ANNUAL
INCREASE
(DECREASE)
IN COST OF
POWER,
S
6271000
6216500
6162000
6107600
AO 53 1 on
5996600
5944100
5889600
5835100
5780600
4989800
4935300
4880800
4826400
4771 9DQ
4114300
4059800
4005300
3950800

CUMULATIVE
NET INCREASE
(DECREASE)
IN COST OF
POWER,
$
6271000
12487500
18649500
24757100
TORI n?no
36808800
42752900
48642500
54477600
AH ?•» R?nn
65248000
70183300
75064100
79690500
flAfi AP&Qf)
88776700
92836500
96841800
100792600
3R9fi3nn n 3«<)fi3no in&6889Qn
2898700
2844200
2789800
2735300

2626300
2571800
2517300
2462600
?4D83na
0
0
0
0
f)
0
0
0
0
	 	 	 __Q 	
2898700
2644200
2789800
2735300
?t\ ft D fl DO
2626300
2571800
2517300
2462600
?40«300
107587600
110431800
113221600
115956900
1 1 8ft ^770 fl
121264000
123835800
126353100
128815900
131 ??&?nn
TOT  127500    573750000
   LIFETIME AVERAGE  INCREASE
                              27321000         648000       12622500
                              (DECREASE)  IN  UNIT  OPERATING COST
                    DOLLARS PER  TON  OF COAL BURNED
                    HILLS PER  KILOWATT-HOUR
                    CENTS PER  MILLION BTU HEAT  INPUT
                    DOLLARS PER  TON  OF SUIFUR RFMnVED
PROCESS COST DISCOUNTED AT  11.6%  TO  INITIAL YEAR, DOLLARS
   LEVELUED INCREASE  (DECREASE)  IN  UNIT  OPERATING COST EQUIVALENT
                    DOLLARS PER  TON  OF COAL BURNED
                    MILLS PER  KILOWATT-HOUR
                    CENTS PER  MILLION BTU HEAT  INPUT
                    DOLLARS PER  TON  OF SULFUR REMOVED
                                                                                       131224200
                                                                                                             131224200
                                                                    TO
DISCOUNTED
4.80
2.06
22.87
202.51
45381700
PROCESS COST OVER
4.26
1.83
20.29
179.59
0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
4.80
2.06
22.87
202.51
45381700
POWER UNIT
4.26
1 .83
20.29
179.59

-------
                                                               TABLE B-9
 LIPE/LIME STONE  SLUDGE  D 1 SPOSAL-IUCS  PROCESS,  1500  MW  NEW  UNIT,  3.5*  S,  16*  ASM  IN COAL,  REGULATED  CO.  ECONOMICS,

                                                 FIXED INVESTMENT:   s   20105000
YEARS ANNUAL POWER UNIT
AFTER OPEkA- HEAT
POWER TIEN, REQUIREMENT,
UNIT KK-HR/ MILLION BTU
START KW /YEAR
1 7000 94500000
2 7000 94500000
3 7000 94500000
4 7000 94500000
__5 	 2000 	 34500000 	
6 7000 94500000
7 7000 94500000
8 7000 94500000
9 7000 94500000
_1Q 	 2000 	 S4500QOO 	
11 5COO 67500000
12 50CO 67500000
., 13 5000 67500000
oo 14 5000 67500000
as _15 	 5000 	 6.2500000 	
16 3500 47250000
17 3500 47250000
18 3500 47250000
19 3500 47250000
_20 	 aSflO 	 42250000 	
21 1500 20250000
22 1500 20250000
23 1500 20250000
24 1500 20250000
-2S^ 	 1500 	 20250QQQ 	
26 1500 20250000
27 1500 20250000
28 1500 20250000
29 1500 20250000
30 1500 	 __202&nono
POWER UNIT
FUEL
CONSUMPTION,
TONS COAL
/YEAR
4500000
4500000
4500000
4500000
	 4500000 	
4500000
4500000
4500000
4500000
450Qnno
3214300
3214300
3214300
3214300
2250000
2250000
2250000
2250000
2250000
964300
964300
964300
964300
9f,43OO
964300
964300
964300
964300
SULFUK
REMOVED
BY
POLLUTION
CONTROL
PROCESS,
TONS/YEAR
106800
106800
106800
106800
	 106.100.
106800
106800
106800
106800
., . lOfefiQO
76300
76300
763UO
76300
53400
53400
53400
53400
53400.
22900
22900
22900
22900
22900
22900
22900
22900
22900
TOT  127500   1721250000     B1964500       1945500
   LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERA
                    DOLLARS PER TON OF COAL BURNED
                    MILLS PER K1LOHATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6* TO INITIAL YEAR, DOLLARS
   LEVFLIZED INCREASE (DECREASE) IN UNIT OPERATING COST
                    DOLLARS PER TON OF COAL BURNED
                    MILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HFAT INPUT
                    DOLLARS PER TON OF SUlFUR REMOVED
BY-PRODUCT
RATE,
EQUIVALENT
TPNS/YEAR

WASTE
SOLIDS
2075500
2075500
2075500
2075500

NET REVENUE,
»/TON

WASTE
SOLIDS
0.0
C.O
0.0
0.0
	 20255 00 	 0 -0 	
2075500
2075500
2075500
2075500
	 2,025500 	
1482500
14B2500
1482500
1482500
\4* Rp'sno
1037800
1037600
1037800
1037600
	 I032fl 00 	
444800
444800
444800
444800
	 444B.OO-
444800
444800
444800
444800
4&&Rfln
37804500
NG COST




ARS
EQUIVALENT TO




0.0
0.0
0.0
0.0
n.o
0.0
0.0
0.0
0.0
. -, 0.0. ^_
0.0
0.0
0.0
0.0
O -fi
0.0
0.0
C.O
0.0
0 Q
0.0
0.0
0.0
0.0
	 0*0 	







TOTAL
OP. COST
INCLUDING
REGULATED TOTAL
RDI FOR NET
POWER SALES
COMPANY, REVENUE,
*/YEAR */YEAR
12289300 0
12192200 0
12095100 0
11998000 0
	 iiaooaoo 	 o_
11803800 0
11706700 0
11609600 0
11512500 0
_114154OQ_ 0_
9681000 0
9583900 0
9486800 0
9389700 0
QJ gp^nfi o
7888400 0
7791300 0
7694200 0
7597100 0
25QOOOQ_ 0 	
5443900 0
5346800 0
5249700 0
5152600 0
SO^S^OQ fi
4958400 0
4861300 0
4764200 0
4667100 0
457QOQ.fi n
254498000 0

3.10 0.0
1.33 0.0
14.79 0.0
130.81 0.0
88798600 0
DISCOUNTED PROCESS COST OVER LIFE OF




2.78 0.0
1.19 0.0
13.24 0.0
117.10 0.0
NET ANNUAL
CUMULATIVE
INCREASE NET INCREASE
(DECREASE)
IN COST OF
POWER,
$
12289300
12192200
12095JOO
11998000
	 naooaoo 	
11803POO
11706700
11609600
11512500
	 11415400 	
9681000
9583900
9486800
9389700
9^9260.0
7888400
7791300
7694200
7597100
(DECREASE)
IN COST OF
POWER,
S
12289300
24481500
36576600
4857*600
__M1425500
72279300
83986000
95595600
107108100
_LL8.5 23500
128204500
137788400
147275200
156664900
1 f»595750O
173845900
181637200
189331400
196928500
	 2500000 	 J044?fl5no
5443900
5346800
5249700
5152600
1055500
4958400
4861300
4764200
4667100
	 452OOOO-
254498000

3.10
1 .33
14.79
130.81
88798600
POWER UNIT
2.78
1.19
13.24
117.10
209872400
215219200
220468900
225621500
PTO6.220OO
235635400
240496700
245260900
249928000
2 "544 90000













-------
                                                                     TABLE B—1O



     LIME/LIMESTQNF  SLUDGE 01SPDSAL-CHEMFIX PROCESS. 200 MW  NEW UNIT, 3.5* S.  16X ASH  IN  COAL, REGULATED CO.  ECONOMICS.
OJ
                                                          FIXED  INVESTMENT:
                                                                                     9249000
YEARS ANNUAL POWER UNIT POWER UNIT
AFTER OPERA- HEAT FUEL
POWER TION, REQUIREMENT, CONSUMPTION
UNIT KW-HR/ MILLION BTU TONS COAL
START KW /YEAR /YEAR
1 7000
2 7000
3 7000
4 7000
6 7000
7 7000
8 7000
9 7000
JO 70OO
11 5000
12 5000
13 5000
14 5000
15. _ -5.Q.QQ.
16 3500
17 3500
16 3500
19 3500
?0 ^5.0.0.
21 1500
22 1500
23 1500
24 1500
_25 	 15.0.D._
26 1500
27 1500
28 1500
29 1500
_3Q 	 15_0.0._
TOT 127500
LIFETIME
PROCESS COST
LEVELIZED
12880000 613300
12860000 613300
12880000 613300
12880000 613300
1 ?ftflQn.[)0 hl^nn
12880000 613300
12880000 613300
12B80000 613300
12880000 613300
12fl800QQ f>13300
9200000 438100
9200000 438100
9200000 438100
9200000 438100
97OOOOO 438^00
6440000 306700
6440000 306700
6440000 306700
6440000 306700
644000Q 30fc7oo
2760000 131400
2760000 131400
2760000 131400
2760000 131400
?7t»OGQQ 13.14.00
2760000 131400
2760000 131400
2760000 131400
2760000 131400
UbOOOD 131400
SULFUR BY-PRODUCT
REMOVED RATE,
BY EQUIVALENT
POLLUTION TONS/YEAR
, CONTROL
PROCESS, WASTE
TONS/YEAR SOLIDS
14600
14600
14600
14600
14600
14600
14600
14600
16.SOO
10400
10400
10400
10400
]0400
7300
7300
7300
7300
7300
3100
3100
3100
3100
3100
3100
3100
3100
3100
3100
290500
290500
290500
290500
290500
290500
290500
290SOO
207500
207500
207500
207500
145300
145300
145300
145300
1&S30O
62300
62300
62300
62300
62300
62300
62300
62300
6.2.100
234600000 11171000 265500 5292000
AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
MILLS PER KILDWATT-HOUR
CENTS'PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
DISCOUNTED AT 11.6* TO INITIAL YEAR, DOLLARS
INCREASE IDECREASF) IN UMT OPERATING COST EQUIVALENT TO
DOLLARS PER TON OF CDAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
TOTAL
OP. COST
INCLUDING
NET REVENUE. REGULATED
S/TON ROI FOR
POWER
WASTE COMPANY,
SOLIDS $/YEAR
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
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
0.0
	 Q-Q—
DISCOUNTED
TOTAL
NET
SALES
REVENUE,
t/YEAR
5360200 0
5311500 0
5262700 0
5214000 0
-L .. , - ^5165200 0
5116500
5067800
5019000
4970300
4241600
4192800
4144100
4095300
3462600
3433800
3385100
3336300
3?f)7f.on
2438000
2389300
2340500
2291BOO
2194300
2145600
2096800
2048100
111241300
9.96
4.36
47.42
418.99
38655100
PROCESS COST OVER
8.88
3.89
42.27
373.12
0
0
0
0
0
0
0
0
n
0
0
0
0
n
o o o o a
0
0
0
0
o
0
0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
NET ANNUAL
INCREASE
(DECREASE)
IN COST OF
POWER,
$
5360200
5311500
5262700
5214000
, 51*5200
5116500
5067800
5019000
4970300
4Q21500
4241600
4192800
4144100
4095300
3482600
3433800
3385100
3336300
2438000
2389300
2340500
2291800
2194300
2145600
2096800
2048100
1944300
111241300
9.96
4.36
47.42
418.99
38655100
POWER UNIT
8.88
3.89
42.27
373.12
CUMULATIVE
NET INCREASE
(DECREASE)
IN COST OF
POWER,
$
5360200
10671700
15934400
21148400
31430100
36497900
41516900
46487200
55650300
59843100
63987200
68082500
7?1?
-------
                                                          TABLE  B-ll
 LIME/LIMESTONE  SLUDGE  DISPOSAL  -  CHEMFIX  PROCESS,  500  Mrf  NEW UNIT  , 3.5* S,  16* ASH  IN COAL, REGULATED CD, ECONOMICS

                                                 FIXED  INVESTMENT:   t    13531000
                                                                                        TOTAL
                                            SULFUR       BY-PRODUCT                     DP. COST
                                            REMOVED        RATE,                       INCLUDING
                                                        EQUIVALENT      NET REVENUE,   REGULATED
YEARS ANNUAL
AFTER (1PERA-
POWER TION,
UNIT KN-HR/
START KW
1 7000
2 7000
3 7000
4 7000
^ 7nnn
6 7000
7 7000
B 7000
9 7000
10 7000
11 5000
12 5000
13 5000
14 5000
_15 	 5.QOO 	
16 3500
17 3500
IB 3500
19 3500
?O _3iQQ.
21 1500
22 1500
23 1500
24 1500
_25 	 15.QO —
26 15 CO
27 1500
28 1500
29 1500
_3Q 	 15.00 	
POWER UNIT
HEAT
REQUIREMENT,
MILLION BTU
/YEAR
31500000
31500000
31500000
31500000
-\ | 500000
31500000
31500000
31500000
31500000
31SQQQQD
22500000
22500000
22500000
22500000
	 225DDHDD
15750000
15750000
15750000
15750000
1 57 c 000 D
6750000
6750000
6750000
6750000
	 6_Z5J}QO.D. 	
6750000
6750000
6750000
6750000
6J50I1QO
POWER UNIT
FUEL
CONSUMPTION,
TONS COAL
/YEAR
1500000
1500000
1500DOO
1500000
1 500000
1500000
1500000
1500000
1500000
i snnnnn
1071400
1071400
1071400
1071400
\ n "71 40D
750000
750000
750000
750000
75nnn n
321400
321400
321400
321400

321400
321400
321400
321400
3?i&nn
BY
POLLUTION
CONTROL
PROCESS,
TONS/YEAR
35600
35600
35600
35600
?5fiOp
35600
35600
35600
35600
\ 56 tin
25400
25400
25400
25400
2 *tt* pn
17800
17800
17800
17800
	 _17flQOL
7600
7600
7600
7600
	 26.00.-
7600
7600
7600
7600
	 7.600.-
TOT  127500    573750000     27321000        648000
   LIFfTJHE AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
                    DOLLARS PER TON OF COAL BURNED
                    HILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6* TO INITIAL YEAR, DOLLARS
   LEVELIZED INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO DISCOUNTED PROCESS COST OVER LIFE OF
                    DOLLARS PER TON OF COAL BURNED                                        5.55
                    MILLS PER KILOWATT-HOUR                                               2.38
                    CENTS PER MILLION BTU HEAT INPUT                                     26.43
                    DOLLARS PER TON OF SULFUR REMOVED                                   233.87
TONS/YEAR

WASTE
SOI I OS
710500
710500
710500
710500
	 _Z1H5.QO_
710500
710500
710500
710500
-r- -. 7105.QO ___.
507500
507500
507500
507500
507500
355300
355300
355300
355300
^55^00
152300
152300
152300
152300
152300
152300
152300
152300
i ^ y \ n n
12942000
NG COST




ARS
t/TON

WASTE
SOLIDS
0.0
0.0
0.0
0.0
	 D^O
0.0
0.0
0.0
0.0
0-0
0.0
0.0
0.0
0.0
t) -'n
0.0
0.0
0.0
0.0
	 Q^O.
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
	 fl^U.







ROI FOR
POWER
COMPANY,
J/YEAR
8223700
8154600
8085500
8016400
22.&_Z3J1Q 	
7878200
7B09100
7740000
7670900
7fc017Qf)
6416100
6347000
6277900
6208800
61 ^9700
5185400
5116300
5047200
4978100
	 4aoJB.SflQ 	
3529900
3460800
3391700
3322600
3184400
3115300
3046200
2977100
, 79080DP ,
167942300

6.15
2.63
29.27
259.17
59099300

TOTAL
NET
SALES
REVENUE,
J/YEAR
0
0
0
0
o
0
0
0
0
0
0
0
0
0
n
0
0
0
0
n
0
0
0
0
0
0
0
0
0
n
0
0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
NET ANNUAL
INCREASE
(DECREASE)
IN COST OF
POWER,
*
8223700
8154600
8085500
8016400
7947300 ,
7878200
7809100
7740000
7670900
7fcDX700
6416100
6347000
6277900
6208800
6.1337.0.0.
51B5400
5116300
5047200
4978100
490ft QOO
3529900
3460800
3391700
3322600
"\7 5^ 50Q
3184400
3115300
3046200
2977100
?QQfi onn
167942300
6.15
2.63
29.27
259.17
59099300
POWER UNIT
5.55
2.38
26.43
233.87
CUMULATIVE
NET INCREASE
(DECREASE)
IN COST OF
POWER.
i
8223700
16378300
24463800
32480200
^ ^^40477500
48305700
56114800
63854800
71525700
791 77400
85543500
91890500
98168400
104377200
110516900
115702300
120818600
125865800
130843900
1 35.75.?flQfl
139282700
142743500
146135200
149457800
J5771 TiOO
155895700
159011000
162057200
165034300
1 f»"7Q& ? ^00












-------
                                                               TABLE  B-12

 LIKE/LIMESTONE  51UDGE DJSPOSAL-CHEMFIX PROCESS, 1500 HW NEW UNIT, 3.5*  S.  16*  AiM  IN  COAl,  HEGULATtD  CO. ECONOMICS.
                                                 FIXED  INVESTMENTS
                                                                         24104000
YEARS ANNUAL
AFTER' OPERA-
POWER TION,
UNIT KW-HR/
START KW
1 7000
2 7000
3 7000
4 7000
_5 	 2000 	
6 7000
7 7000
8 7000
9 7000
_io_ _zoao_
11
12
13
16
17
18
19
_20 	
21
22
23
24
25
26
27
28
29
5000
5000
5000
5000
3500
3500
3500
3500
1500
1500
1500
1500
1500
1500
1500
1500
1500
__150Q 	
POWER UNIT
HEAT
REQUIREMENT.
MILLION BTU
/YEAR
94500000
94500000
94500000
94500000
	 94500000-
94500000
94500000
94500000
94500000
67500000
67500000
67500000
67500000
-6.2500000-
47250000
47250000
47250000
47250000
	 4225DODO-
20250000
20250000
20250000
20250000
20250000
20250000
20250000
20250000
- 2O25.00QO-
POWER UNIT
FUEL
CONSUMPTION,
TONS COAL
/YEAR
4500000
4500000
4500000
4500000
	 65QQQOQ —
4500000
4500000
4500000
4500000
3214300
3214300
3214300
3214300
•1214100
2250000
2250000
2250000
2250000
225pnnn
964300
964300
964300
964300
964300
964300
964300
964300
364^00
SULFUR
REMOVED
BY
POLLUTION
CONTROL
PROCESS,
TONS/YEAR
106800
106800
106800
106800
r- „ 106800
106800
106800
106800
106800
76300
76300
76300
76300
	 7.6.100
53400
53400
53400
53400
534f)n
22900
22900
22900
22900
22900
22900
22900
22900
22,900
BY-PRODUCT
RATE,
EQUIVALENT
TONS/YEAR
HASTE
SOLIDS
TOTAL
UP. COST
INCLUDING
NET REVENUE, REGULATED TOTAL
S/TON RG1 FOR NET
POWER SALES
WASTE COMPANY, REVENUE,
SOLIDS »/YEAR »/YEAR
2131500 0.0 16616100
2131500 0.0 16502200
2131500 0.0 16386400
2131500 0.0 16270600
	 2131500 	 Q^Q 	 .—16J.5A200 	
2131500 0.0 16038900
2131500 0.0 15923000
2131500 0.0 15807200
2131500 0.0 15691400
1522500
1522500
1522500
1522500
1065800
1065800
1065800
1065800
456800
456800
456800
456800
456(100
456800
456800
456800
0.0
0.0
0.0
0.0
	 o*a_
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
12755100
12639200
12523400
12407500
I229iinn
10086400
9970500
9B54700
9738800
6554500
6438700
6322900
6207000
5975300
5859500
5743700
5627800
55,12000-
0
0
0
0
0
0
0
0
n
0
0
0
0
n
0
0
0
0
n
0
0
0
0
n
0
0
0
0
0
NET ANNUAL
INCREASE
(DECREASE)
IN COST OF
POWER,
S
16618100
16502200
16386400
16270600
16038900
15923000
15807200
15691400
12755100
12639200
12523400
12407500
10086400
9970500
9854700
9738800
6554500
6438700
6322900
6207000
5975300
5859500
5743700
5627800
CUMULATIVE
NET INCREASE
(DECREASE)
IN COST OF
POWER,
$
16618100
33120300
49506700
65777300
97970900
113893900
129701100
145392500
173723100
186362300
198885700
211293200
233671300
243641800
253496500
263235300
279412800
285851500
292174400
298381400
310447900
316307400
322051100
327678900
^3190900
TOT  127500   1721250000      81964500        1945500       36624500                    333190900         0   333190900
   LIFETIME AVERAGE  INCREASE  (DECREASE)  IN UNIT  OPERATING COST
                     DOLLARS PER  TON  OF  COAL BURNED                                        4.07       0.0         4.07
                     MILLS PER  KILOWATT-HOUR                                               1.74       0.0         1.74
                     CENTS PER  MILLION BTU HEAT  INPUT                                     19.36       0.0         19.36
                     DOLLARS PER  TON  OF  SULFUR  REMOVED                                   171.26       0.0       171.26
PROCESS COST DISCOUNTED AT  11.6*  TO INITIAL YEAR, DOLLARS                           119154500          0   119154500
   LFVELIZED INCREASE  (DECREASE)  IN  UNIT  OPERATING COST EQUIVALENT TO DISCOUNTED PROCESS COST OVER LIFE OF POWER UNIT
                     DOLLARS PER  TON  OF  CDAL BURNED                                        3.73       0.0         3.73
                     MILLS PER  KILOWATT-HPUR                                               1.60       0.0         1.60
                     CENTS PER  MILLION BTU HEAT  INPUT                                     17.76       0.0         17.76
                     DOLLARS PER  TON  OF  SULFUR  REMOVED                                   157.13       0.0       157.13

-------
                      APPENDIX C




CONSTANT ON-STREAM TIME - LIFETIME REVENUE REQUIREMENTS
                           391

-------
                                                         TABLE C-l
LIME/LIMESTONE  SLUDGE  DISPOSAL - UNTREATED, 200 MW NEW UNIT , 3.5*  S,  7000 HRS CONSTANT ONSTEAH, REGULATED CO. ECONOMICS
                                               FIXED INVESTMENT:  *    12882000

SULFUR
REMOVED
YEARS ANNUAL POWER UNIT POWER UNIT BY
AFTER OPERA- HEAT FUEL POLLUTION
POWER TIDN, REOUIREMENT, CONSUMPTION, CONTROL
UNIT KW-hR/ MILLION BTU TONS COAL PROCESS,
START KW /YEAR /YEAR TONS/YEAR
1 7000 12880000 613300 14600
2 7000 12880000 613300 14600
3 7000 12880000 613300 14600
4 7000 1288COOO 613300 14600
•> 7000 I?BBOf)(]0 _ . filBlOO 	 ^__lAfQC 	
t 7000 12880000 613300 14600
7 7000 12880000 613300 14600
8 7000 1288COOO 613300 14600
9 7000 1288COGO 613300 14600
10 70QO 12B80QQQ 61T*f>Q 14600
11 7000 1288COOO 613300 14600
12 7000 12880000 613300 14600
13 7000 1288COOO 613300 14600
14 7000 12880000 613300 14600
15 2QO.Q 12fiaCQCQ 	 6133HQ 	 litQO
16 7000 12880000 613300 14600
17 7000 12880000 613300 14600
10 7000 12880000 613300 14600
19 7000 12880000 613300 14600
20 .7000 ^ l?fifiCOOD 	 hinQn 14*00
21 7000 1288COOO 613300 14600
22 7000 12880000 613300 14600
23 7000 12880000 613300 14600
24 7000 12880000 613300 14600
25 200.0, 	 _J2£flQQQQ_ _ -6133D.Q 	 146.0.0 	
26 7000 1288COOO 613300 1460C
27 7000 12880000 613300 14600
28 7000 12880000 613300 14600
29 7000 12880000 613300 14600
30 3000 12B8.CQOQ . 6.133QO... - .__.146QC -_.
TOT 210000 386400000 16399000 438000

BY-PRODUCT
RATE,
EQUIVALENT
TONS/YEAR

WASTE
SOLIDS
332500
332500
332500
332500
_ 3325QO-
332500
332500
332500
332500
3^2500.
332500
332500
332500
332500
332500-
332500
332500
332500
332500
H 325QQ
332500
332500
332500
332500
_ 332500-
332500
332500
332500
332500
__ . 332500
9975000



NET REVENUE,
I/TON

WASTE
SOLIDS
0.0
0.0
0.0
0.0
	 0.^.0 	
0.0
0.0
0.0
0.0
JJ fi
0.0
0.0
0.0
0.0
p —fl
0.0
0.0
0.0
0.0
0-.Q
0.0
0.0
c.o
0.0
r n
0.0
0.0
0.0
0.0
p (]

TOTAL
OP. COST
INCLUDING
REGULATED
R01 FOR
POWER
COMPANY,
I/YEAR
3662300
3595000
3527700
3460300
3393000^.
3325700
3258400
3191100
3123700
	 3fl.564.QD. _
2989100
2921800
2854500
2767100
531 Sflflfl
2652500
2585200
2517900
2450500
	 23 A3 20 Q_
2315900
2248600
2181200
2113900
2Q46&OQ
1979300
1912000
1644600
1777300
13100.00
80564600



TUTAL
NET
SALES
REVENUE,
S/YEAR
0
0
0
0
n
0
0
0
0


NET ANNUAL
INCREASE
(DECREASE)
IN COST OF
POWER ,
$
3662300
3595000
3527700
3460300
3393000
3325700
3258400
3191 100
3123700


CUMULATIVE
NET INCREASE
(DE.CREASE)
IN COST OF
POWER,
t
3662300
7257300
10785000
14245300
	 1J6,3£3QO
20964000
24222400
27413500
30537200
_0_^ 305640Q 335936DO
0
0
0
0
0
0
0
0
0

0
0
0
0
D
0
0
0
0
0
0
2989100
2921800
2854500
2787100
2~^ t q o fjfj
2652500
2585200
2517900
2450500
P3fl 3 ?nn
2315900
2248600
2181200
2113900
204660Q
1979300
1912000
1844600
1777300
1710000
36582700
39504500
42359000
45146100
A T o i. con n
50518400
53103600
55621500
58072000
604 55J*.OO
62771100
65019700
67200900
69314800
71^6,1400
73340700
75252700
77097300
78874600
n ntfi/. Ann
80564600
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
COLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU NEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED








PROCESS COST DISCOUNTED AT 11.6* TO INITIAL YEAR, DOLLARS
LEVEL12ED INCREASE (DECREASE) IN UNIT OPERATING COST
COLLARS PER TEN OF CUAL BURNED
MILLS PER KILOHATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
COLLARS PER TON DF SULFUR REMOVED
EQUIVALENT TO




4.38
1.92
20.66
183.98
26228200
DISCOUNTED PROCESS COST OVER




5.15
2.26
24.53
216.40
0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
4.38
1.92
20.86
163.98
26228200
POWER UNIT
5.15
2.26
24.53
216.40











-------
                                                           TABLE  C-2

LIME/LIMESTONE SLUDGE  DISPOSAL  - UNTREATED. 200  HH NEW UNIT, 3.5* S, 5000 HRS CONSTANT ONSTEAH. REGULATED CO.  ECONOMICS
                                                 FIXED INVESTMENTS  $
                                                                        10682000
YEARS ANNUAL POWER UNIT
AFTER OPERA- HEAT
POWER TICN, REQUIREMENT
UNIT KW-HR/ MILLION BTU
START KW /YEAR
)
2
3

-------
                                                           TABLE C-3



LIHE/LlMtSTONE SLUDGE  DISPOSAL  - UNTREATED.  500  MM  NEW UNIT  ,  3.5* S.  1000  HRS  CONSTANT QNSTEAH, REGULATED CO.  ECONOMICS



                                                FIXED INVESTMENT.:  »    23212000



YEARS ANNUAL
AFTER OPfRA-
POWER TIDN,
UNIT KW-HR/
START KW
1 7000
2 7000
3 7000
4 7000
.5 20QQ
6 7000
7 7000
B 7000
9 7000

SULFUR
REMOVED
POWER UNIT POWER UNIT BY
HEAT FUEL POLLUTION
REQUIREMENT, CONSUMPTION, CONTROL
MILLION BTU TONS COAL PROCESS,
/YEAR /YEAR TONS/YEA*
3150COOO 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
	 3150QQOD 	 ISOflOnfl 	 15600 	
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
10 7DOO 3isoonon isnnnnn 35f,nn
11 7000
12 7000
13 7000
14 7000
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600

BY-PRODUCT
RATE,
EQUIVALENT
TONS/YEAR

WASTE
SOL IDS
812000
612000
812000
612000
-, . ..-"12000 	
812000
812000
812000
612000
	 412000
812000
812000
612000
812000



NET REVENUE,
$/TON

HASTE
SOLIDS
0.0
0.0
0.0
0.0
	 C-G 	
0.0
0.0
0.0
0.0
	 	 O..Q
0.0
0.0
0.0
0.0
TOTAL
OP. COST
INCLUDING
REGULATED
ROI FOR
POWER
COMPANY,
(/YEAR
6345200
6224600
6104000
5983400
5B62&00-
5742200
5621600
5501100
5360500



TOTAL
NET
SALES
REVENUE,
»/YEAR
0
0
0
0

0
0
0
0
,5253900 _ ft
5139300
5018700
4898100
4777500
15 20.00. 31500000 ISOQOnO 35600 812DQD C-D 4656900
It 7000
17 7000
18 7000
19 7000
?0 7000
21 7000
22 7000
23 7000
24 7000
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
315QOQQQ _ 15QQQQ.Q 	 35AOC 	
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
812000
812000
812000
812000
_ 812000-
812000
812000
812000
612000
25 2QQQ 315QQQOO 15QQDQO 	 356.00 	 	 fll2noa
26 7000 31500000 1500000 35600
27 7000
28 7000
29 7000

TOT 210000
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 35600
31500000 1500000 	 ^35600
945000000 45000000 1068000
812000
812000
612000
612000
o ] 2QQQ
24360000
0.0
0.0
0.0
0.0
__o.o 	
0.0
0.0
0.0
0.0
	 	 £..0 	
0.0
0.0
0.0
0.0
	 0-0 	

4536300
4415800
4295200
4174600
0
0
0
0
0
0
0
0
0


NET ANNUAL
INCREASE
(DECREASE)
IN COST PF
POWER,
i
6345200
6224600
6104QOO
5983400
5fl62BDfl
5742200
5621600
5501100
5380500
525SSDO
5139300
5018700
4898100
4777500
&656.9QG
4536300
4415800
4295200
4174600


CUMULATIVE
NET INCREASE
(DECREASE )
IN COST OF
POWER,
i
6345200
12569600
18673800
24657200
3Q52.QQQO
36262200
41883800
47384900
52765400
c p Q2 53DO
63164600
68183300
73081400
77858900
8.25158.00
87052100
91467900
95763100
99937700
t.n'it.nnn ^ n insinnn iniaoiinn
3933400
3812800
3692200
3571600
	 3451000 	
3330500
3209900
3069300
2968700
2P4B100.
137699200
0
0
0
0
Q
0
0
0
0

0
3933400
3812800
3692200
3571600
107925100
111737900
115430100
119001100
3.&51CCO, I2?45?inn
3330500
3209900
3069300
2968700
? ft 4fi in 0
137899200
125783200
128993100
132082400
135051100
* a T o QQ ?flO

LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST




PROCESS COST
LEVELIZED




DOLLARS PER TON OF COAL BURNED
HILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED








DISCOUNTED AT 1 1 .6* TO INITIAL YEAR, DOLLARS
INCREASE (DECREASE) IN UNIT OPERATING COST
COLLARS PER TON OF COAL BURNED
HILLS PER KILOWATT-HOUR
CENTS PER PILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
ECUIVALENT TO




3.06
1.31
14.59
129.12
45197300
DISCOUNTED PROCESS COST OVER




3.63
1.56
17.29
152.95
0.0
0.0
0.0
o.c
0
LIFE OF
0.0
0.0
o.c
0.0
3.06
1.31
14.59
129.12
45197300
POWER UNIT
3.63
1.56
17.29
152.95











-------
                                                                    TABLE C-4



     LIME/LIMESTONE SLUDGE DISPOSAL -  UNTREATED. 500 MW NEK UNIT, 3.5* S. 5000 HRS  CONSTANT  ONSTEAM. REGULATED CO. ECONOMICS
Ul
                                                      FIXED INVESTMENT:
                                                                              18937000
SULFUR BY-PRODUCT
REMOVED RATE,
YEARS ANNUAL POWER UNIT POWER UNIT BY EQUIVALENT
AFTER OPERA- HEAT FUEL POLLUTION TENS/YEAR
POWER TION. REQUIREMENT, CONSUMPTION, CONTROL
UNIT KW-HR/ MILLION BTU TONS COAL PROCESS. WASTE
START KW /YEAR /YEAR TONS/YEA* SGLIDS
1 5000 225000CO 1071400 25400
2 5000 22500000 1071400 25400
3 5000 22500000 1071400 25400
4 5000 22500000 1071400 25400
s snno_ _ 225fl"PnO 1071400 2540.0
6 5000 2250QOOO 1071400 25400
7 5000 22500000 1071400 25400
8 5000 22500000 1071400 25400
9 5000 22500000 1071400 25400
10 	 5000 	 225DPOqO 	 1071400 25400
11 5000 22500000 1071400 25400
12 5000 22500000 1071400 25400
13 5000 22500000 1071400 25400
14 5000 22500000 1071400 25400
_15 	 5UOQ 	 2250000.0 	 	 1Q2140.0 	 25400 	 	
16 5000 22500000 1071400 25400
17 5000 22500000 1071400 25400
18 5000 22500000 1071400 25400
19 5000 22500000 1071400 25400
20 5000 225GGODD . JQ21400 _ 25400
21 5000 22500000 1071400 25400
22 5000 22500000 1071400 25400
23 5000 22500000 1071400 25400
24 5000 22500000 1071400 25400
25 5000 22500000 1Q2140Q .25400
26 5000 22500000 1071400 25400
27 5000 22500000 1071400 25400
26 5000 2250COCO 1071400 25400
29 5000 22500000 1071400 25400
3p *>flno 22SODOOO ")7.J*Q0 ____25400_-__— _
580000
580000
580000
580000
580000
580000
580000
580000
580000
.. .SflOQQQ 	
580000
580000
580000
580000
580QOQ
580000
580000
580000
580000
_ 580000- .
580000
580000
580000
580000
	 580000- .
580000
580000
580000
580000
580QOO_ .
TOT 150000 675000000 32142000 762000 17400000
LIFETIME AVERAGE INCREASE (DECREASE! IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
HILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT 11.6* TO INITIAL YEAR, DOLLARS
LEVELIZED INCREASE IDECREASEI IN UNIT OPERATING COST EQUIVALENT TO
DOLLARS PER TON DF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
TOTAL
OP. COST
INCLUDING
NET REVENUE, REGULATED
S/TON ROI FOR
POWER
WASTE COMPANY.
SOLIDS S/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
C.O
. 	 _(UO_
0.0
0.0
C.O
0.0
	 C-0 	
0.0
0.0
0.0
0.0
5229600
5130900
5032300
4933600
4fi3«;nnr>
4736400
4637700
4539100
4440400
_ 4341800 	
4243100
4144500
4045900
3947200
	 3848600 	
3749900
3651300
3552700
3454000
_ _ 3355400. .
3256700
3158100
3059400
2960800
	 2862 200 	
2763500
2664900
2566200
2467600
23fcflSDIL
113977700
3.55
1.52
16.89
149.58
37296900
DISCOUNTED PROCESS COST OVER
4.19
1.80
19.97
176.93
TOTAL
NET
SALES
REVENUE,
»/YEAR
0
0
0
0
Q
0
0
0
0
0
0 O O O C
0
0
0
0
Q
0
0
0
0
	 fl
0
0
0
0
_ fl
0
0.0
0.0
O.Q
0.0
0
LIFE OF
O.C
o.c
0.0
0.0
NET ANNUAL CUMULATIVE
INCREASE NET INCREAS^
(DECREASE) (DECREASE)
IN COST CF IN COST OF
POWER, POWER,
» $
5229600 5229600
5130900 10360500
5032300 15392800
4933600 20326400
4835000 — 2516.1&DO
4736400 29897800
4637700 34535500
4539100 39074600
4440400 43515000
__ . -4341 flOQ^_._ 43B5fifloo
4243100 52099900
4144500 56244400
4045900 60290300
3947200 64237500
	 .3848600 	 6aOfl6100
3749900 71836000
3651300 75487300
3552700 79040000
3454000 82494000
.3355400. 85B49.4GO
3256700 89106100
3158100 92264200
3059400 95323600
2960800 98284400
286220.0. 1Q1146.6.GO
2763500 103910100
2664900 106575000
2566200 109141200
2467600 111608800
2368SQQ 1 1 39777flO
113977700
3.55
1.52
16.89
149.58
37296900
POWER UNIT
4.19
1.80
19.97
176.93

-------
                                                                TABLE  C-5
 L IMF/LIMESTONE  SLUDGE  DISPOSAL - UNTREATED, 1500 HW KEk UNIT  ,  3.5* Si  7000  KRS  CONSTANT  ONSTEAH,  REGULATED CO. ECONOMICS
                                                 FIXED INVESTMENT:
                                                                        50462000


YEARS
AFTER


ANNUAL
OPERA-


POMER UNIT
HEAT


POWER UNIT
FUEL

SULFUR
REMOVED
BY
POLLUTION

BY-PRODUCT
RATE,
EQUIVALENT
TONS/YEAR


NET REVENUE,
S/TON
TOTAL
OP. COST
INCLUDING
REGULATED
ROI FOR


TOTAL
NET


NET ANNUAL
INCREASE
(DECREASE)


CUMULATIVE
NET INCREASE
(DECREASE !
 POKER  TION.    REQUIREMENT.  CONSUMPTION,
 UNIT   KH-HR/   MILLION  BTU   TONS  COAL
 START    KM       /YEAR         /YEAR
  CONTROL
  PROCESS,
TONS/YEA*
                               POWER
                                          SALES
                                                  IN COST OF   IN COST CF
WASTE
SOLIDS
WASTE
SOLIDS
COMPANY,   REVENUE,   POWER,
                                                                                         I/YEAR
           $/YEAR
POWER,
1 7000 94500000
2 7000 94500000
3 7000 94500000
4 7000 9450COOO
Si 7QQO 94^DCDQO ,
6 7000 94500000
7 7000 94500000
8 7000 94500000
9 7000 94500000
10 2000. 3450QQQQ
11 7000 9450COOO
12 7000 94500000
13 7000 94500000
14 7000 94500000
15 20.CO. 3450QQ00-
16 7000 94500000
17 7000 94500000
18 7000 94500000
19 7000 94500000
20 7000 945CCDOQ
4500000
4500000
4500000
4500000
45nnnnn
4500000
4500000
4500000
4500000
45QOOQO
4500000
4500000
4500000
4500000
	 4500000 	
4500000
4500000
4500000
4500000
«snnnnn
21 7000 94500000 4500000
22 7000 94500000 4500000
23 7000 94500000 4500000
24 7000 94500000 4500000
.25 	 2000. 	 345QQQQQ 	 450.0.00.0. 	
26 7000 S450COCO 4500000
27 7000 94500000 4500000
28 7000 94500000 4500000
29 7000 94500000 4500000
3D 	 2000. 	 3&5HCDOO — — 4500000 	
106800
106600
106800
106800
106800
106800
106800
106800
-1066.00-
106800
106800
106800
106800
106800
106800
106800
106800
2432500
2432500
2432500
2432500
	 	 243250Q _
2432500
2432500
2432500
2432500
	 2432500.
2432500
2432500
2432500
2432500
	 	 2432500 	
2432500
2432500
2432500
2432500
2432500
0.0
0.0
0.0
G.O
G.O
0.0
C.O
G.O
C..O
0.0
c.o
c.o
0.0
C-Q
C.O
c.o
G.O
G.O
D-Q
13549000
13289700
13030400
12771100
12252500
11993200
11733900
11474600
_ 112154QQ
10956100
10696800
10437500
10178200
9918900 ™
9659600
9400300
9141000
8881700
flfc22SQG
0
0
0
0
Q
0
0
0
0
fl
0
0
0
0
0
0
0
0
n
13549000
13289700
13030400
12771100
122525CO
11993200
11733900
11474600
112154.QQ
10956100
1C696800
10437500
10178200
9659600
9400300
9141000
8881700
B4225CD
13549000
26838700
39869100
52640200
_ 65152DOO
71404500
89397700
101131600
112606200
-1238.21600
134777700
145474500
155912000
166090200
185668700
1950690UO
204210000
213091700
221714JDO
106800 2432500 0 .0 8363200 0 8363200 230077400
106800 2432500 0.0 8103900 0 8103900 236181300
106800 2432500 G.O 7844600 0 7844600 246025900
106800 2432500 G.O 7585300 0 7585300 253611200
	 10.6fl.QO 	 2432500 	 C-0 	 23 26 0.0. Q 	 0 	 23260QQ 	 260237.200
10680G 2432500 0.0 7066700 0 7066700 268003900
106800 2432500 0.0 6807400 0 6807400 274811300
106800 2432500 C.O 6548100 0 6548100 281359400
106800 2432500 0.0 6288800 0 6288800 287648200
	 106400 	 	 2432500- 	 G..Q 	 6029600 	 	 0 	 6023600 	 233622flCO
TOT  210000     2835000000    135000000       3204000       72975000
   LIFETIME AVERAGE INCREASE  (CECREASE)  IN UNIT OPERATING COST
                    COLLARS PER TON OF COAL BURNED
                    MILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6* TO INITIAL YEAR, DOLLARS
                                             293677800

                                                 2.18
                                                 0.93
                                                10.36
                                                91.66
                                             96399600
                                            0.0
                                            0.0
                                            0.0
                                            0.0
   IEVELIZED INCREASE (DECREASE) IN UNIT OPERATING COST
                    DOLLARS PER TON OF COAL BURNED
                    MILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT  INPUT
                    COLLARS PER TON OF SULFUR REMOVED
               EQUIVALENT  TO  DISCOUNTED  PROCESS COST OVER  LIFE
                                               0
                                               OF
                                                 2.58
                                                 1.11
                                                12.29
                                               108.74
                                            0.0
                                            0.0
                                            o.c
                                            0.0
                                 293677800

                                      2.16
                                      0.93
                                     10.36
                                     91 .66
                                  96399600
                                POWER UNIT
                                      2.58
                                      1.11
                                     12.29
                                    108.74

-------
     LJUf/LJHfSTONE  SLUDGE  DISPOSAL - UNTREATED,  150O MH UNIT. 3.5*  S.  50OO HRS CCNSTANT UNSTEAH,  REGULATfcD CO. ECONOMICS
                                                       FIXED  INVESTMENT:
                                                                               40438000
UJ
SULFUR BY-PRODUCT
REMOVED RATE,
YEARS ANNUAL POWER LN1T POkER UNIT BY tOUVALENT
AFTER DPtRA- HEAT FUEL POLLUTION TCNS/YEAR
POWER TION, RECUIREHENT, CONSUMPTION, CONTROL
UNIT KH-HR/ MILLION BTU TOfiS COAL PROCESS, WASTE
START KW /YEAR /YEAR TONS/YEA* SCLIDS
1 5000 6750COOO 3214300 76300 1737500
2 5000 6750COOO 3214300 76300 1737500
3 5000 6750COOO 3214300 76300 1737500
4 5000 67500000 3214300 76300 1737500
.5 5CGQ £^5jQCO£}£l 3j?l &3QG 76300 1 73.7500
6 5000 6750COOO 3214300 76300 1737500
7 5000 6750COOO 3214300 76300 1737500
f 5000 67500000 3214300 76300 1737500
9 5000 67500000 3214300 76300 1737500


NET REVENUE
$/TON

WASTE
SOLIDS
0.0
c.o
0.0
0.0
C-.C
0.0
0.0
0.0
0.0
TOTAL
OP. COST
INCLUDING
. REGULATED
ROI FOR
POWER
COMPANY.
t/YEAR
109610CO
10752400
10543600
10335100
I OI 2t% *>flfl
9917900
9709200
9500600
9291900


TOTAL
NET
SALES
REVENUE,
$/YEAR
0
0
0
0

o~~
0
0
0
_1D 	 5.0.0.0. 	 625.0DO.DO 	 321430.0. 	 26300 	 12325. QQ 	 0-0 	 2043300 	 0_
11 5000 67500000 3214300 76300 1737500
12 5000 67500000 3214300 76300 1737500
13 5000 67500000 3214300 76300 1737500
14 5000 67500000 3214300 76300 1737500
0.0
0.0
0.0
0.0
_15 	 5.00.0 	 taSDCODfl 	 3214300 	 2i3QO 	 123350Q 	 C-.C 	
16 5000 67500000 3214300 76300 1737500
17 5000 67500000 3214300 76300 1737500
18 5000 6750COOO 3214300 76300 1737500
19 5000 67500000 3214300 76300 1737500
PO SDQO 6350COQQ 3? 1 4300 7fi3QQ 173T5OO
21 5000 67500000 3214300 76300 1737500
22 5000 6750COOO 3214300 76300 1737500
23 5000 67500000 3214300 76300 1737500
24 5000 67500000 3214300 76300 1737500
25 500Q 63500000 	 32143QQ _ ^ IfclOO 13.335QO_
26 5000 6750COCO 3214300 76300 1737500
27 5000 67500000 3214300 76300 1737500
26 5000 67500000 3214300 76300 1737500
29 5000 67500000 3214300 76300 1737500
A«S ^nfiO fe "15 DO ODD ^ ? 1 A^OO 	 76300 1 IZ335QQ
TOT 150000 2025000000 96429000 2289000 52125000
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT 11.6* TO INITIAL YEAR, DOLLARS
LEVELIZED INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT
COLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
0.0
c.o
0.0
0.0
0 -0
c.o
c.o
c.o
0.0
. _ 0-0
c.o
0.0
0.0
0.0
	 . C-Q . .







8874700
8666000
8457400
8248800
0
0
0
0

NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE! (DECREASE)
IN COST OF IN COST OF
PUHER, POKER,
* i
10961000 10961000
10752400 21713400
10543800 32257200
10335100 42592300
1Q126SDO. 53"7lnflnn
— ^VIA*-M ^MU_ — _~— w£^^JDOUU
9917900 62636700
9709200 72345900
9500600 61846500
9291900 91138400
	 20fl33Dfl 	 10.0221300
8874700 109096400
8666000 117762400
8457400 126219800
8246800 134468600
	 	 __HQ4010U_— 	 	 ___D_____flfl4QlflQ 	 , 14?5Q.87_GO
78315CO
7622900
7414200
7205600
f*QQ7nf)fl
6786300
6579700
6371000
6162400
5,9!k3flflQ
5745100
5536500
5327900
5119200
AQ 1 Qf)f) A
238074400

2.47
1.06
11.76
104.01
78056500
TO DISCOUNTED PROCESS COST OVER




2.93
1.25
13.93
123.25
0
0
0
0
fl
0
0
0
0
_ _0
0
0
0
0
	 fl 	
0

0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
7831500 150340200
7622900 157963100
7414200 165377300
7205600 172582900
t p o T n fi fl 13 9579 90 0
67883CO 166368200
6579700 192947900
6371000 199318900
6162400 205481300
5.25.3flOQ 211435100
57451GO 217180200
5536500 222716700
5327900 228044600
5119200 233163800
f Q JQ t. QQ 23 BQ Tit 40f)
236074400

2.47
1.06
11 .76
104.01
78056500
POWER UNIT
2.93
1 .25
13.93
123.25

-------
                                                                  TABLE  C-7
U)

00
    LIME/LIMESTONE SLUDGE DISPOSAL - DRAVD PROCESS, 200 MW NEW UNIT, 3.5* S, 7000 CONSTANT ONSTEAM. REGULATED CD. ECDNL1KI1CS

                                                    FIXED  INVESTMENT:. $   leeiscoo

YEARS ANNUAL POWER tNIT
AFTER OPERA- HJA7
POWER TION, REQUIREMENT
UNIT KW-HR/ MILLKll* BTU
START KW /YEAR
1 7000 1288COOO
2 7000 I268COOO
3 7000 12B8COOO
4 7000 12880000
">.__,. 7C
-------
                                                                 TABLE  C-8
HUE/LIMESTONE  SLUDGE  DISPOSAL  -  DRAVD  PROCESS.  200 MM NEW  UNIT.  3.5*  S,  5000  MRS CONSTANT  ONSTEAH.  REGULATED CO. ECONOMICS
                                                 FIXED INVESTMENT:  »
                                                                        14759COO


YEARS ANNUAL POWER UNIT
AFTER OPERA- HEAT
POWER TION, REQUIREMENT.
UNIT KW-HR/ MILLION BTU
START KW /YEAR
1 5000 9200000
2 5000 92000CO
3 5000 9200000
4 5000 9200000


POWER UNIT
FUEL
CONSUMPTION,
TONS COAL
/YEAR
438100
438100
438100
438100
__5 	 5000, 	 2200000 	 &3&100 	
6 5000 9200000
7 5000 9200000
8 5000 9200000
9 5000 9200000
.10 	 5000 	 220000 Q 	
11 5000 9200000
12 5000 9200000
13 5000 920COOO
14 5000 9200000
i^_ 5JQU0 S^HflfiCO
16 5000 92000CO
17 5000 920COCO
18 5000 9200000
19 5000 9200000
_2D 	 5000 	 2200DOD 	
21 5000 9200000
22 5000 9200000
23 5000 9200000
24 5000 9200000
25. 50QQ 220G000
26 5000 92000CO
27 5000 9200000
28 5000 920COOO
29 5000 920COOO
qf) 5OOO 	 S2DCDDD 	
438100
438100
438100
438100
	 43flinn . , ._ _
438100
438100
438100
438100
438 100
438100
438100
43B100
438100
TOTAL
SULFUR BY-PRODUCT OP. COST
REMOVED RATE. INCLUDING
BY EGLIVALENT NET REVENUE. REGULATED TOTAL
POLLUTION TONS/YEAR »/TON R01 FOR NET
CONTROL POWER SALES
PROCESS, WASTE WASTE COMPANY. REVENUE.
TONS/YEAR SCLIDS SOLIDS S/YEAR i/YEAR
10400 25500 C.O 4865200 0
10400 25500 C.O 4786400 0
10400 25500 0.0 4707500 0
10400 25500 0.0 4628700 0

NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE) (DECREASE)
IN COST DF IN COST OF
POWER, POWER,
t J
4865200 4865200
4786400 9651600
4707500 14359100
4628700 18987800
	 10400 	 2550Q 	 0-0 	 45.498.00 	 0 	 45428.00 	 23533600
10400 25500 0.0 4470900 0
10400 25500 0.0 4392100 0
10400 25500 C.O 4313200 0
10400 25500 0.0 4234400 0
	 10400 	 25500 	 C-0 	 4155500 	 0_
10400 25500 0.0 4076600 0
10400 25500 C.O 3997800 0
10400 25500 0.0 3918900 0
10400 25500 C.O 3840000 0
— — -1D40C __ _ _25500_ __ C— fl_____ _ _33£1200_ 0
10400 25500 C.O 3682300 0
10400 25500 C.O 3603500 0
10400 25500 C.O 3524600 0
10400 25500 0.0 3445700 0
	 4.3E100 	 10400 	 25500 	 C-.Q 	 336.6200 	 0_
438100
438100
438100
438100
43A100
438100
438100
438100
438100
	 43.8100 	
10400 25500 0.0 3288000 0
10400 25500 0.0 3209100 0
10400 25500 C.O 3130300 0
10400 25500 0.0 3051400 0
	 10400 	 	 25500 	 	 C-G 	 	 2222600 0
10400 25500 0.0 2893700 0
10400 25500 C.O 2814800 0
10400 25500 0.0 2736000 0
10400 25500 C.O 2657100 0
1O6OD 	 755DD 	 D_D ysTftinn n
4470900 28008500
4392100 32400600
4313200 36713800
4234400 40948200
	 4155500 	 451032DO
4076600 49180300
3997800 53178100
3918900 57097000
3840000 60937000
	 3261200 	 6.46.28,200
3662300 68380500
3603500 71984000
3524600 75508600
3445700 78954300
	 336iS00 	 82321200
3288000 65609200
3209100 88818300
3130300 91948600
3051400 95000000
2232600 .22222600
2893700 100866300
2814800 103681100
2736000 106417100
2657100 109074200
	 257fl3on . _iii£*?cnn
TOT  150000
   LIFETIME
                                                                                       111652500
               27600COOO     13143000         312000         765000
            AVERAGE  INCREASE (CECREASE)  IN UNIT OPERATING  COST
                     DOLLARS PER TON OF COAL BURNED
                     MILLS PER KILOWATT-HOUR
                     CENTS PER MILLION BTU HEAT  INPUT
                     COLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6%  TO  INITIAL  YEAR, DCLLARS                            ^-.TOJUU
   lEVfLIZED INCREASE  (DECREASE) IN UNIT OPERATING COST  EQUIVALENT  TO DISCCUNTED PROCESS COST OVER L
                     nm i «DC DEB Tnw DF fDAI RUB MFD                                        9.76
                                                                                          4.28
                                                                                          8.50
                                                                                          3.72
                                                                                         40.45
                                                                                        357.86
                    COLLARS PER TON OF COAL BURNED
                    HILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT  INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
                                                                                         46.49
                                                                                        411.33
0.0
0.0
o.c
0.0
   0
FE OF
0.0
o.c
0.0
0.0
 111652500

      8.50
      3.72
     40.45
    357.86
  35498100
PUWER UNIT
      9.76
      4.28
     46.49
    411.33

-------
                                                                  TABLE  C-9

 LIME/LIMESTONE  SLUDGE  DISPOSAL  - DRAVC  PROCESS,  500  MW  NEW  UNIT,  3.5*  S, 7000 CONSTANT ONSTEAM, REGULATED CO. ECONOMICS
                                                 FIXED INVESTMENT:   $
 YEARS ANNUAL
 AFTER OPERA-
 POKER TION,
               POUEK  UNIT
                  HEAT
               REQUIREMENT,
 POkER UNIT
    FUEL
CONSUMPTION.
 SULFUR
 REMOVED
   BY
POLLUTION
 CONTROL
BY-PRODUCT
   RATE,
EQUIVALENT
 TONS/YEAR
                                                                        30293000
NET REVENUE.
    S/TON
  TOTAL
 OP. COST
INCLUDING
REGULATED
 RQI FOR
  POWER
TOTAL
 NET
SALES
NET ANNUAL
 INCREASE
(DECREASE)
IN COST DF
 CUMULATIVE
NET INCREASE
 (DECREASE)
 IN COST OF
UNIT KW-HR/
START Kh
1 7000
2 7000
3 7000
4 7000
__5 	 20QO__
t 7000
7 7000
8 7&00
9 7000
_10 	 2C.QO 	
11 7000
12 7000
13 7000
14 7000
g ii 	 21100 	
0 16 7000
17 7000
18 7000
19 7000
_20 	 2000 	
21 7000
22 7000
23 7000
24 7000
2.5 _2000
26 7000
27 7000
28 7000
29 7000
-3.0 	 2000 	
MILLION BTU
/YEAR
31500000
3150COOO
31500000
31500000
	 31500000 	
31500000
31500000
3150COOO
3150COOO
_ 31500000- _
31500000
31500000
31500000
31500000
3150DOO.O 	
31500000
31500000
31500000
31500000
31500000
31500000
31500000
31500000
31500000
31500000
31500000
31500000
31500000
	 31500000—
TO^S CF1AL PROCESS,
/YEAR TONS/YEAR
WASTE
SOLIDS
WASTE
SOLIDS
COMPANY,
i/YEAR
REVENUE.
J/YEAR
POWER, POWER,
1 t
1500000 35600 875000 C .0 10405500 0 10405500 10405500
1500000 35600 875000 0.0 10247300 0 10247300 20652800
1500000 35600 875000 0.0 10069100 0 10089100 30741900
1500000 35600 875000 0.0 9930900 0 99309CO 40672800
	 1500000 	 35600 	 B250QQ 	 fUO 	 9222200 	 0 	 9222200 	 5.0445500
1500000 35600 675000 0.0 9614600 0 96146GO 60060100
1500000 35600 875000 0.0 9456400 0 9456400 69516500
1500000 35600 875000 0.0 9298200 0 9298200 78814700
1500000 35600 875000 0.0 9140000 0 9140000 81954700
	 1500000 	 „.. - ^^»,nn »i«;nrm ft n Roninnn n nonionn a/.o-»Ai;nn
1500000
1500000
1500000
1500000
	 1500000. 	
1500000
1500000
1500000
1500000
_ 15QQQQO- 	
1500000
1500000
1500000
1500000
	 J5000OO 	 	
1500000
1500000
1500000
1500000
—isoooao- __
35600
35600
35600
35600
	 35600 	
35600
35600
35600
35600
	 156,00 	
35600
35600
35600
35600
	 35600 	
35600
35600
35600
35600
	 35600 	
875000
875000
875000
875000
	 _B25QQQ_
875000
875000
875000
875000
	 a250QO _
875000
875000
875000
875000
	 8,25000 	
875000
875000
875000
875000
	 £25000 	
0.0
0.0
0.0
0.0
o _n
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
n.n
0.0
0.0
0.0
0.0
8823600
8665400
8507200
8349000
8032700
7874500
7716300
7558100
7241700
7083500
6925400
6767200
6450800
6292600
6134400
5976200
0
0
0
0
0
0
0
0
0
o.
0
0
0
0
0
0
0
0
8823600 105760100
6665400 114425500
8507200 122932700
8349000 131281700
£130300 133422600
8032700 147505300
7874500 155379800
7716300 163096100
7558100 170654200
1333300 118.054.100
7241700 1852958CO
7083500 192379300
6925400 199304700
6767200 206071900
6£iQ300Q 21264,0300
6450800 219131700
6292600 225424300
6134400 231558700
5976200 237534900
	 5B.1EOOQ 	 243352300
TOT  210000    945000000
   LIFETIME AVERAGE INCREASE
                             45000000       1066000       26250000
                             (DECREASE) IN UNIT OPERATING COST
                    COLLARS PER TON OF COAL BURNED
                    MILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6* TO INITIAL YEAR, DOLLARS
   LEVELIZED INCREASE (DECREASE! IN UNIT OPERATING COST EQUIVALENT
                    DOLLARS PER TON UF COAL BURNED
                    MILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    COLLARS PER TON OF SULFUR REMOVED
                                                                   TO
                                                          243352900         0   243352900

                                                              5.41       O.C          5.41
                                                              2.32       0.0          2.32
                                                             25.75       0.0         25.75
                                                            227.86       0.0        227.66
                                                          76570300          0     76570300
                                           D1SCCUHTED PROCESS COST OVER LIFE OF POWER  UNIT
                                                              6.15       0.0          6.15
                                                              2.64       0.0          2.64
                                                             29.29       0.0         29.29
                                                            259.12       0.0        259.12

-------
                                                              TABLE C-10
LIME/LIHtSTONE SLUDGE DISPOSAL - DRAVO PROCESS. 500 MU NEW UNIT, 3.5* 5, 5000 HRS CONSTANT ONSTEAH, rEGULATFO  CD.  ECONOMICS

                                                FIXED  INVESTMENTS. >   25711COO
YEARS ANNUAL POWER UNIT
AFTER OPERA- HEAT
POWER TION, REQUIREMENT
UNIT KW-HR/ MILLION BTU
START KW /YEAR
1 5000 22500000
2 5000 22500000
3 5000 2250COOO
4 5000 22500000
~6 5000 2250COCO
7 5000 225000CO
8 5000 22500000
9 5000 22500000
_IQ 	 50.QQ 	 2 25 Q Q CO. D_
11 5000 2250COCO
12 5000 22500000
13 5000 22500000
14 5000 22500000
0 -1$ 	 SflDQ 	 22500000-
!-• 16 5000 22500000
17 5000 22500000
18 5000 22500000
19 5000 22500000
_2fl 	 5000 	 22500QQQ-
21 5000 22500000
22 5000 22500000
23 5000 22500000
24 5000 22500000
-25 	 5000 	 22500000-
26 5000 22500000
27 5000 22500000
28 5000 22500000
29 5000 22500000
_3fl 	 50,00. 	 225EE&LD-
SULFUR BY-PRODUCT
REMOVED RATE,
POWER UNIT BY EQUIVALENT
FUEL POLLUTION TCNS/VEAR
, CONSUMPTION. CONTROL
TONS COAL PROCESS, WASTE
/YEAR TONS/YEA* SOLIDS
1071400
1071400
1071400
1071400
1071400
1071400
1071400
1071400
	 1Q7.14D.Q 	
1011400
1071400
1071400
1071400
	 .10.71MJO. ...
1071400
1071400
1071400
1071400
	 1Q114HO. 	
1071400
1071400
1071400
1071400
1071*00 	 T
1071400
1071400
1071400
1071400
25400
25400
25400
25400
	 25400 	
25400
25400
25400
25400
	 254 QO 	
25400
25400
25400
25400
625000
625000
625000
625000
£25000
625000
625000
625000
625000
__£250DQ 	
625000
625000
625000
625000
£.2SnntL
TOTAL
OP. COST
INCLUDING
NET REVENUE, REGULATED TOTAL
4/TGN ROI FOR NET
POWER SALES
WASTE COMPANY, REVENUE,
SCLIDS (/YEAR i/YEAR
0.0
C.O
0.0
0.0
0.0
C.O
0.0
C.O
C.O
C.O
0.0
0.0
D^C
8702300
8566600
8430900
8295200
8023900
7888200
7752500
7616800
7345400
7209700
7074000
6938300
bfiQPbCO
0
0
0
0
0
0
0
0
Q
0
0
0
0
D
NET ANNUAL CUMULATIVE
INCREASE KET INCREASE
(imREASF) (DECREASE)
IN COST PH IN COST OF
PkWER, POWER,
* *
H7023CO
8566600
8430900
8295200
8023900
7888200
7752500
/6168CO
24.B11QQ
73454CO
7209700
707ACOO
6938300
f>Bn?tnn
25400 625000 0.0 6667000 0 6667000
25400 625000 C.O 6531300 0 6531300
25400 625000 C.O 6395600 0 6395600
25400 625000 C.O 6259900 0 6259900
	 2540C 	 625QOO 	 CUD 	 £124200 	 0 	 61242CO 	
25400 625000 C.O 5988500 0 5988500
25400 625000 0.0 5852800 0 5852800
25400 625000 C.O 5717100 0 5717100
25400 625000 0.0 5581400 0 5581400
	 25400 _. 	 6250QD. C..O 54457Cf> n 5t<.«;-?nn
25400
25400
25400
25400
	 2S40.C 	
625000
625000
625000
625000
0.0
C.O
0.0
C.O
	 C..O 	
5310000 0 5310000
5174400 0 51744PO
5038700 0 5038700
4903000 0 49030CC
8702300
11268900
25699BOO
33995000
42154500
50178400
58066600
65819100
73435900
flQ3120QO
882624CO
95472100
102546100
109484400
122954000
129485300
135880900
1421408CO
1542535CO
160106300
165823400
171404800
182160500
187334900
192373600
191276600
                             32142000        762000       18750000
                             (DECREASE) IN UNIT OPERATINC COST
                    DOLLARS PER TO.N OF COAL BURNED
                    MILLS PER KILOWATT-HOUR
                    CENTS PER PILLION BTU HEAT INPUT
                    COLLARS PER TON OF SULFUR REMOVED
             DISCOUNTED AT  11.6* TO INITIAL YEAR, DOLLARS
             INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO DISCOUNTED
                    COLLARS PER TON OF COAL BURNED
                    MILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
TCT  150000    61500COOO
   LIFETIME AVERAGE INCREASE
PROCESS COST
   LEVELIZEC
                                                                                      202043900
2020439CO
6.29
2.69
29.93
265.15
63826800
PROCESS COST OVER Li
7.18
3.08
34.18
302.78
0.0
0.0
0.0
0.0
0
i FE OF
0.0
0.0
0.0
0.0
6.29
2.69
29.93
265 .15
63826800
POWER UNIT
7.18
3 .08
34 .18
302 .78

-------
                                                             TABLE  C-ll



LIME/LIMESTONE SLUDGE  DISPOSAL  -  ORAVO PROCESS, 1500 Mk NEK UNIT, 3.5* S,  1000  HRS  CONSTANT ONSTEAM, REGULATED CD. ECONOMICS



                                               FIXED  INVESTMENT:  t   62551000
SULFUR BY-PRODUCT
REMOVED RATE,
YEARS ANNUAL POWER UNIT POWER UNIT BY EOLIVALENT NET REVENUE
AFTER OPERA- HEAT FUEL POLLUTION TONS/YEAR */TON
POWER TIUN, REQUIREMENT, CONSUMPTION. CONTROL
UNIT KW-HR/ MILLION BTU TOMS COAL PROCESS, WASTE WASTE
START KW /YEAR /YEAR TONS/YEA* SOLIDS SOLIDS
1 7000 94500000 4500000 106800 2625000 0.0
2 7000 94500000 4500000 106800 2625000 C.O
3 7000 94500000 4500000 106800 2625000 0.0
4 7000 94500000 4500000 106800 2625000 C.O
	 5 	 20.00 	 945H.CJlQfl 	 iittOOflO 	 lOfcfiOC 	 2625QQQ 	 0..0 	
6 7000 9450UOOO 4500000 106800 2625000 0.0
7 7000 94500000 4500000 106800 2625000 0.0
8 7000 94500000 4500000 106800 2625000 0.0
9 7000 9450COOO 4500000 106800 2625000 C.O
-10 	 20.00 	 S45DQQO.Q 	 45QQQO.Q 	 1Q6.B.QO 	 2625000 	 C-C 	
11 70CO S450COOO 4500000 106800 2625000 0.0
12 7000 94500000 4500000 106800 2625000 C.O
13 7000 94500000 4500000 106800 2625000 C.O
14 7000 94500000 4500000 106800 2625000 0.0
_1_5 ^70 OQ 345 DO 00 Q 4 50DGQO Ifi&fiQQ ?&? 50 HO CO
0 16 7000 94500000 4500000 106800 2625000 0.0
to 17 7000 94500000 4500000 106800 2625000 0.0
18 7000 94500000 4500000 106800 2625000 0.0
19 7000 94500000 4500000 106800 2625000 0.0
20 7flOQ , 945CCOOO 45aQnnn in^pon, 	 	 2625000. 	 . __^ o*0_.^
21 7000 94500000 4500000 106800 2625000 0.0
22 7000 94500000 4500000 106800 2625000 0.0
23 7000 94500000 4500000 106800 2625000 0.0
24 7000 945000CO 4500000 106800 2625000 C.O
25 20,00 	 S45QQQQO._ 	 45.QQQQQ- 	 1068.00 	 	 2625000- _,. 	 IUD_ .
26 7000 S450COCO 4500000 106800 2625000 0.0
27 7000 94500000 4500000 106800 2625000 0.0
28 7000 94500000 4500000 106800 2625000 C.O
29 7000 94500000 4500000 106800 2625000 0.0
3H 7(1CD 9.45.DQD.OO 4500000 106BOC __ 2625000 _ _. C«Q 	
TOT 210000 2835000000 135000000 3204000 18750000
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
COLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT 11.6% TO INITIAL YEAR, DOLLARS
TOTAL
OP. COST
INCLUDING
. REGULATED TOTAL
R01 FOR NET
POWER SALES
COMPANY. REVENUE,
»/YEAR $/YEAR
22624000 0
22302800 0
21981600 0
21660300 0

NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE) (DECREASE)
IN COST OF IN COST OF
POWER, POWER,
» 1
22624000 22624000
22302800 44926800
21981600 66908400
21660300 88568700
	 21333100 	 0 	 21333100 	 10320.ZB.OO
21011900 0
20696700 0
20375500 0
20054300 0
	 1S2331QQ 	 0_
19411900 0
19090700 0
18769500 0
1B448200 0
	 	 1B123QOO.. 0
17805800 0
17484600 0
17163400 0
16842200 0
	 1£521000_ Q
16199800 0
15878600 0
15557400 0
15236100 0
	 14514300 	 	 _fl
14593700 0
14272500 0
13951300 0
13630100 0
1330BSCO 13
538992900 0

3.99 0.0
1.71 0.0
19.01 0.0
168.23 0.0
167889600 0
LEVELIZED INCREASE (DECREASE) IN UNIT OPERATING COST EOLIVALENT TO DISCOUNTED PROCESS COST OVER LIFE OF
COLLARS PER TON UF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
4.49 0.0
1.93 0.0
21.40 0.0
189.38 0.0
21017900 13C9257CO
20696700 151622400
20375500 171997900
20054300 192052200
	 122331DO 	 211285300
194119CO 231197200
19090700 250287900
18769500 269057400
18448200 287505600
1£1Z2DCC 305632I>£D
17805800 323438400
17484600 340923000
17163400 358086400
16842200 374928600
i f E p» non 39144 Qfco n
16199800 401649400
15878600 423528000
15557400 439085400
15236100 454321500
_ 149JL4.SQQ 	 46.S23.6.400
14593700 483830100
14272500 498102600
139513CO 512053900
13630100 525684000
133 D£ SCt 53B.S92SOO
538992900

3.99
1 .71
19.01
166.23
167B896CO
POWER UMT
4.49
1 .93
21 .40
189.38

-------
                                                              TABLE  C-12
LIHE/LiMfSTDNE SLUDGE  DISPOSAL  - DRAVO PROCESS,  1500  Mk  NEh UNIT, 3.5* S. 50CO HRS CONSTANT  ONSTEAM, REGULATED CO.  ECONOMICS
                                                  FIXED INVESTMENT:.  $   si99eooo
SULFUR BY-PRODUCT
REMOVED RATE,
YEARS ANNUAL POWER UNIT POWER UNIT BY EQUIVALENT
AFTER OPERA- HEAT FUEL POLLUTION TCNS/YEAR
PGWFR TIUN, RECU1REMENT, CONSUMPTION, CONTROL
UNIT KH-HR/ MILLION BTU TONS COAL PROCESS, WASTE
START KW /YEAR /YEAR TONS/YEAH SOLIDS
1 5000 67500000 3214300 76300 1875000
2 5000 67500000 3214300 76300 1875000
3 5000 6750COOO 3214300 76300 1875000
4 5000 67500000 3214300 76300 1875000
__5 	 5000 	 fc250COOO 	 3214300 	 26300 	 __lfl250QQ
TOTAL
DP. COST
INCLUDING NET ANNUAL CUMULATIVE
NET RtVENUE. REGULATED T.JTAL INCREASE NET INCREASE
$/TDN R01 FOR NET IDECREASE) (DECREASE)
POWER SALES IN COST OF IN COST OF
WASTE COMPANY, REVENUE, POWER, POWER.
SOLIDS »/YEAR t/YEAR t }
C.O
0.0
C.O
0.0
C^Q
6 5000 675COOOO 3214300 76300 1875000 C.O
7 5000 67500000 3214300 76300 1875000 0.0
8 5000 67500000 3214300 76300 1875000 0.0
9 5000 67500000 3214300 76300 1875000 0.0
_10 	 5000 	 625HJCHIJJ 	 3214300 	 26300 	 1325000 	 C-0_.
11 5000 6750COOO 3214300 76300 1875000 0.0
12 5000 67500000 3214300 76300 1875000 0.0
13 5000 6750COOO 3214300 76300 1875000 C.O
j>. 14 5000 6750COCO 3214300 76300 1875000 0.0
O ^15 5DQO 	 .62500000. 	 32X4300.. 	 r, T7<»300 -, 1875000 n -n
w 16 5000 675CCOCC 3214300 76300 1875000
17 5000 6750COOO 3214300 76300 1875000
If 5000 6750COOO 3214300 76300 1875000
19 5000 67500000 3214300 76300 1875000
2fl 50CO 63500000 321430", 7fc3DD _, , l»75noO
21 5000 67500000 3214300 76300 1875000
22 5000 67500000 3214300 76300 1875000
23 5000 67500000 3214300 76300 1875000
24 5000 67500000 3214300 76300 1875000
25 5QQQ 625QQC.D.Q 3214300 	 	 26300 	 .18.2500.0.
26 5000 6750COCO 2214300 76300 1875000
27 5000 6750COOO 3214300 76300 1875000
28 5000 67500000 3214300 76300 1875000
29 5000 67500000 3214300 76300 1875000
30 5000 625XJOOOO 3214300 	 26300 _ _ 1A2500Q
TOT 150000 2025000000 96429000 2289000 56250000
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
COLLARS PER TON OF COAL BURNED
HILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR XEMOVFD
PRCCES5 COST DISCOUNTED AT 11.6* TO INITIAL YEAR, DCLLARS
LEVEL1ZEC INCREASE (DECREASE) IN UNIT OPERATING CBS1 EOLIVALENT
COLLARS PER TON OF COAL BURIED
MILLS PER KILDWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
COLLARS PER TON OF SULFUR REMOVFO
0.0
C.O
0.0
0.0
C.O
C.O
C.O
0.0
	 fUQ .
C.O
C.O
C.O
0.0
TO CISCCUkTED
18314900
18045400
17775900
17506500
I 72370(10
0 18314900 10314900
0 18045400 36360300
0 17775900 54136200
0 17506500 71642700
n 17>^7nnfl uaololrvn
16967600 0 16967600 105847300
16698100 0 16698100 122545400
16428700 0 16428700 138974100
16159200 0 16159200 155133300
	 158.8.SJ10Q 	 D 	 15.8. .8.3 .BOO 	 12102.3100
15620300 0 15620300 186643400
15350800 0 15350800 201994200
15081400 0 150814CO 217075600
14811900 0 14811900 231887500
1454250Q 1 lt^43^nfi 3i.f,/.7nnnn
14273000
14003600
13734100
13464700
	 _131S52flfl_ _
12925800
12656300
12386800
12117400
	 11B42SCO_
11578500
11309000
11039600
10770100
	 10500200
432232700
4.48
1.92
21.34
188.83
135328300
PROCESS COST OVER I
5.07
2.17
24.15
213.69
0 14273COO 260703000
0 14003600 274706600
0 13734100 2b8440700
0 13464700 301905400
n I3i95?nn 31510Q6CO
0 12925800 328026400
0 12656300 340682700
0 12386800 353069500
0 12117400 365186900
0 llfi.479.nO. 377034800
0 11578500 3886133CO
0 11309000 399922300
0 11039600 410961900
0 10770100 421732000
0 432232700
0.0 4.48
0.0 1.92
0.0 21.34
0.0 168. B3
0 135328300
1FE OF POWER UNIT
0.0 5.07
0.0 2.17
0.0 24 . 1 5
0.0 213.69

-------
                                                              TABLE  C-13
LIME/L IMESTCNE SLUDGE  DISPOSAL  - IUCS PRflCESS,  200  Mh  NEW  UNJT,  3.5*  S, 7000 HRS CONSTANT ONSTfcAH, REGULATED CO. ECONOMICS
                                                FIXED  INVESTMENT!
                                                                       1369000
SULFUR BY-PRODUCT
REMOVED RATE.
YEARS ANNUAL
AFTER OPERA-
POKER TIDN,
UNIT KW-HR/
START KU
1 7000
2 7000
3 7000
4 7000
__i 	 20.0.0...
fc 7000
7 7000
8 7000
9 7000
_Jfl 	 ZflCfl —
11 7000
12 7000
13 7000
14 7000
_15 	 2CD.O. 	
_p~ 16 7000
0 17 7000
"^ 18 7000
19 7000
PCkER UNIT POhER UNIT BY EOtlVALENT
HEAT FUEL POLLUTION
REQUIREMENT, CONSUMPTION, CONTROL
MILLION BTU TOhS COAL PROCESS,
/YEAR /YEAR TONS/YEA*
12880000 613300 14600
12860000 613300 14600
12880000 613300 14600
126fiCOGO 613300 14600
	 l28.BCf)QQ 	 ^ 	 M33nO^ 	 . . Ifchfltl .
128BCOOO 613300 14600
12680000 613300 14600
12880000 613300 14600
1268COCG 613300 14600
12flBCO.DO — 6.133D.Q 14600
12860000 613300 14600
12860000 613300 14600
126800CO 613300 14600
12880000 613300 14600
IJflflOfJfiQ 1) 1 3^f)Q 14 ft (ID
12880000 613300 14600
12880000 613300 14600
12880000 613300 14600
12880000 613300 14600
TONS/YEAR

WASTE
SOLIDS
283500
283500
283500
283500
	 2B35QO.
283500
283500
283500
283500
_ 2B350Q
283500
283500
283500
283500
_ 2B350.0.
283500
283500
283500
263500
_2Q 	 20.0.0. 	 12flB.DD.DO. 	 t,133HQ 	 16,6.00 	 2B35.D.Q 	
21 7000
22 7000
23 7000
24 7000
25 -20.QQ
26 7000
27 7000
28 7000
29 7000
_30 	 20.0.0.--
TOT 210000
12880000 613300 14600
12880000 613300 14600
12B8COOO 613300 14600
12880000 613300 14600
_12£BOQOO 	 6.133DO 	 	 libQD 	
12660000 613300 14600
12880000 613300 14600
12860000 613300 14600
12880000 613300 14600
283500
283500
283500
283500
	 2B350Q_
283500
283500
283500
283500
TOTAL
OP. COST
INCLUDING
NET REVENUE. REGULATED
»/TON

WASTE
SOLIDS
0.0
0.0
0.0
c.o
	 C..Q 	
0.0
0.0
0.0
0.0
{}..£
0.0
0.0
0.0
0.0
0-0
0.0
c.o
0.0
0.0
	 0-Q 	
0.0
0.0
0.0
0.0
R01 FOR
POWER
COMPANY,
t/YEAR
4259000
4221300
4183700
4146100
T ,4108400
4070800
4033200
3995500
3957900
^*JPD30D
3882600
3845000
3807400
3769700
17^2110
3694500
3656800
3619200
3581600

TOTAL
NET
SALES
REVENUE.
t/YEAR
0
0
0
0
A
0
0
0
0
Q
0
0
0
0
Q
0
0
0
0
	 35.43200. 	 fl_
3506300
3468700
3431000
3393400
	 C..O. 	 _33S5flDO_
0.0
c.o
0.0
0.0
3318100
3280500
3242900
3205200
0
0
0
0
Q
0
0
0
0
NET ANNUAL
CUMULATIVE
INCREASE NET INCREASE
(DECREASE)
IN COST OF
PL] HER ,
$
4259000
4221300
4183700
4146100
4J 08400
4070800
4033200
3995500
3957900
332Q300
(DECREASE 1
IN COST OF
POHER,
$
4259000
6480300
12664000
16810100
20 Q i fl^nn
24989300
29022500
33018000
36975900
<.nRQ*.?nn
38826CO 44778800
3845000
3807400
3769700
32321QQ
3694500
3656800
3619200
3581600
48623800
52431200
56200900
j- g q -, T rifi f\
63627500
67284300
70903500
74485100
	 3S4.33CQ 	 2B02SOOO
35063CO
3468700
3431000
3393400
81535300
85004000
88435000
91828400
335.5fl.QO _S51£4.2QO
3318100 98502300
3280500
3242900
3205200
101782800
105025700
108230900
	 12flfl£HDD 	 M.33DQ 	 L6&QD 	 2B.35.QQ 	 Q^Q 	 31 636.00 	 D 	 3JjbJ.fi .Ofl 	 11133.851)0
386400000 18399000 436000
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING




PROCESS COST
LEVEL1ZED




DOLLARS PER TON OF COAL BURNED
WILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
COLLARS PER TON OF SULFUR REMOVED
8505000
COST










DISCOUNTED AT 11.6% TO INITIAL YEAR, DOLLARS
INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO
COLLARS PER TON OF COAL BURNED
MILtS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REHDVED




111398500

6.05
2.65
28.83
254.33
33019700
DISCOUNTED PROCESS COST OVER




6.49
2.84
30.89
272.44
0

0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
111398500

6.05
2.65
28.83
254.33
330197CO
POHER UNIT
6 .49
2.84
30.89
272.44













-------
                                                             TABLE C-14

LIME/LIMESTONE SLUDGE DISPOSAL - IOCS PROCESS, 200 MM MEW UNIT. 3.5* S, 5000 MRS CONSTANT ONSTEAH. REGULATED CO.  ECONOMICS
                                                FIXED  INVESTMENT:
                                                                        721*000
YEARS ANNUAL POWER UNIT
AFTER DPERA- HEAT
POWER TION, REQUIREMENT,
UNIT KW-HR/ MILLION BTU
START KW /YEAR
1
2
3
4
6
7
6
9
_Jfl 	
11
12
13
14
16
17
18
19
_2Q 	
21
22
23
26
27
28
29
.30. 	
5000
5000
5000
5000
920COOO
9200000
9200000
9200000
. 9200000
5000 9200000
5000 9200000
5000 9200000
5000 9200000
.5000. 	 S2DDQDfl 	
5000 920COOQ
5000 9200000
5000 9200000
5000 9200000
.50.00. 	 9200000
5000
5000
5000
5000
.50.00. 	
5000
5000
5000
5000
920COOO
9200000
9200000
9200000
	 3200000 	
9200000
9200000
920COOO
9200000
qjnnnnn
5000 9200000
5000 920COQO
5000 9200000
5000 9200000
.5.000. 	 9.200000 	
SULFUR
REMOVED
POWER UNIT BY
FUEL POLLUTION
CONSUMPTION, CONTROL
TONS COAL PROCESS,
/YEAR TONS/YEA*
438100
438100
438100
438100
436100
438100
438100
438100
	 438-100 	
438100
438100
438100
438100
4381QQ
10400
10400
10400
10400
BY-PRODUCT
RATE.
EQUIVALENT
TENS/YEAR
WASTE
SOLIDS
202500
202500
202500
202500
2D2500
TOTAL
OP. COST
INCLUDING
NET REVENUE, REGULATED TOTAL
I/TON ROI FOR NET
POWER SALES
WASTE COMPANY. REVENUE,
SOLIDS */YEAR t/YEAR
0.0
0.0
0.0
0.0
c«o
10400 202500 0.0
10400 202500 0.0
10400 202500 0.0
10400 202500 0.0
	 iQAOO 	 202500 	 £-0 	
10400 202500 C.O
10400 202500 C.O
10400 202500 0.0
10400 202500 0.0
in^nn 202500 o.o
438100 10400 202500
438100 10400 202500
438100 10400 202500
438100 10400 202500
	 &3B-IOQ 	 10&00 	 202500 	
438100 10400 202500
438100 10400 202500
438100 10400 202500
438100 10400 202500
,438.100-^^ 	 lOAnn 2025nn
438100
438100
438100
438100
	 A3filQO 	
10400
10400
10400
10400
	 10400 	
c.o
0.0
0.0
0.0
	 C-0 	
0.0
c.o
0.0
0.0
c^o
202500 C.O
202500 C.O
202500 0.0
202500 C.O
	 20,2500 	 O.Q 	
4075600
4038000
4000300
3962700
	 332510 Q_ —
0
0
0
0
0
3887400 0
3849800 0
3812200 0
3774500 0
	 3J3J>9J)0 	 fl_
3699300 0
3661600 0
3624000 0
3586400 0
	 35.4B200 	 Q
3511100
3473500
3435800
3398200
	 3360600 	
3322900
3285300
3247700
3210000
3I1240Q
3134800
3097100
3059500
3021900
	 2S.B&20Q 	
0
0
0
0
0
0
0
0
o
0
0
0
0
	 o_
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE) (DECREASE)
IN COST OF IN COST OF
POWER, POWER,
* »
4075600
4038000
4000300
39627CO
-3323100
4075600
8113600
12113900
16076600
3887400 23889100
3849800 27738900
3612200 31551100
3774500 35325600
	 333f>SCQ 	 32Dt2500
3699300 42761800
3661600 46423400
3624000 50047400
3586400 53633800
	 3568.300 	 531fl2500
3511100 60693600
3473500 64167100
3435800 67602900
3398200 71001100
	 aafiQfcOQ 	 243&1300
3322900 77684600
3285300 80969900
3247700 84217600
3210000 87427600
3122600 qfif-nnnnn
3134800
3097100
3059500
3021900
93734800
96831900
99891400
102913300
TOT  150000    27600COOO     13143000
   LIFETIME AVERAGE INCREASE (DECREASE1
                                TON
                                             312000        6075000
                                        IN UNIT OPERATING COST
                    DOLLARS PER TON OF COAL BURNED
                    HILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6* TO INITIAL YEAR, DOLLARS
105897500

    8.06
    3.53
   38.37
  339.42
31497700
                                                                                                            1058975CO
   IEVEL1ZEC INCREASE IDECREASE) IN UNIT OPERATING COST EQUIVALENT TO DISCOUNTED PROCESS COST OVER LIFE OF
                    COLLARS PER TON OF COAL BURNED                                        8.66
                    MILLS PER KILOWATT-HOUR                                               3.79
                    CENTS PER MILLION BTU HEAT INPUT                                     41.25
                    DOLLARS PER TON OF SULFUR REMOVED                                   364.98
0.0
0.0
0.0
0.0
0
FE OF
0.0
0.0
0.0
0.0
8,06
3.53
38.37
339.42
31497700
POWER UNIT
8 .66
3.79
41 .25
364.98

-------
                                                            TABLE  C-15
LIME/L IMESTCNE  SLUDGE  DISPOSAL  -  1UCS PROCESS, 500 MW NEW UNIT, 3.5* S, 70CO MRS CONSTANT  ONSTEAM, REGULATED  CO.  ECCNPHICS
                                               FIXED  INVESTMENT:
                                                                      11159COO
1
SULFUR BY-PRODUCT
REMOVED RATE,
YEARS ANNUAL POKER UNIT POWER UNIT BY EQUIVALENT
AFTEK OPERA- HEAT FUEL POLLUTION TCNS/YEAR
POKER T10N, REQUIREMENT, CONSUMPTION. CONTROL
UNIT KW-HR/ MILLION BTU TONS COAL PROCESS, WASTE
START Kk /YEAR /YEAR TONS/YEA* SCL1DS
1 7000 31500000 1500000 35600 693000
2 7000 31500000 1500000 35600 693000
3 7000 3150COCO 1500000 35600 693000
4 7000 31500000 1500000 35600 693000
5 J2CDO ,_J31fiflCDCO ,. 1500QDQ. ^ __ 3560D ^ . 693000
6 7000 31500000 1500000 35600 693000
7 7000 31500000 1500000 35600 693000
8 7000 31500000 1500000 35600 693000
9 7000 31500000 1500000 35600 693000
, Jf) 	 7000 T. 3J5DPOOQ ^T. 150000.0 _„ 35*00 . 493QQQ
11 7000 31500000 1500000 35600 693000
12 7000 31500000 1500000 35600 693000
13 7000 3150COCO 1500000 35600 693000
14 7000 31500000 1500000 35600 693000



NET REVENUE,
$/TCN

HASTE
SCLIDS
0.0
c.o
0.0
c.o
0-0 , --,
0.0
0.0
0.0
0.0
0-0
0.0
c.o
c.o
0.0
-P~ 1.5 2HOO 315£CO£0. J5QOQQQ 35600 6.93QQO C-G
g 16 7000 31500000 1500000 3560C 693000
17 7000 31500000 1500000 35600 693000
16 7000 3150COOO 1500000 35600 693000
19 7000 3150COCO 1500000 35600 693000
20 7000 3I5DODOD I5onnpo 3.56.QQ 6S^Pon
21 7000 3150COOO 1500000 35600 693000
22 7000 31500000 1500000 35600 693000
23 7000 31500000 1500000 35600 693000
24 7000 31500000 1500000 35600 693000
25. 7QOO 11500000 _ __J5nnDQO 35&QQ ._, .„ *,93000,
26 7000 3150COOO 1500000 35600 693000
27 7000 3150GOOO 1500000 35600 693000
28 7000 31500000 1500000 35600 693000
29 7000 31500000 1500000 35600 693000
c.o
0.0
0.0
0.0
_ _- C..D
0.0
0.0
0.0
0.0
0 ^fl
0.0
c.o
0.0
0.0
_3Q 	 ZD.CQ 	 315D.QO.QD. 	 15QO.JJQD. 	 356.dC 	 433QQO 	 0-fl 	
TOT 210000 945CGCOCO 45000000 1068000 20790000
LIFETIME AVERAGE INCREASE (DECREASE! IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT 11.6* TO INITIAL YEAR, DOLLARS
LEVELI2EC INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO
COLLARS PER TON OF CRAL BURNED
HILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
COLLARS PER TON OF SULFUR REMOVED







TOTAL
DP. COST
INCLUDING
REGULATED
ROf FOR
POHER
COMPANY,
*/YFAR
6377900
6323500
6269000
6214500
6.1 600IDO
6105500
6051000
5996500
5942000
*»fl fi "7*iOQ
5833100
5778600
5724100
5669600
«,*,!«; inn
5560600
5506100
5451600
5397100
5362600
5288200
5233700
5179200
5124700
50 7(12 Qfl
5015700
4961200
4906700
4852200



KlTAL
NET
SALES
REVENUE,
S/YEAR
0
0
0
0

0
0
0
0
fl
0
0
0
0

0
0
0
0
	 B
0
0
0
0
Q
0
0
0
0


NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE ) (DECREASE )
IN COST PF IN COST OF
POWER, POWER,
1 $
6377900 6377900
6323500 12701400
6269000 18970400
6214500 25184900
ftjtOOin 31344900
6105500 37450400
60510CO 43501400
5996500 49497900
5942000 55439900
5887500 6132240°
5833100 67160500
5778600 72939100
5724100 78663200
5669600 84332800
~S£1510Q fl.3S£23flO
5560600 95508500
5506100 101014600
5451600 106466200
5397100 111863300
-^ ,^347600 ^117205900
5288200 122494100
5233700 127727800
5179200 132907000
5124700 138031700
5Q20.2QQ 1431Q13HO
5015700 148117600
4961200 153078800
4906700 157985500
4852200 162837700
	 4232ICQ 	 0 	 429220Q 	 16.2635400
167635400

3.73
1.60
17.74
156.96
49563800
DISCOUNTED PROCESS COST OVER




3.98
1.71
18.96
167.73
0

0.0
o.n
0.0
0.0
0
LiFE OF
O.C
o.c
0.0
0.0
167635400

3.73
1 .60
17.74
156.96
49563800
POWER UNIT
3.98
1.71
18.96
167.73

-------
                                                               TABLE C-16
LIME/LIMESTONE SLUDGE DISPOSAL  - IUCS  PROCESS, 500 HW NEW UNIT. 3.51 S, 5000 MRS CONSTANT ONSTEAM  REGULATED CO. ECONOMICS
                                                 FIXED INVESTMENT:  s
                                                                        10719000
YEARS ANNUAL
AFTER OPERA-
POWER TIDN,
UNIT KW-HR/
START KW
1 5000
2 5000
3 5000
4 5000
	 i____5flflO_
6 5000
7 5000
8 5000
9 5000
_10____5fl.QO_
11 5000
12 5000
13 5000
14 5COO
-fc- _a5____5HDO_
5 16 5000
17 5000
18 5000
19 5000
2,0 _50.QO,
21 5000
22 5000
23 5000
24 5000
25 "ionn
26 5000
27 5000
28 5000
29 5000
30 5ilOO
TOT 150000
LIFETIME
PROCESS COST
LEVEIIZEC
SULFUR BY-PRODUCT
REMOVED RATE,
POWER UNIT POWER UNIT BY EQUIVALENT
HEAT FUEL POLLUTION TENS/YEAR
REQUIREMENT, CONSUMPTION, CONTROL
MILLION BTU TONS COAL PROCESS. WASTE
/YEAR /YEAR TONS/YEA* SOLIDS
22500000 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
	 ?25000QO______Jn71*OiJ . 75400 495.000
22500000 1071400 25400 495000
2250COOO 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
	 '310.0.QQQ 	 . _10J14QO „ - 25400 . ^ 455000
2250COCO 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
	 22500.000 	 1QZ140D 	 25400 	 4354100 	
22500000 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
225000.00 1011400 ^ 	 25400 	 . .495000 	
2250COCO 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1021400 	 25400- , 495non
22500000 1071400 25400 495000
2250COCO 1071400 25400 495000
22500000 1071400 25400 495000
22500000 1071400 25400 495000
225QQuDQi_ 1071400 	 25400 4S50QQ
615COCOCO 32142000 762000 14850000
AVERAGE INCREASE (DECREASEI IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
HILLS PER KHOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
DISCOUNTED AT 11.6* TO INITIAL YEAR, DOLLARS
INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO
COLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
COLLARS PER TON OF SULFUR REMOVED
TOTAL
OP. COST
INCLUDING
NET REVENUE. REGULATED
t/TCN ROI FOR
POWER
HASTE COMPANY.
SOLIDS I/YEAR
0.0
0.0
0.0
0.0
c.o
0.0
0.0
0.0
	 	 fl.,0 	
0.0
c.o
0.0
0.0
c.o
c.o
0.0
0.0
0.0
0.0
0.0
0.0
o-n
0.0
c.o
0.0
0.0
	 Q.O 	
5946200
5891700
5837200
5782700
5673700
5619300
5564800
5510300
54SSBQQ
5401300
5346800
5292300
5237800
5128800
5074400
5019900
4965400
_ 421flaQQ_ .
4856400
4801900
4747400
4692900
-^4638400
4583900
4529500
4475000
4420500
154682700
4.81
2.06
22.92
203.00
45980100
DISCOUNTED PROCESS COST OVER
5.17
2.22
24.62
218.12
TOTAL
NET
SALES
REVENUE,
t/YEAR
0
0
0
0
0
0
0
0
fl_
0
0
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
L 1 FE OF
0.0
0.0
0.0
0.0
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
•DECREASE) (DECREASE)
IN COST OF IN COST OF
POWER, POWER,
5946200
5891700
5837200
5782700
	 5Z2a2Cfl 	
5673700
5619300
5564800
5510300
5455800
5946200
11837900
17675100
23457800
34859700
40479000
46043800
51554100
51nnoQnn
5401300 62411200
5346800 67758000
5292300 73050300
5237800 78288100
	 51B3300 	 83421600
5128600 86600200
5074400 93674600
5019900 98694500
4965400 103659900
	 4210300 	 AOflSlOaOO
4856400
4801900
4747400
4692900
- _4fi3B400 	
4583900
4529500
4475000
4420500
	 436600Q 	
154682100
4.81
2.06
22.92
203.00
45980100
POWER UNIT
5.17
2.22
24 .62
216.12
113427200
118229100
122976500
127669400
136891700
141421200
145896200
150316700
-1546&2JOO

-------
                                                            TABLE C-17
L1ME/LIHESTCNE  SLUDGE  DISPOSAL  -  IUCS PROCESi,  1500 MW NEW UNIT, 3.5* S, 7COC HRS CONSTANT  ONSTEAM. REGULATED CO.  ECONOMICS
                                               FIXED  INVESTMENT:
                                                                      21415COO
*
SULFUR BY-PRODUCT
REMOVED RATE,
YEARS ANNUAL POKER UNIT POkER UNIT BY fCUIVALENT
AFTER OPERA- HEAT FUEL POLLUTION TONS/YEAR
POWER TIUN, REOUIREMENT, CONSUMPTION, CONTROL
UNIT KW-HR/ MILLION BTU TONS COAL PROCESS, WASTE
START KH /YEAR /YEAR TONS/YEAR SCLIDS
1 7000 94500000 4500000 106800 2075500
2 7000 94500000 4500000 106800 2075500
3 7000 94500000 4500000 106800 2075500
4 7000 94500000 4500000 106800 2075500
S. , 7POW 	 945DGGOG ._ ^450000(1 	 __lC6fiOO 	 	 ?f)755f)0
6 7000 94500000 4500000 10680C 2075500
7 7000 94500000 4500000 106800 2075500
E 7000 94500000 4500000 106800 2075500
9 7000 9450COCO 4500000 106800 2075500
.10 	 200Q 	 S45QODDQ_ 	 45QQQO.Q 	 	 10.6800 	 	 2035500
11 7000 9450COCO 4500000 10680C 2075500
12 7000 94500000 4500000 106800 2075500
13 7000 9450COOO 4500000 10680C 2075500
14 7000 94500000 4500000 106800 2075500
*- _15_ _2flflfl 	 S450COflO_ 	 4500flflfl_ 	 1068flC 	 	 20355QC_
g 16 7000 94500000 4500000 106800 2075500
17 7000 9450COOO 4500000 106800 2075500
18 7000 94500000 4500000 106800 2075500
19 7000 94500000 4500000 10680C 2075500
_2D 	 20.00. 	 9450.00.00 	 45QQOQQ 	 10.680,0 	 2025500 	
21 7000 9450COCO 4500000 10680C 2075500
22 7000 94500000 4500000 106800 2075500
23 7000 94500000 4500000 106800 2075500
24 7000 94500000 4500000 106800 2075500
25 3000. 945DOQOQ 4500000 ._ .106.8.00 . 	 2075500 _.
26 7000 94500000 4500000 106800 2075500
27 7000 94500000 4500000 106800 2075500
28 7000 94500000 4500000 106800 2075500
29 7000 9450COOO 4500000 106800 2075500



NET REVENUE.
I/TON

WASTE
SCLIDS
0.0
c.o
c.o
c.o
fl _fl
0.0
0.0
0.0
0.0
	 	 c..c_
0.0
c.o
c.o
c.o
C-Q
c.o
c.o
0.0
c.o
	 0-Q 	
0.0
0.0
c.o
0.0
	 D..C
c.o
0.0
0.0
c.o
30 2QOQ S45£CfiDO_ _ 4^00^00 ., . lOfcPO" . 2P2550Q. *>-n
TOT 210000 2835000000 135000000 3204000 62265000
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
COLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT 11.6% TO INITIAL YEAR, DOLLARS
LEVELIZED INCREASE (DECREASE) IN UNIT OPERATING COST ECIIVALENT TO
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOhATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED







TOTAL
OP. COST
INCLUDING
REGULATED TOTAL
R01 FOR NET
POWER SALES
COMPANY, REVENUE,
»/YF.AR $/YEAR
12605800 0
12508700 0
12411600 0
12314500 0
1 ?2 1 *74flf) n
12120300 0
12023200 0
11926100 0
11829000 0
	 1123190Q 	 _ 0
11634800 0
11537700 0
11440700 0
11343600 0
	 112445130 	 	 0
11149400 0
11052300 0
10955200 0
10858100 0
	 102 61 QUO 	 0_
106639CO 0
10566800 0
10469700 0
10372600 0
	 102255CQ 	 	 0_.
10178400 0
10081300 0
9984200 0
9887100 0
	 92SOJLOO 	 _ _fl_
335937400 0

2.49 0.0
1.07 0.0
11.85 0.0
104.85 O.C
98617900 0
DISCOUNTED PROCESS COST OVER LIFE OF




2.64 0.0
1.13 O.C
12.57 O.C
111.24 0.0


NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE) (DECREASE)
IN COST C1F IN COST OF
POWER, POWER,
$ 1
12605600 126058CO
12508700 25114500
12411600 37526100
12314500 49840600
12Z12&CH £2054000
12120300 74178300
12023200 86201500
11926100 98127600
11829000 109956600
	 1123.1900 _ 121688500
11634800 133323300
11537700 144861000
11440700 156301700
11343600 167645300
1124650Q 12fiB9,lfiOO
11149400 190041200
11052300 201093500
10955200 212048700
10858100 222906800
	 1Q2610QQ 	 233662800
J0663SOO 244331700
10566800 254898500
104697CO 265368200
10372600 275740800
	 1Q2255QQ- _2fi.6.0,16300
10178400 296194700
10081300 306276000
9984200 316260200
9887100 326147300
9390100 335S32400
335937400

2.49
1.07
U.85
104.85
98617900
POWER UNIT
2.64
1 .13
12.57
111.24

-------
^O
                                                               TABLE  C-18

    LIME/LIMESTONE SLUDCf DISPOSAL  -  IUCS  PROCESS.  1500  NW NEW UNIT 3.5* S. 5000 HRS CONSTANT ONSTEAH REGULATED CC. ECONOMICS
                                                     FIXED INVESTMENT:  $
20282000
YEARS ANNUAL
AFTER OPERA-
POWER TION,
UNIT KW-HR/
START KW
1 5000
2 5000
3 5000
4 5000
	 5 	 5000 	
6 5000
7 5000
t 5000
9 5000
JD 5OQQ
11 5000
12 5000
13 5000
14 5000
_15 	 5DOO__.
16 5000
17 5000
16 5000
19 5000
20 500Q
21 5000
22 5000
23 5000
24 5000
P £ ^r fin
26 5000
27 5000
26 5000
29 5000
POWER UNIT
HEAT
RETIREMENT,
MILLION BTU
/YEAR
67500000
67500000
67500000
675000CO
. _fc250DQDQ_
67500000
67500000
6750COOO
67500000
-tJMlLDDfl-
67500000
67500000
67500000
6750COOO
. fc25DQQQQ_
6750COCO
67500000
67500000
67500000
6 35 DC LCD
6750COCO
67500000
67500000
67500000
t35DQCCD
6750COOO
67500000
67500000
67500000
30 5QOQ 62500000
POWER UNIT
SULFUR
REMOVED
BY
FUEL POLLUTION
CONSUMPTION,
TONS COAL
CONTROL
PROCESS,
/YEAR TONS/YEA*
3214300
3214300
3214300
3214300
_321&3QQ_ _
3214300
3214300
3214300
3214300
^? 1 4^00
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3P143DO
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
76300
76300
76300
76300
	 263QO
76300
76300
76300
76300
26300
76300
76300
76300
76300
	 263. QQ—
76300
76300
76300
76300
_2£3Q£
76300
76300
76300
76300
	 2£30fl_
76300
76300
76300
76300
32143HO- 	 2630.0-
BY-PRODUCT
RATE.
EQUIVALENT
TONS/YEAR

WASTE
SOLIDS
1482500
1482500
1482500
1482500
_ . 14fl250Q
1482500
1482500
1482500
1482500
1 46. 25.00
1482500
1482500
1482500
1482500
1 4 fl 7*2 (10
1482500
1482500
1482500
1482500
1 6 R p*>nn
1482500
1482500
1482500
1482500
	 14B25PO _
1482500
1482500
1482500
1482500
	 1482500 	
NET REVENUE
t/TDN

WASTE
SOLIDS
0.0
0.0
G.O
0.0
0.0
0.0
0.0
0.0
0.0
nun
0.0
0.0
0.0
0.0
fl-C
0.0
0.0
0.0
0.0
_ c.n
0.0
0.0
0.0
0.0
	 	 C..O 	
c.o
0.0
0.0
0.0
TOTAL
OP. COST
INCLUDING
. REGULATED
ROI FOR
POWER
COMPANY.
»/YEAR
11328900
11231800
11134700
11037600
TOTAL
NET
SALES
REVENUE.
S/YEAR
0
0
0
0
1 OS 40. SO 0— n
10843400
1 {(746300
10649200
10552200
0
0
0
0
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE)
IN COST OF
POWER,
*
11328900
11231800
11134700
11037600
(DECREASE)
IN COST OF
POWER,
i
11328900
22560700
33695400
44733000
1Q34Q5DQ 	 55623500
10843400 66516900
10746300
10649200
10552200
77263200
67912400
98464600
__1Q45510Q_. n iD4«>5inn inn<»i a-»nn
10358000
10260900
10163800
10066700
9969.600
9872500
9775400
9678300
9581200
Q&flii inn
9387000
9289900
9192800
9095700
0
0
0
0
fl
0
0
0
0
o
0
0
0
0
10358COO 119277700
10260900
10163800
10066700
129538600
139702400
149769100
22626QQ 15S23&2QO
9872500 169611200
9775400
9678300
9581200
179386600
189064900
198646100
9AB41QO 2AB130200
9387000 217517200
9289900
9192800
9095700
226807100
235999900
245095600
., ... ..&998&OQ _ n nooBAnn yc.t.nnt.inn
8901600
8804500
8707400
8610300
0
0
0
0
89016CO
8804500
8707400
8610300
262995800
271800300
280507700
289118000
— Q..0. - £5.1.32.00- _ Q 85132DQ 293631200
    TOT  150000   2025CCCOOO     96429000       2289000       44475000                    297631200          0    297631200
       LIFETIME AVERAGE INCREASE (DECREASE! IN UNIT OPERATING COST
                        DOLLARS PER TON OF CDAL BURNED                                        3.09        0.0          3.C9
                        HILLS PER KILOWATT-HOUR                                               1.32        0.0          1.32
                        CENTS PER MILLION BTU HEAT  INPUT                                     14.70        0.0         14.70
                        DOLLARS PER TON CF SULFUR REMOVED                                   130.03        0.0        130.03
    PROCESS COST DISCOUNTED AT  11.6* TO INITIAL YEAR, DOLLARS                            88019300           0     B8019300
       IEVELIZEC INCREASE (DECREASEI  IN UNIT OPERATING CCST EBL1VALENT TO DISCOUNTED PRPCESS COST OVER LIFE  OF  PUWER  UNIT
                        COLLARS PER TON OF CDAL BURNED                                        3.30        0.0          3.30
                        MILLS PER KILOWATT-HOUR                                               1.41        0.0          1.41
                        CENTS PER MILLION BTU HEAT  INPUT                                     15.71        0.0         15.71
                        DOLLARS PER TON OF SULFUR RFMOVED                                   138.99        0.0        138.99

-------
                                                            TABLE C-19



LIME/LIMESTONE SLUDGE  DISPOSAL  - CHEHF1X  PROCESS,  200  KH  NEW UNIT, 3.5» S. 7000 HRS CONSTANT ONSTEAH,  REGULATED CO. ECONOMICS
                                                FIXED  INVESTMENTS  *
9432000
SULFUR
REMOVED
YEARS ANNUAL POKER UNIT POKER UNIT BY
AFTER OPERA- HEAT FUEL POLLUTION
PC1WER T10N, RECUIREMENT, CONSUMPTION, CONTROL
UNIT KW-HR/ MILLION BTU TONS COAL PROCESS,
START KW /YEAR /YEAR TONS/YEA*
1 7000 12880000 613300 1460C
2 7000 12680000 613300 14600
3 7000 12680000 613300 14600
4 7000 12860000 613300 14600
	 i 	 2000 	 12BaOQBQ_ 	 613300 	 14600 	
6 7000 12880000 613300 14600
7 7000 12860000 613300 14600
f> 7000 12660000 613300 14600
9 7000 12880000 613300 14600
_10 	 7POO_^^128flOODO 	 ^ 	 613200 	 	 14600 	 ,
11 7000 12680000 613300 14600
12 7000 12880000 613300 14600
13 7000 12860000 613300 14600
14 7000 12880000 613300 14600
_15 	 2000 	 	 12flflCGQQ_ 	 6133OQ 	 14600 	
16 7000 12880000 613300 14600
17 7000 12860000 613300 14600
16 7000 12880000 613300 14600
19 7000 12880000 613300 14600
20- -2000- 12flB..CQOQ_ 	 613300 	 14600 	
21 7000 12880000 613300 1460C
22 7000 12880000 613300 14600
23 7000 12880000 613300 14600
24 7000 12860000 613300 14600
2i 2000- 12flfiCQOQ 	 	 613300 	 ,- J46QO
26 7000 12880000 613300 14600
27 7000 12880000 613300 14600
26 7000 12B8COOO 613300 14600
29 7000 1288COOO 613300 14600
30 2000 12.il8.OQQQ 613300,- 	 --1&6.QQ 	
TOT 210000 3664CCOCO 16399000 438000
BY-PRODUCT
RATE,
EQUIVALENT
TONS/YEAR

WASTE
SOL IDS
290500
290500
290500
290500
	 290500-
290500
290500
290500
290500
_ 2905.00 _
290500
290500
290500
290500
	 290500-
290500
290500
290500
290500
_ 290500-
290500
290500
290500
290500
_ 290500-
290500
290500
290500
290500
_ 290500-
8715000


NET REVENUE,
S/TON

WASTE
SOLIDS
0.0
0.0
0.0
0.0
c c
0.0
0.0
0.0
0.0
f] »n
c.o
0.0
0.0
0.0
	 C..C-
0.0
0.0
0.0
0.0
D-0
G.O
0.0
0.0
0.0
	 C-D 	
0.0
0.0
0.0
0.0
£ Q

TOTAL
OP. COST
INCLUDING
REGULATED
ROI FOR
POWER
COMPANY.
J/YEAR
5404600
5355900
5307100
5258400
5209*10 ._
5)60900
5112100
5063400
5014600
&Q &*» Qfifl
4917200
4868400
4819700
4770900
. 	 4222200-
4673400
4624700
4575900
4527200
44 78.5.00.
4429700
4381000
4332200
4283500
. 	 4234200. 	
4186000
4137200
4088500
4039700
. 	 3991000 	
140934100


TOTAL
NET
SALES
REVENUE,
$/YEAR
0
0
0
0

0
0
0
0
_ 0
0
0
0
0
	 o
0
0
0
0
	 Q
0
0
0
0
	 fl
0
0
0
0
_ Q
0

NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE) (DECREASE)
IN COST OF IN COST OF
POWER, POWER,
$ 1
5404600 54046CO
5355900 10760500
5307100 16067600
5256400 21326000
52096QQ 265356UO
5160900 31696500
5112100 36608600
5063400 41872000
5014600 46886600
4965900 51H525CO
4917200 56769700
4868400 61638100
4819700 66457800
4770900 71228700
42222QQ 25950900
4673400 8C6243QO
4624700 85249000
4575900 89824900
4527200 94352100
	 4A2fi500 _ 98.6.30600
4429700 103260300
4361000 107641300
4332200 111973500
4283500 116257000
4234.200 120491200
4186000 124677700
4137200 U8814900
4088500 132903400
4039700 136943100
3991000 140934100
140934100
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
HILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED








PROCESS COST DISCOUNTED AT 11.6% TO INITIAL YEAR, DOLLARS
LEVEL12EC INCREASE (DECREASE) IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
HILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
EQUIVALENT TO




7.66
3.36
36.47
321.77
41840600
DISCOUNTED PROCESS COST OVER




8.22
3.60
39.14
345.22
0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
7.66
3.36
36.47
321 .77
41840600
POWER UNIT
8.22
3 .60
39.14
345.22

-------
LIME/LIMESTONE SlUOCE  C ISPDSAL  - CHEMF1X PROCESS. 200  fW  NEW  UNIT.  3.5* S. 5000 MRS CONSTANT DNSTEAM,  REGULATED CO. ECONOMICS
                                                 FIXED  INVESTMENT:   *
                                                                          9214000
SULFUR
REMOVED
YEARS ANNUAL POWER UNIT POKER UNIT BY
AFTER OPERA- HEAT FUEL POLLUTION
POKER T10N, REQUIREMENT, CONSUMPTION, CONTROL
UNIT KW-HR/ MILLION BTU TONS COAL PROCESS,
START KW /YEAR /YEAR TONS/YEA*
I 5000 920COOO 438100 10400
2 5000 9200000 438100 10400
3 5000 9200000 438100 10400
4 5000 9200000 438100 10400
5 50QQ 9POQODD n 43B1QO 1Q40D
6 5000 9200000 438100 10400
7 5000 9200000 438100 10400
8 5000 9200000 438100 10400
9 5000 9200000 438100 10400
10 . soon , 9?pooop _, ^ 4^B}QO 10400
11 5000 9200000 438100 10400
12 5000 9200000 438100 10400
13 5000 920COOO 436100 10400
14 5000 9200000 438100 10400
.1.5 	 5000 	 SiDBQflQ- 	 43.fl.taO _ 	 10400 	
It 5000 9200000 438100 10400
17 5000 9200000 438100 10400
18 5000 9200000 438100 10400
19 5000 9200000 438100 10400
20 SHOO. 92DOQDQ 43B100 ,in4nn
21 5000 92000CO 438100 10400
22 5000 9200000 438100 10400
23 5000 9200000 438100 10400
24 5000 9200000 438100 10400
2.5 5000 220CCCQ 43&10.Q 	 	 10400 	
2t 5000 9200000 438100 10400
27 5000 9200000 438100 10400
28 5000 9200000 438100 10400
29 5000 9200000 438100 10400
30 , SDCO 	 22.01! 000 	 43A100 	 10400 	
TOT 150000 27600COOO 13143000 312000
BY-PRODUCT
RATE,
EQUIVALENT
TONS/YEAR

WASTE
SCLIDS
507500
507500
501500
507500
	 50250.0.
507500
507500
507500
507500
	 502500
507500
507500
507500
507500
	 502500.
507500
507500
507500
507500
	 5025QQ
507500
507500
507500
507500
502500 	
507500
507500
507500
507500


NET REVENUE.
S/TDN

WASTE
SCLIOS
C.O
c.o
C.O
c.o
_ 0..0
0.0
0.0
0.0
0.0
G..Q
0.0
c.o
0.0
c.o
	 fl.,0
0.0
0.0
0.0
c.o
0-0 .. _ .
0.0
0.0
0.0
0.0
	 £..0- _
0.0
c.o
0.0
c.o
	 502500 	 C-C 	
15225000

TOTAL
OP. COST
INCLUDING
REGULATED TOTAL
R01 FDR NET
POWER SALES
COMPANY. REVENUE,
t/YEAR t/YEAR
5226100 0
5177400 0
5128600 0
5079900 0
5031100. 	 fl_
4982400 0
4933700 0
4884900 0
4836200 0
426240Q 	 0_
4738700 0
4689900 0
4641200 0
4592400 0
	 4543200- 	 0
4495000 0
4446200 0
4397500 0
4348700 0
	 43QOOQQ_ , _0
4251200 0
4202500 0
4153700 0
4105000 0
_ 4056300- 0
4007500 0
3958800 0
3910000 0
3861300 0

NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE) (DECREASE)
IN COST OF IK COST OF
POWER, POWER,
* $
5226100 5226100
5177400 10403500
5128600 15532100
5079900 20612000
50.31100 _ 25fc431QO
4982400 30625500
4933700 35559200
4884900 40444100
4836200 45280300
42B740Q 50067100
47387CO 54806400
4689900 59496300
4641200 64137500
4592400 68729900
	 £542200 	 Z3223£CO
4495000 77768600
4446200 62214800
4397500 86612300
4348700 90961000
_430flOOO_ 	 2S2610CO
4251200 99512200
4202500 103714700
41537CO 107868400
4105000 111973400
4QSf)3DO 116029200
4007500 120037200
3958800 123996000
3910000 127906000
3861300 131767300
	 38.12.500 	 0 	 3 B. 12500 	 135S22BOO
135579800 0
135579800
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING COST
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED








PROCESS COST DISCOUNTED AT 11.6* TO INITIAL YEAR, DOLLARS
IEVEL1ZED INCREASE (DECREASE) IN UNIT OPERATING COS1
COLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
EQUIVALENT TO




10.32 0.0
4.52 0.0
49.12 0.0
434.55 0.0
40359100 0
DISCOUNTED PROCESS COST OVER LIFE OF




11.10 0.0
4.86 0.0
52.85 0.0
467.66 0.0
10.32
4.52
49.12
434.55
403591CO
POWER UNIT
11 .10
4.86
52.85
467.66

-------
                                                          TABLE C-21
LIME/LIMESTONE SLUDGE DISPOSAL - CHEHFIX PROCESS, 500 *W NEW  UNIT,  3.5*  S,  7000  HRS  CONSTANT  ONSTEAH  REGULATED  CO.  ECONOMICS
                                                FIXED INVESTMENT!
                                                                        13984000
YEARS ANNUAL
AFTER OPERA-
POWER TION,
UNIT KW-HR/
START KW
I
2
3
__5 	
6
7
8
9
_10 	
11
12
13
_15 	
16
17
18
19
20 _,
21
22
23
24
-25 	
26
27
28
29
_30 	
7000
7000
7000
7000
_2000_.
7000
7000
7000
7000
.2000—
7000
7000
7000
7000
.2OOO 	
7000
7000
7000
7000
JHOfl
7000
7000
7000
7000
2000.
7000
7000
7000
7000
SULFUR
REMOVED
POWER UNIT POWER UNIT BY
HEAT FUEL POLLUTION
REQUIREMENT, CONSUMPTION, CONTROL
MILLION BTU TONS COAL PROCESS,
/YEAR /YEAR TONS/YEA*
31500000 1500000
31500000 1500000
31500000 1500000
31500000 1500000
	 315COQOO_ .1500000 	
35600
35600
35600
35600
. _ 35600-
BY-PRODUCT
RATE,
EQUIVALENT
TONS/YEAR
WASTE
SOLIDS
710500
710500
710500
710500
21DSOD
31500000 1500000 35600 710500
31500000 1500000 35600 710500
31500000 1500000 35600 710500
31500000 1500000 35600 710500
	 315.DH1UO 	 15000OO 	 35600 	 210500 	
31500000 1500000 35600 710500
31500000 1500000 35600 710500
31500000 1500000 35600 710500
31500000 1500000 35600 710500
31500000 isnnono 35600 7in«;nn
31500000
31500000
31500000
31500000
^isnonnn
31500000
31500000
31500000
31500000
31500000-
31500000
31500000
31500000
31500000
	 315.00000-
1500000
1500000
1500000
1500000
1500000
1500000
1500000
1500000
_150QQfl,Q 	
1500000
1500000
1500000
1500000
	 15flOBQfl 	
35600
35600
35600
35600
_ -.35600-
35600
35600
35600
35600
356.00
710500
710500
710500
710500
	 _ 210500 	
710500
710500
710500
710500
71CSQO
35600 710500
35600 710500
35600 710500
35600 710500
	 35600 	 210500 	
TOTAL
OP. COST
INCLUDING
NET REVENUE, REGULATED
S/TQN ROI FOR
POWER
HASTE COMPANY,
SOLIDS »/YEAR
0.0 8331800
0.0 8262700
0.0 8193600
0.0 8124500
.,„-,_ , .C-.0 	 ._ flQ554P0 _
TUTAl
NET
SALES
REVENUE.
S/YEAR
0
0
0
0
n
0.0 7986300 0
0.0 7917200 0
0.0 7848100 0
C.O 7779000 0
	 0-0 	 22QS9QO 	 . 	 0__
0.0 7640800 0
0.0 7571600 0
C.O 7502500 0
0.0 7433400 0
	 	 C-.0-1 33A430Q_ 0
0.0
0.0
0.0
c.o
_ 	 fl-0_
0.0
0.0
c.o
0.0
	 C..O-
0.0
c.o
0.0
0.0
	 C-0.
7295200
7226100
7157000
7087900
7oiRfino
6949700
6880500
6811400
6742300
	 _ _ 6623200-
0
0
0
0
0
0
0
0
n
6604100 0
6535000 0
6465900 0
6396800 0
	 63222BQ 	 fl_
NET ANNUAL
INCREASE
(DECREASE)
IN COST OF
POWER ,
$
8331800
8262700
8193600
8124500
£055400
7986300
7917200
7848100
7779000
	 2203SLO_
76408CO
7571600
7502500
7433400
236&300
7295200
7226100
7157000
7087900
6949700
6880500
6811400
6742300
6604100
6535000
6465900
6396800
	 6322200-
CUMULATIVE
NET INCREASE
(DECREASE )
IN COST OF
POWER,
$
8331800
16594500
24788100
32912600
60S6UQQO
48954300
56871500
64719600
72498600
	 a02Qfi500
67849300
95420900
102923400
110356600
	 112221100
125016300
132242400
139399400
146487300
160455800
167336300
174147700
180890000
194167300
200702300
207168200
213565000
	 21SfiS22CO
TOT  210000    945000000     45000000
   LIFETIME AVERAGE INCREASE (DECREASE)
                                            1068000       21315000
                                        IN UNIT OPERATING COST
                    DOLLARS PER TON OF COAL BURNED
                    MILLS PER KILOWATT-HOUR
                    CENTS PER MILLION BTU HEAT INPUT
                    DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6% TO INITIAL YEAR. DOLLARS
219892700

    4.89
    2.09
   23.27
  205.89
64876200
                                                                                                           2198927CO
  LEVELIZED INCREASE  (DECREASE) IN UNIT OPERATING CDS1 EQUIVALENT TO DISCOUNTED PROCESS COST OVER
                   DOLLARS PER TON OF COAL BURNED
                   KILLS PER KILOWATT-HOUR
                   CENTS PER MILLION BTU HEAT INPUT
                   DOLLARS PER TON OF SULFUR REMOVED
                                                                                          5.21
                                                                                          2.23
                                                                                         24.81
                                                                                        219.55
L
0.0
0.0
0.0
0.0
0
IFE OF
0.0
0.0
0.0
0.0
4.89
2.09
23.27
205.89
64876200
POWER UNIT
5.21
2.23
24.81
219.55

-------
                                                            TABLE C-22

LJME/LIMESTONE  SLUDGE  DISPOSAL  - CHEHFIX PROCESS. 500 I"W NEW UNIT, 3.5* S, 5000 HRS CONSTANT ONSTEAH,  REGULATED  CO. ECONOMICS
                                                 FIXED INVESTMENT:  »
                                                                        13515000
YEARS ANNUAL POhER UNIT
AFTER OPERA- HEAT
POWER TION, REQUIREMENT,
UNIT KW-HR/ MILLION BTU
START KH /YEAR
1 5000
2 5000
3 5000
4 5000
6 5000
7 5000
8 5000
9 5000
_IO 	 5QOQ 	
n 5000
12 5000
13 5000
14 5000
-15 _ 5flOO_ _ _
16 5000
17 5000
IP 5000
19 5000
_20 	 5QOQ 	
21 5000
22 5000
23 5000
24 5000
_25 	 50,00 	
26 50CO
27 5000
2? 5000
29 5000
_3Q 	 5flOQ 	
2250000
2250000
2250000
2250000
2250000
2250000
2250000
225COOO
_225DQQQ_
225COCO
2250000
225COOO
2250000
_2250DflQ_
2250000
2250000
2250000
2250000
_2250£DD 	
2250000
2250000
2250000
225COOO
225.QQQQ-
225COCO
225COOO
2250000
2250000
-225COOQ-
POhER UNIT
FUEL
CONSUMPTION.
TONS COAL
/YEAR
107100
107100
107100
107100
107100
107100
107100
107100
	 10,210.0.
107100
107100
107100
107100
107100
107100
107100
107100
107100
	 unum 	
107100
107100
107100
107100
	 1U210.0.
107100
107100
107100
107JOO
SULFUR
REMOVED
BY
POLLUTION
CONTROL
PROCESS.
TONS/YEAR
25400
25400
25400
25400
25400
25400
25400
25400
	 25400
25400
25400
25400
25400
25400
TOTAL
BY-PRODUCT OP. COST
RATE, INCLUDING NET ANNUAL CUMULATIVE
EOtlVALENT NET REVENUE. REGULATED TOTAL INCREASE NET INCREASE
TONS/YEAR »/TCN R01 FOR NET (DECREASE) (DECREASE)
POHER SALES IN COST OF IN COST OF
HASTE HASTE COMPANY. REVENUE. POWER, POHER,
SOLIDS SOLIDS »/YEAR WYEAR * $
501500
501500
501500
501500
	 	 50J50Q_
501500
501500
501500
501500
	 	 50J500- 	
501500
501500
501500
501500
stnsnn
25400 501500
25400 501500
25400 501500
25400 501500
	 25AOC 	 5035CQ 	
25400 501500
25400 501500
25400 501500
25400 501500
_ _ 254DO 503500
25400
25400
25400
25400
	 254 Q0_.
501500
501500
501500
501500
0.0
0.0
0.0
0.0
	 1UO 	
0.0
0.0
c.o
0.0
0.0
0.0
G.O
0.0
0.0
0.0
0.0
0.0
c.o
0.0
c.o
c.o
0.0
c.o
c.o
c.o
7479100
7410000
7340900
7271BOO
7202600
7133500
7064400
6995300
6926200
6857100
6788000
6718900
6649800
6580700
. 	 £511500 	
6442400
6373300
6304200
6235100
	 6166000
6096900
6027800
5958700
5889600
5420400—
5751300
5682200
5613100
5544000
	 5424300- _
0
0
0
0
0
0
0
0
0
0
0
0
_ fl
0
0
0
0
Q
0
0
0
0
Q
0
0
0
0
	 fl
7479100 1479100
7410000 14889100
7340900 22230000
7271800 29501800
71335CO 43837900
7064400 50902300
6995300 57897600
6926200 64823800
	 6E5210Q 	 216ao.SOO
6788000 78468900
6718900 85187800
66498CO 91837600
6580700 98418300
6442400 111372200
6373300 111745500
6304200 124049100
6235100 130284800
60969CO 142547100
6027800 148575500
5958700 154534200
5889600 160423800
	 5&2Q4QQ 	 166244200
5751300 171995500
5682200 177677700
5613100 183290800
5544000 188834800
— ...5.&24SDJ} 	 1243D97DO
TQT  150000     67500000       3213000         762000        15225000
   LIFETIME AVERAGE  INCREASE  (DECREASE I  IN  UNIT  OPERATING COST
                     COLLARS PER  TON  OF CtlAL BURNED
                     HILLS  PER  KILOWATT-HOUR
                     CENTS  PER  MILLION BTU HEAT  INPUT
                     DOLLARS PER  TON  OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT  11.6*  TO INITIAL  YEAR, DOLLARS
194309700

   60.48
    2.59
  287.87
  255.00
57798000
0.0
0.0
0.0
0.0
   LEVELIZED INCREASE  (DECREASE)  IN  UNIT  OPERATING  COST  EQUIVALENT  TO  D1SCCUKTED  PROCESS COST  OVER LIFE OF
                    DOLLARS PER  TON  OF  COAL  BURNED                                        65.01       0.0
                    MILLS PER  KILOWATT-HOUR                                                2.79       0.0
                    CENTS PER  MILLION BTU HEAT  INPUT                                     309.48       0.0
                    COLLARS PER  TON  OF  SULFUR REMOVED                                    274.18       0.0
 194309700

     60.48
      2.59
    287.87
    255.00
  57798000
POWER UNIT
     65.01
      2.79
    309.48
    274.18

-------
                                                              TABLE C-23




LIME/LIMESTONE SLUDGE  DISPOSAL - CHEMFIX  PROCESS.  1500  HM  NEW  UNIT,  3.5X  S. 1000 MRS CONSTANT ONSTEAH. REGULATED CD. ECONOMICS



                                                FIXED INVESTMENT:  S   25453000
TOTAL
SULFUR BY-PRODUCT OP. COST
REMOVED RATE, INCLUDING
YEARS ANNUAL POWER UNIT POKER UNIT BY EQUIVALENT NET REVENUE. REGULATED
AFTER OPERA- HEAT FUEL POLLUTION TONS/YEAR WTON ROI FOR
POWER TION, REQUIREMENT, CONSUMPTION, CONTROL POWER
UNIT KH-HR/ MILLION BTU TONS COAL PROCESS, WASTE
START KW /YEAR /YEAR TONS/YEA* SOLIDS
1 7000 94500000 4500000 106800
2 7000 94500000 4500000 106800
3 7000 94500000 4500000 106800
4 7000 94500000 4500000 106800
	 5. 	 ^7000. . .94.5.00000 _ 45nnnno in«,apo
6 7000 94500000 4500000 106800
7 7000 94500000 4500000 106800
8 7000 94500000 4500000 106800
9 7000 94500000 4500000 106800
10 70QQ S4.5.0QOOQ 4500000 infcnnn
11 7000 94500000 4500000 106800
12 7000 94500000 4500000 106800
13 7000 94500000 4500000 106800
14 7000 94500000 4500000 106600
15. 7.000 94500000 ^snpnnn lOfcflDO
16 7000 94500000 4500000 106800
17 7000 94500000 4500000 106800
18 7000 94500000 4500000 106800
19 7000 94500000 4500000 106800
?n "/n fid Qfionoon &5nnnnn infi^nn
21 7000 94500000 4500000 106800
22 7000 94500000 4500000 106800
23 7000 94500000 4500000 106600
24 7000 94500000 4500000 106800
25 7000 9&5QOOOQ 	 4500000,,, ... infeBOO 	
26 7000 94500000 4500000 106800
27 7000 94500000 4500000 106800
28 7000 945000CO 4500000 106800
29 7000 94500000 4500000 106800
30 20.00 945.000.00 6*500000 . 106900. ........
TOT 210000 2835000000 135000000 3204000
LIFETIME AVERAGE INCREASE (DECREASE) IN UNIT OPERATING
DOLLARS PER TON OF COAL BURNED
HILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
PROCESS COST DISCOUNTED AT 11.6* TO INITIAL YEAR, DOLLARS
2131500
2131500
2131500
2131500
?1 iisnn
2131500
2131500
2131500
2131500
? i ^ i s fin
2131500
2131500
2131500
2131500
y i "3 1 son
2131500
2131500
2131500
2131500
-2131500—
2131500
2131500
2131500
2131500
21315 00
2131500
2131500
2131500
2131500
WASTE
SOLIDS
0.0
0.0
0.0
0.0
0*0
0.0
0.0
0.0
0.0
^0.0 	 T
0.0
0.0
0.0
0.0
p.n
0.0
0.0
0.0
0.0
D Q
0.0
0.0
0.0
0.0
	 0-0
0.0
0.0
0.0
0.0
COMPANY,
S/VEAR
16943900
16826100
16712200
16596400
)f,4BO5nn
16364700
16248900
16133000
16017200
i *»Qfi i "^nn
15765500
15669700
15553600
15438000
i t^i?5 1 nn
15206300
15090400
14974600
14858600
1 &7&29QQ
14627100
14511200
14395400
14279600
1 41 fc 3 "7 0 0
14047900
13932000
13816200
13700300
TOTAL
NET
SALES
REVENUE,
*/VEAR
0
0
0
0
n
0
0
0
0
n
0
0
0
0

0
0
0
0

0
0
0
0
0
0
0
0
0
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE) (DECREASE?
IN COST OF IN COST OF
POWER ,
*
16943900
16826100
16712200
16596400
l/.&AO'ino
16364700
16248900
16133000
16017200
15901300
15785500
15669700
15553600
15438000
1 5 322 100
15206300
15090400
14974600
14858800
I474?qnn
14627100
14511200
14395400
14279600
i f. i fa3 700
14047900
13932000
13816200
13700300
POWER,
$
16943900
33772000
50484200
67080600
ff3^hi inn
99925800
116174700
132307700
148324900
jtA32i»2nn
180011700
195681400
211235200
226673200
241325300
257201600
272292000
287266600
302125400
31 fiflfifl "?nn
331495400
346006600
360402000
374681600
oo g o 453 0 0
402893200
416825200
430641400
444341700
2131500 n.n ii^A&^nn n iicn^cnn Lf.™->^->nr\
63945000
COST












457926200

3.39
1.45
16.15
142.92
133464500
LEVEL1ZED INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT TO DISCOUNTED PROCESS COST OVER
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED








3.57
1.53
17.02
150.55
0

0.0
0.0
0.0
0.0
0
LIFE OF
0.0
0.0
0.0
0.0
457926200

3.39
1.45
16.15
142.92
133464500
POWER UNIT
3.57
1.53
17.02
150.55













-------
                                                         TABLE C-24
LIWE/LIMSSTONE SLUDGE DISPOSAL - CHEMFIX PROCESS, 1500 HH NEW UNIT, 3.5* S, 5000 MRS CONSTANT ONSTEAM, REGULATED CO. ECONOMICS

                                                FIXEC  INVESTMENT:  *   24066000
YEARS ANNUAL POhER UNIT
AFTER OPERA- HEAT
POWER TION, REQUIREMENT,
UNIT KW-HR/ MILLION BTU
START KW /YEAR
1 5000 67500000
2 5000 67500000
3 5000 67500000
4 5000 67500000
	 5 	 50.00 	 615.0£000_
6 5000 67500000
7 5000 67500000
6 5000 67500000
9 5000 6750COCO
_1Q 	 5000. 	 £150.00,00. 	
11 5000 6750COCO
12 5000 67500000
13 5000 67500000
14 5000 67500000
15 50.00 62500000
16 5000 67500000
17 5000 67500000
18 5000 67500000
19 5000 67500000
20 5000 fiTSQCOQQ
21 5000 6750COOO
22 5000 67500000
23 5000 67500000
24 5000 6750COOO
25 50QQ f>7_50.0QQQ
SULFUR
REMOVED
POWER UNIT BY
FUEL POLLUTION
CONSUMPTION, CONTROL
TONS COAL PROCESS,
/YEAR TONS/YEAH
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
	 3216.30,0 	
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
3214300
•4714-300
76300
76300
76300
76300
	 16300 	
76300
76300
76300
76300
	 1630.0 	
76300
76300
76300
76300
16300
76300
76300
76300
76300
	 16300 	
76300
76300
76300
7C300
761QQ
BY-PRODUCT
RATE,
EQUIVALENT
TONS/YEAR
WASTE
SOLIDS
NET REVENUE.
t/TON
WASTE
SOLIDS
1522500 0.0
1522500 0.0
1522500 0.0
1522500 0.0
	 15225QQ 	 0-0 	
1522500 0.0
1522500 0.0
1522500 C.O
1522500 0.0
	 15225 OQ 	 0-0 	
1522500 0.0
1522500 0.0
1522500 0.0
1522500 0.0
1522500
1522500
1522500
1522500
	 15225QQ _
1522500
1522500
1522500
1522500
152250Q
0.0
0.0
0.0
c.o
0.0
c.o
0.0
c.o
C -0
26 5000 6750COCC 3214300 76300 1522500 0.0
27 5000 67500000 3214300 76300 1522500 C.O
28 5000 67500000 3214300 76300 1522500 0.0
29 5000 67500000 3214300 76300 1522500 0.0
_30 	 5000 	 61500000 	 321430.0 	 16300 	 1522500. 	 C-0 	
TOTAL
OP. COST
INCLUDING
REGULATED
RDI FOR
POWER
COMPANY.
»/YEAR
14417000
14301100
14185300
14069400
	 13353600 	
13837700
13721900
13606100
13490200
	 13324400 	
13258500
13142700
13026800
12911000
	 12135200 	
12679300
12563500
12447600
12331800
._ _1221600Q 	
12100100
11984300
11868400
11752600
. .11636100 	
TOTAL
NET
SALES
REVENUE,
»/YEAR
0
0
0
0
_ 0_
0
0
0
0
	 fl_
0
0
0
0
jQ
0
0
0
0
0
0
0
0
0
11520900 0
11405100 0
11289200 0
11173400 0
	 11051500 	 0_
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
(DECREASE) (DECREASE)
IN COST OF IN COST OF
POWER, POWER,
» *
14417000 14417000
14301100 28718100
14185300 42903400
14069400 56972800
	 133536EO 	 20326400
13837700 84764100
13721900 98486000
13606100 112092100
13490200 125582300
	 13314400 	 13B3562QO
13258500 152215200
13142700 165357900
13026800 178384700
12911000 191295700
	 12135200 	 204030300
12679300 216770200
12563500 229333700
12447600 241781300
12331800 254113100
. 12216000 	 266323100
12100100 278429200
11984300 290413500
11868400 302281900
11752600 314034500
	 11636200 	 325611200
115209CO 337192100
11405100 348597200
11289200 359886400
11173400 371059800
	 11051500 	 34211130 0
TOT  150000
   LIFETIME
  2025000000
AVERAGE INCREASE
PROCESS CCST
   LEVELI2ED
                96429000       2289000       45675000
                (DECREASE) IN UNIT  OPERATING COST
       COLLARS PER TON OF COAL BURNED
       HILLS PER KILOWATT-HOUR
       CENTS PER MILLION PTU HEAT INPUT
       DOLLARS PER TON OF SULFUR REMOVED
DISCOUNTED AT  11.6* TO INITIAL YEAR, DOLLARS
INCREASE (DECREASE) IN UNIT OPERATING COST EQUIVALENT
       DOLLARS PER TON OF COAL BURNED
       MILLS PER KILOWATT-HOUR
       CENTS PER MILLION BTU HEAT INPUT
       COLLARS PER TON OF SULFUR REMOVED
                                                                                      382117300
                                                                                                            382117300





TO DISCOUNTED




3.96
1.7C
18.81
166.94
112489900
PROCESS COST OVER
4.22
1.81
20.08
177.62
0.0
0.0
0.0
0.0
0
LI FE OF
0.0
0.0
0.0
0.0
3.96
1.70
18.87
166.94
112489900
POWER UNIT
4 .22
1 .81
20. C8
177.62

-------
                                TECHNICAL REPORT DATA
                         (Please read Instructions on the reverse before completing)
1. REPORT NO.
 EPA-600/7-78-023a
                           2.
                                                      3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE Economics of Disposal of Lime/Lime-
stone Scrubbing Wastes: Untreated and Chemically
Treated Wastes
                              5. REPORT DATE
                              February 1978
                              6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
J.W.Barrier, H.L.Faucett, and L.J.Henson
                                                      8. PERFORMING ORGANIZATION REPORT N'o.
                                                      Bulletin Y-123
9. PERFORMING ORGANIZATION NAME AND ADDRESS
 Tennessee Valley Authority
 National Fertilizer Development Center
 Muscle Shoals, Alabama 35660
                                                      10. PROGRAM ELEMENT NO.
                              INE624A
                              11. CONTRACT/GRANT NO.
                              EPA Interagency Agreement
                                 IAG-D7-E721
 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
                              Final; 3/76-6/77	
                              14. SPONSORING AGENCY CODE
                               EPA/600/13
 15. SUPPLEMENTARY NOTES jERL-RTP project officer is Julian W. Jones, Mail Drop 61, 919/
 541-2489.
 16. ABSTRACT
               report gives results of a detailed, comparative economic evaluation of
 four alternatives available to the utility industry for the disposal of wastes from flue
 gas desulfurization using limestone or lime slurry scrubbing.  The alternatives are
 untreated sludge (pond or  landfill) and sludge chemically treated by three commercial
 processes — Dravo's Synearth process (pond and landfill), I. U. Conversion Systems'
 Poz-O-Tec process (landfill) , and Chemfix's ultimate disposal process (landfill) , all
 assumed to be technically proven and applicable to full-scale installations.  The base
 case for each alternative is a new 500 MW power plant burning coal with 3. 5% sulfur,
 16% ash,  and 10,500 Btu/lb heating value.  A limestone wet scrubber (1. 5 stoichiome-
 try) was used to remove flyash and SO2 to meet New Source Performance Standards.
 Underflow from the scrubber to the waste disposal system is a 15% solids slurry. A
 total of 121 system design  and operation variations were prepared for the alternative
 processes.  Total capital investments, annual revenue requirements, and lifetime
 revenue requirements for power plants  operating over both declining- and constant-
 load 30-year profiles  are  included for the 121 cases. Investment and revenue require-
 ments vary considerably for the 121 cases. The most economical disposal alternative
 cannot be determined  from generalities since costs depend on such site -specific var-
 iables as plant size, remaining life, land  availability and cost, and coal analysis.
17.
                             KEY WORDS AND DOCUMENT ANALYSIS
                DESCRIPTORS
                                          b.IDENTIFIERS/OPEN ENDED TERMS
                                             COSATI Field/Group
 Pollution
 Sludge Disposal
 Economic Analysis
 Calcium Oxides
 Limestone
 Scrubbers
Flue Gases
Desulfurization
Electric Power
 Plants
Fly Ash
Pollution Control
Stationary Sources
13B
07A
05C
07B
08G
21B
07D

10B
18. DISTRIBUTION STATEMENT

 Unlimited
                  19. SECURITY CLASS (This Report)
                  Unclassified
                         21. NO. OF PAGES

                            452
                  20. SECURITY CLASS (This page)
                  Unclassified
                         22. PRICE
EPA Form 2220-1 (9-73)
                                       416

-------