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
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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.
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
$/ton
wet sludge
4.04
6.06
5.31
4.63
4.14
3.51
2.94
2.57
2.77
2.35
1.90
1.60
4.34
3.72
4.69
3.68
8.50
5.32
3.52
6.81
9.24
4.44
-
4.55
6.40
7.95
4.69
6.07
7.20
7.41
6.12
5.08
4.15
3.70
2.90
5.77
3.03
3.41
4.75
5.24
5.65
6.04
Basis
Midwest plant location, mid-1980 costs; 7,000 hr/yr plant on-stream time; S0? and flyash removed
to meet NSPS.
Base case
New 500-MW plant with 30-yr life; direct ponding of 15% solids slurry in a clay-lined pond 1 mi
from scrubber facilities; settled density in pond 50% solids.
84
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TABLE 29. SUMMARY OF TOTAL ANNUAL REVENUE REQUIREMENTS -
DRAVO PROCESS^
Case
Base case
Variation from base case
200 MW new
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S in coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate - variation 1
Fixation additive rate - variation 2
Lime scrubbing process
Intermediate ponding and truck to landfill
200 MW, constrained pond acreage (50% of optimum)
200 MW, constrained pond acreage (75% of optimum)
Constrained pond acreage (50% of optimum)
Constrained pond acreage (75% of optimum)
1500 MW, constrained pond acreage (50% of optimum)
1500 MW, constrained pond acreage (75% of optimum)
Total
annual
amount, k$
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
$/ton
wet sludge
7.66
10.21
9.94
9.37
9.18
7.12
6.63
6.39
5.44
5.15
4.75
4.52
8.22
7.79
8.73
7.04
12.84
8.74
6.01
9.29
10.70
7.05
8.43
4.05
7.57
12.39
11.58
10.41
9.03
7.76
6.59
Basis
Midwest plant location, mid-1980 costs; 7,000 hr/yr plant on-stream time; SC>2 and flyash removed
to meet NSPS.
Base case
New 500-MW plant with 30-yr life; ponding of 35% solids slurry in a clay-lined pond 1 mi from
scrubber facilities; settled density in pond - 50% solids; pipeline transport to the disposal
area; Calcilox for stabilization (7% of dry sludge).
85
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TABLE 30. SUMMARY OF TOTAL ANNUAL REVENUE REQUIREMENTS -
IUCS PROCESS3
Case
Total
annual
amount, k$
Unit revenue requirements
T~r~ $/ton
$/tOn y/ Lull
Mills/kWh dry sludge wet sludge
Base case
Variation from base case
200 MW new
200 MW existing, 25-yr remaining life
200 MW existing, 20-yr remaining life
200 MW existing, 15-yr remaining life
Existing, 25-yr remaining life
Existing, 20-yr remaining life
Existing, 15-yr remaining life
1500 MW new
1500 MW existing, 25-yr remaining life
1500 MW existing, 20-yr remaining life
1500 MW existing, 15-yr remaining life
12% ash in coal
20% ash in coal
2% S in coal
5% S In coal
200 MW, no flyash
No flyash
1500 MW, no flyash
5 mi to disposal
10 mi to disposal
Fixation additive rate variation 1
Fixation additive rate variation 2
Lime scrubbing process
3,zyi
3,567
3,699
3,725
3,822
5,402
5,430
5,559
10,411
10,656
10,684
10,900
4,533
5,971
4,654
6,188
3,396
4,650
8,162
6,490
7,475
4,994
5,511
5,093
1 .31
2.55
2.64
2.66
2.73
1.54
1.55
1.59
0.99
1.01
1.02
1.04
1.30
1.71
1.33
1.77
2.43
1.33
0.78
1.85
2.14
1.43
1.57
1.46
i£ . jj
20.68
20.66
20.80
21.35
12.55
12.62
12.92
8.23
8.24
8.26
8.43
13.05
11.84
15.57
11.29
37.03
20.87
12.17
15.40
17.73
11.96
12.95
13.88
/ .DJ
12.59
12.73
12.82
13.16
7.63
7.68
7.86
5.02
5.02
5.04
5.14
7.94
7.23
9.71
6.88
16.45
9.23
5.42
9.37
10.78
7.28
7.91
8.46
Basis
Midwest plant location, mid-1980 costs; 7,000 hr/yr plant on-stream time; S02 and flyash removed to
meet NSPS.
Base case
New 500-MW plant with 30-yr life; landfill disposal of 60% solids material 1 mi from scrubber
facilities; truck transport of treated sludge to disposal area; lime for stabilization (4% of dry
sludge).
86
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TABLE 31. SUMMARY OF TOTAL ANNUAL REVENUE REQUIREMENTS -
CHEMFIX PROCESS3
Case
Total
annual
amount, k$.
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
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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
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