EPA
TVA
United States
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Research Triangle Park, NC 27711
EPA-600/8-85-006
March 1985
Tennessee Valley
Authority
Power and Engineering
Energy Demonstrations
and Technology
Muscle Shoals, AL 35660
TVA/OP/EDT-84/37
Shawnee Flue Gas
Desulfurization
Computer Model
Users Manual
Interagency
Energy/Environment
R&D 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
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the SPECIAL REPORTS series. This series is
reserved for reports which are intended to meet the technical information needs
of specifically targeted user groups. Reports in this series include Problem Orient-
ed Reports. Research Application Reports, and Executive Summary Documents.
Typical of these reports include state-of-the-art analyses, technology assess-
ments, reports on the results of major research and development efforts, design
manuals, and user manuals.
EPA REVIEW NOTICE
This report has been reviewed by the U.S. Environmental Protection Agency, and
approved for publication. Approval does not signify that the contents necessarily
reflect the views and policy of the Agency, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/8-85-006
TVA/OP/EDT-84/37
March 1985
Shawnee Flue Gas Desulfurization
Computer Model Users Manual
by
F.A. Sudhoff and R.L. Torstrick
TVA, Power and Engineering
Division of Energy Demonstrations and Technology
Muscle Shoals, Alabama 35660
EPA Interagency Agreement No. 79-D-X0511
EPA Project Officer: J. David Mobley
Industrial Environmental Research Laboratory
Office of Environmental Engineering and Technology
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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DISCLAIMER
This report was prepared by the Tennessee Valley Authority and has been
reviewed by the Office of Energy, Minerals, and Industry, U.S. Environmental
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.
ii
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ABSTRACT
In conjunction with the U.S. Environmental Protection Agency (EPA)-
sponsored Shawnee test program, Bechtel National, Inc., and the Tennessee
Valley Authority (TVA) Jointly developed a computer model capable of pro-
jecting preliminary design and economics for lime- and limestone-scrubbing
flue gas desulfurization (FGD) systems. The model is capable of projecting
relative economics for spray tower, turbulent contact absorber (TCA), and
venturi-spray tower scrubbing options. It may be used to project the effect
on system design and economics of variations in required SC>2 removal,
scrubber operating parameters [gas velocity, liquid-to-gas (L/G) ratio, alkali
stoichiometry, liquor hold time in slurry recirculation tanks], reheat
temperature, and scrubber bypass. It may also be used to evaluate alternative
waste disposal methods or additives (MgO or adipic acid) on costs for the
selected process. Although the model is not Intended to project the economics
of an Individual system to a high degree of accuracy, it allows prospective
users to quickly project comparative design and costs for limestone and lime
case variations on a common design and cost basis.
The users manual provides a general description of the Shawnee FGD
computer model and detailed instructions for its use. It describes and
explains the user-supplied input data which are required such as boiler size,
coal characteristics, and S02 removal requirements. Output includes a
material balance, equipment list, and detailed capital investment and annual
revenue requirements. The users manual provides information concerning the
use of the overall model as well as sample runs to serve as a guide to
prospective users in identifying applications. The FORTRAN-based model is
maintained by TVA, from whom copies or individual runs are available.
ill
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iv
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CONTENTS
Abstract ill
Figures vii
Tables ix
Abbreviations and Conversion Factors xl
Executive Summary S-1
Introduction 1
General Information 3
Background 3
Documentation 4
Scope of the Model 4
Availability 5
Model Description 7
Input 7
Output 8
Options 8
Print Options 9
Particulate Collection Device Option 9
Reheat Option 13
Emergency Bypass Option 13
Partial Scrubbing/Bypass Option 14
Coal-Cleaning Option 14
Input Composition Option 17
Particulate Removal Option 18
S02 Removal Option 20
Operating Condition Calculation Option 22
Scrubbing Absorbent Option (Lime or Limestone) 24
Chemical Additive Option 24
Forced-Oxidation Option 29
Booster Fan Option 34
Scrubbing Option 34
Spare Equipment Options 37
Waste Disposal Option 37
Pond Disposal Option 42
Landfill Disposal Option 50
Disposal Site Liner Option 54
Economic Premises Option 54
v
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56
Sales Tax and Freight Option 5g
Overtime Option
Separate Waste Disposal Site Construction Indirect Investment ^
Factors Option 55
Operating Profile Option
Using the Model
81
Model Structure
91
References
Appendix A - Process Flowsheets and Layouts
Appendix B - Design and Economic Premises for Emission Control
Evaluations B~1
Appendix C - Detailed Descriptions of Model Input Variables C-1
Appendix D - Base Case Shawnee Computer Model Input and Printout . . . D-1
Appendix E - Adipic Acid Interactive Model E-1
Appendix F - Pond Interactive Model F~1
Appendix G - Landfill Interactive Model G-1
VI
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FIGURES
Number Page
1 Controlled S02 emission requirements for 1979 NSPS. Premise
coals, shown underlined, are based on premise boiler
conditions 21
2 Operating profile assumed for IOPSCH = 1 based on old TVA
premises 67
3 Operating profile assumed for IOPSCH = 2 based on historical
Federal Energy Regulatory Commission data 68
vii
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vi±±
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TABLES
Number Page
1 Variable Ranges 7
2 Example Results Illustrating Short-Form Printout 10
3 Example Results Illustrating Mechanical Collector Particulate
Removal 12
4 Example Results Illustrating Partial Scrubbing/Bypass .... 15
5 Example Results Illustrating User Input Flue Gas
Composition 19
6 Example Results Illustrating Lime-Scrubbing Input 25
7 Example Results Illustrating Lime-Scrubbing Output 26
8 Example Results Illustrating Lime-Scrubbing, Raw Material-
Handling, and Preparation Areas 27
9 Example Results Illustrating the Addition of Adipic Acid . . 30
10 Example Results Illustrating Forced Oxidation, Two Effluent
Tanks 35
11 Example Results Illustrating Forced Oxidation, One Effluent
Tank 36
12 Example Results Illustrating a Venturi-Spray Tower
Absorber 38
13 Example Results Illustrating No Spare Equipment 39
14 Example Results Illustrating Pond Waste Disposal 43
15 Example Results Illustrating Thickener - Filter - Pond Waste
Disposal 44
16 Example Results Illustrating Solids Disposal Fixation -
Landfill 45
17 Example Revenue Requirements Table Illustrating Fixation
Costs 48
18 Example Results Illustrating Pond Site Acreage Constraint . . 51
19 Example Results Illustrating Landfill Disposal Based Minimum
Costs with Synthetic Liner 52
20 Example Results Illustrating Synthetic Pond Liner Output . . 55
21 Example Revenue Requirements Using the Economic Premises
with No Levelizing Factors 57
22 Example Revenue Requirements Using the Old Economic
Premises 59
23 Example Investment Summary Table with Sales Tax and Freight
Excluded ^ 61
24 Example Investment Summary Table with Common Indirect
Investment Factors for Process and Landfill 63
ix
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TABLES (Continued)
Number
25 Example Results Illustrating the Effects of Fixation on
Landfill Design ...................... 61*
26 Example Lifetime Revenue Requirements Using the Old TVA
Premises Operating Profile ................. 70
27 Example Lifetime Revenue Requirements Using the Historical
FERC/FPC Operating Profile ................. 71
28 Example Lifetime Revenue Requirements Using a User-Supplied
Operating Profile ..................... 72
29 Example Lifetime Revenue Requirements Using a User-Supplied
Plant Lifetime Profile and Operating Capacity Factor .... 73
30 Example Procedure for Executing the Model in Batch Mode ... 77
31 Example JCL to Execute the Model Using a Procedure File ... 78
32 Sample Command Procedure for Executing the Model
Interactively ....................... 79
33 Alphabetical Listing of the Subroutines in the Investment
Program Identifying the Function of Each Subroutine .... 82
34 Alphabetical Listing of the Subroutines in the Revenue
Requirement Program Identifying the Function of Each
Subroutine ......................... 86
35 Hierarchy Chart for Execution of the Investment Program of
the Overall Computer Model in the Batch Mode ........ 87
36 Hierarchy Chart for Execution of the Revenue Requirement
Program of the Overall Computer Model ........... 90
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ABBREVIATIONS AND CONVERSION FACTORS
ABBREVIATIONS
aft3/min actual cubic feet per
minute
Btu British thermal unit
°F degrees Fahrenheit
dia diameter
FGD flue gas desulfurization
ft feet
ft2 square feet
ft3 cubic feet
gal gallon
Ggal 109 gallons
gpm gallons per minute
gr grain
hp horsepower
hr hour
in. inch
k thousand
kW kilowatt
kWh kilowatthour
Ib pound
L/G liquid-to-gas ratio in
gallons per thousand
actual cubic feet of gas
at outlet conditions
M million
mi mile
mo month
MW megawatt
ppm parts per million
psig pounds per square inch
(gauge)
rpm revolutions per minute
SCA specific collection area
sec second
sft3/min standard cubic feet per
minute (6QQF)
SS stainless steel
yr year
xi
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CONVERSION FACTORS
EPA policy is to express all measurements in Agency documents in metric units. Values in this
report are given in British units for the convenience of engineers and other scientists accustomed to
using the British systems. The following conversion factors may be used to provide metric equivalents.
To convert British
Multiply bv
To obtain Metric
ac
Btu
°F
ft
ft3
ft/min
ft3/min
gal
gpm
gr
gr/ft3
hp
in,
lb
Ib/ft3
Ib/hr
psi
mi
rpm
sft3/min
ton
ton/hr
acre 0.405
British thermal unit 0.252
degrees Fahrenheit minus 32 0.5556
feet 30.48
square feet 0.0929
cubic feet 0.02832
feet per minute 0.508
cubic feet per minute 0.000472
gallons (U.S.) 3-785
gallons per minute 0.06308
grains 0.0648
grains per cubic foot 2.288
horsepower 0.746
inches 2.54
pounds 0.4536
pounds per cubic foot 16.02
pounds per hour 0.126
pounds per square inch 6895
miles 1609
revolutions per minute 0.1047
standard cubic feet per 1.6077
minute (60°F)
tons (short) 0.9072
tons per hour 0.252
hectare
kilocalories
degrees Celsius
centimeters
square meters
cubic meters
centimeters per second
cubic meters per second
liters
liters per second
grams
grams per cubic meter
kilowatts
centimeters
kilograms
kilograms per cubic meter
grams per second
pascals (newton per square
meters
radians per second
normal cubic meters per
hour (0°C)
metric tons
kilograms per second
ha
kcal
°C
cm
m2
m3
cm/s
m3/s
L
L/s
kW
cm
kg ,
kg/up
g/s
meter) Pa (N/m2)
m
rad/s
m3/hr (0°C)
tonne
kg/s
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SHAWNEE FLUE GAS DESULFURIZATION COMPUTER MODEL
USERS MANUAL
EXECUTIVE SUMMARY
The Shawnee lime-limestone computer model was developed by Bechtel
National, Inc., and the Tennessee Valley Authority (TVA) to model lime-
limestone wet-scrubbing flue gas desulfurization (FGD) systems and is capable
of projecting comparative investment and revenue requirements for these
systems. The computer model has been developed to permit the rapid estimation
of relative economics of these systems for variations in process design alter-
natives (i.e., limestone versus lime scrubbing, alternative scrubber types, or
alternative sludge disposal methods), variations in the values of independent
design parameters [i.e., scrubber gas velocity and liquid-to-gas (L/G) ratio,
alkali stoichiometry, slurry residence time, reheat temperature, and specific
sludge disposal design], and the use of additives (MgO or adipic acid).
Although the model is not intended to compute the economics of an individual
system to a high degree of accuracy, it is based on sufficient detail to allow
the quick projection of preliminary conceptual design and costs for various
lime-limestone case variations on a common design and cost basis.
PROGRAM DEVELOPMENT
The technical development of the Shawnee lime-limestone computer model is
based on actual data obtained at the Shawnee test facility. Bechtel and TVA
shared the responsibility of model development. Bechtel was responsible for
analyzing the test results and developing the models which calculate the
overall material balance flow rates and stream compositions. Bechtel provided
these models to TVA. TVA was responsible for determining the size limitations
of the required equipment to establish the minimum number of parallel equip-
ment trains, accumulating cost data for the major equipment items, and devel-
oping models for projecting equipment and field material costs as a function
of equipment capacity. Utilizing these relationships, TVA developed models to
project the overall investment cost breakdown and a procedure for using the
output of the material balance and investment models as inputs to a previously
developed TVA model for projecting annual and lifetime revenue requirements.
The model has been periodically updated to include new or improved data
and process developments in FGD. The basic processes in the current model
consist of limestone and lime scrubbing; spray tower, turbulent contact
absorber (TCA), and venturi-spray tower absorbers; and pond or landfill
disposal. Process options include three alternative modes of forced oxidation
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and provisions for MgO or adipic acid addition. Several dozen additional
input and output options provide further flexibility in the use of the model.
The specific mathematical treatments of material balances, including
S02 removal efficiencies, are not fully documented in published works.
Descriptions of the mathematical treatment of S02 removal in spray tower and
TCA are given in Shawnee test facility reports (1).
The absorption of S02 into scrubbing liquid approximates the mass
transfer situation of absorption followed by a chemical reaction, a circum-
stance for which no comprehensive theoretical basis exists. Such treatment
requires mathematical expressions of turbulent fluid behavior and reaction
orders that cannot be rigorously defined. Overall mass transfer models are
usually based on modifications of general theoretical treatments that differ
in concept but mathematically approach similar conclusions in some cases.
Standard references (2) and texts (3) provide discussions and access to the
literature.
In practice, the mass transfer functions are reduced by a number of
simplifying assumptions based on a knowledge of the system and the likely or
probable important and unimportant factors. The mathematical expression at
once becomes manageable and specific to the situation, to which it can be
further correlated empirically. The development of such expressions is
discussed in detail by Wen and Fan (4), Rochelle and King (5), Chang and
Rochelle (6), and Wen and others (7), for specific FGD applications.
The Shawnee model expression is simplified by the assumptions that
liquid-side resistance controls the absorption rate and that liquid-phase
reactions are not limiting (that is, dissolved S02 does not significantly
affect the absorption rate). Both of these assumptions are supported by
experimental results (1).
o
S02 = 1 - exp [- 6 KLaz/Hv]
The simplified expression for the fraction of S02 removed contains an
enhancement factor, 6, to represent the effects of chemical reaction and a
group (consisting of a liquid-side mass transfer coefficient, KL°; inter-
facial area, a; vertical distance, z; Henry's law constant, H; and gas
velocity, v) to represent physical absorption. The enhancement factor
contains expressions for pH, effective magnesium, flue gas, S02 content, and
in some cases, chloride concentration. The expression is fitted to Shawnee
test facility data for each particular absorber and absorbent combination
using eight coefficients. The fitted expressions have standard errors of
estimate of about 4J. Pressure drop expressions for the three absorbers were
developed by fitting expressions containing pertinent variables to Shawnee
test facility data. The development of these expressions is discussed in the
Shawnee test facility reports and symposium proceedings cited.
S-2
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MODEL CAPABILITY
The Shawnee lime-limestone scrubbing model is capable of projecting a
complete conceptual design package for these systems utilizing a spray tower,
TCA, or venturi-spray tower absorber, each with or without use of additives;
and with any of five sludge disposal options, including options with and
without forced oxidation. Flow diagrams illustrating these process alterna-
tives are shown in Appendix A. Ranges for basic design parameters are shown
below.
Plant size
Coal sulfur
Scrubber gas velocity
Liquor recirculation rate
Slurry residence time
Scrubber slurry solids
Reheat (steam)
100-1,300 MW
2%-5% (1,500-4,000 ppm S02)
8-12.5 ft/sec
25-120 gal/aft3 (at scrubber outlet)
2-25 min
555-15$
225°F maximum reheat temperature
Results for conditions outside these design ranges are not necessarily invalid
but are subject to potential reduced accuracies.
The output of the model includes projections of annual and lifetime
revenue requirements to allow comparison of the economics of the alternative
system designs. The basis for these projections is described in the report
appendices.
The process technology _is divided into seven major areas to facilitate
projection of the process design and the estimated capital investment. The
facilities included in each area are Identified in the process description
along with the basis for design of the FGD system.
PROCESS DESCRIPTION
Processing Areas
The seven major processing areas used to define the limestone- and lime-
scrubbing systems are identified below along with a description of the facili-
ties included within the battery limits of each processing area, and the basis
for design of these facilities.
Raw Material Handling—
This area provides for receiving either limestone or lime. For the
limestone slurry process, the raw material-handling area includes equipment
for receiving limestone by truck or rail, a storage stockpile, and live in-
process limestone storage equipment.
For the lime slurry process, the raw material-handling area includes
equipment for receiving lime by truck or rail and a storage silo.
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The direct investment costs for the raw material-handling area includes
costs for all of the lime-limestone receiving equipment and field construction
materials up to and including the raw material feed bin.
Raw Material Preparation—
This area provides for preparation of a limestone or lime slurry for feed
to the S02 scrubbing area. The raw material preparation area for the lime-
stone slurry process includes gyratory crushers for crushing the limestone for
feed to the wet ball mills. The wet ball mills grind the limestone to the
desired size for feed to the scrubbers. The product slurry from the mills at
a concentration of 60$ solids is pumped to a slurry feed tank adjacent to the
scrubbing area for distribution to the scrubbers.
The raw material preparation area for the lime slurry process includes
equipment for slaking the lime at a concentration of 20$ to 25$ solids for
feed to the scrubbers. The product slurry from each of the slakers overflows
to a slurry receiving tank from which it is pumped to a common slurry feed
tank. The slurry is then pumped to the scrubbing area for distribution to the
scrubbers.
The direct investment costs for the feed preparation area include all
preparation equipment and field construction materials from the raw material
bin weigh feeder to the slurry feed tanks.
Gas Handling—
Flue gas from the power unit ducts is fed to a common plenum from which
any number of scrubber trains can be fed. To minimize the problems associated
with gas distribution for such a system, separate fans are included on each
side of the plenum. The power plant fans are conventional induced-draft (ID)
fans for balanced-draft boilers. The scrubber fans can be specified as
forced-draft (FD) or ID and are designed to overcome the pressure drop of the
pollution control facilities.
The direct investment costs for the gas-handling area include costs for
the flue gas equipment and field materials downstream of the air heater up to,
but excluding, the stack plenum. Costs for the scrubber fans are included;
however, costs for the power plant fan, the stack plenum, and the stack are
considered to be an integral part of the power plant and are, therefore, not
included in the estimate.
S02 Scrubbing—
Flue gas is contacted with a lime or limestone slurry in either a spray
tower, TCA, or venturi-spray tower. The absorbers are equipped with a
chevron-vane mist elimination system designed for upstream and downstream wash
with fresh makeup water. Makeup lime or limestone slurry from the slurry feed
tank and recycled supernate or filtrate from the waste disposal area are fed
to the absorber hold tanks where they are blended with the slurry draining
from the absorber. The slurry recirculation loop can be designed for use of
either one or two hold tanks below the absorber. For the 2-tank option, if
forced oxidation is specified, air is injected into the tank which receives
the effluent from the scrubber. Scrubber slurry is bled from this tank for
S-4
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disposal. Overflow from this tank flows by gravity to the second tank where
fresh limestone slurry Is added. The combined slurry Is then reclrculated to
the absorber and either the presaturator or venturl, depending on the process
selected. The bleedstream Is pumped to the waste disposal area where the
sludge Is dewatered. The supernate or filtrate Is returned to the scrubbing
and raw material preparation areas. The S02 scrubbing area can be designed
without the use of additives or with the use of either (1) MgO or (2) adlplc
acid to enhance SC>2 removal.
The S02 removal model can be run with any of the following four options
for relating stoichiometry, L/G ratio In the absorber, and 803 removal
efficiency:
Option Input Calculate
1 Stoichiometry, L/G S02 removal
2 Stoichiometry, S02 removal L/G
3 L/G, S02 removal Stoichiometry
4 Stoichiometry, L/G, and S02 removal Force-through alternative,
no calculation
Direct investment costs for the S02 absorption area include all slurry
and S02 absorption equipment and field construction materials between the
slurry feed tank and the waste disposal feed tank. Costs for a mechanical
collector may be included optionally.
Oxidation—
This area is an optional area which provides for oxidation of the S02
absorbed as calcium sulfite to calcium sulfate to facilitate subsequent
dewatering and disposal of the FGD wastes. If the forced-oxidation option is
not specified, the model results are based on only natural oxidation occurring
in the scrubbing loop with about 5%-20% of the absorbed S02 being In the
oxidized (calcium sulfate) form. Two forced-oxidation alternatives are
available: (1) within-loop forced oxidation in which air is sparged into the
absorber hold tank and scrubber slurry is recirculated to the absorber and (2)
bleedstream forced oxidation in which a bleedstream from the absorber is
sparged with air in a separate tank with the bleedstream subsequently
processed for disposal. In both oxidation alternatives, equipment, primarily
compressors and air spargers for option (1) and compressors, air spargers,
tanks, agitators, and pumps for option (2), are provided.
Direct investment costs for the oxidation area, when selected, include
costs for the equipment and associated field construction materials.
Reheat—
The outlet gas from the scrubber is reheated to the desired temperature
by either (1) indirect steam reheat, (2) blending scrubber outlet gas with hot
flue gas which bypasses the scrubber (only available if overall S02 removal
efficiency is less than 90£), or (3) a combination of (1) and (2). The
reheater gas is discharged to the stack plenum.
S-5
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Direct investment costs for the reheat area include costs for the
reheater equipment and field construction materials for installation.
Waste Disposal— .. ,
The model has provisions for the following five alternate waste disposal
options:
1. Onsite pond
a. Unllned pond
b. Clay-lined pond (cost and depth of clay lining is input)
c. Synthetic-lined pond (cost of liner is input)
2. Thickener - pond
3. Thickener - fixation fee
H. Thickener - filter - fixation fee
5. Thickener - filter - landfill
The onsite ponding options may also be run with fixation fees applied to
them. For alternatives 3 and 4, the fixation fee must include costs for
transportation and disposal of the fixed sludge off site. For alternatives 1
and 2, however, only the costs for fixation need to be provided since the
fixed sludge can be disposed of at the existing pond site. For alternative 5,
a landfill-fixation option may be provided using model calculations. Using
this option, the disposal facility is appropriately sized for the additional
fixation volume requirements.
For the waste disposal alternatives, the model allows for the onsite
facility to be sized larger or smaller than the normal projected lifetime
capacity. This option has been incorporated (1) to account for variations in
the sulfur content of fuel, (2) to evaluate design philosophy in construction
of ponds or landfills for less than the total amount of sludge to be disposed
(this requires assessment of additional costs for enlarging the waste disposal
area later), or (3) to allow the feed preparation and scrubbing areas to be
sized based on maximum sulfur contents expected while sizing the waste
disposal area based on average sulfur contents.
Direct Investment costs for the waste disposal area include costs for the
equipment and field construction materials downstream of the waste disposal
feed tank including those associated with the supernate return pumps and
piping.
Process Equipment Design Basis
Based on results from the material balance model and some user-supplied
variables, major process equipment is specified by area. The equations for
S-6
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predicting equipment costs were updated in 1983. The design assumptions used
as a basis for projecting the size or specifications of the major process
equipment are given below for each major equipment item included in the
alternative PGD options.
Gyratory Crushers-
Two parallel 50% capacity gyratory-type crushers are utilized to reduce
the inlet stone size from minus 1-1/2 inches to minus 3M inch for feed to the
ball mills.
Ball Mills—
The grinding mills are rubber-lined, open-circuit, overflow wet ball
mills that have a 30$ ball charge and produce a 60% slurry. The number of
ball mills is determined by total mill horsepower calculated from the lime-
stone throughput rate specified in the material balance, and the fineness of
grind and limestone hardness factors which are program inputs. The fineness
of grind index factor is related to the desired particle size distribution of
the ground limestone. One-mill systems are used for horsepower less than 200
and two parallel mill systems for horsepower between 200 and 5,000. For
horsepower greater than 5,000, the number of parallel mill systems is deter-
mined assuming a maximum mill size of 2,500 horsepower.
Lime Storage Silo—
A 30-day dead storage capacity is used to calculate the volume of the
lime storage silos. The silos are concrete, with the height of the actual
storage section of the silo assumed to be one and a half times the diameter.
Total height of the silo is equal to the height of the actual storage section
plus the height of the carbon steel hopper plus 5 feet. Parallel storage
silos are used for storage volumes greater than the capacity of the largest
silo (U7,200 ft3).
Lime Slaker—
Lime is slaked at slurry concentrations of 20% to 25$ solids in dual-
compartment, overflow slakers which can be designed with slaking capacities of
up to 33 ton/day. Parallel slaking trains are used for larger lime capaci-
ties. The number and size of parallel slakers required are determined based
on the capacity of the largest size slaker available (33 ton/day).
Fans—
The fans are centrifugal (double width, double inlet) with radial impel-
lers. The FD fans are constructed of carbon steel and the ID fans are con-
structed of Inconel 625. They are equipped with variable-speed fluid drives.
Fan horsepower is calculated based on the inlet gas flow rate per train and
the calculated pressure drop for the scrubber, mist eliminator, reheater, and
duct.
Scrubbing Trains—
The following procedures are utilized for determining the size or speci-
fications of the major process equipment in the scrubbing area. The number of
parallel scrubbing trains is either an input to the program or is established
as an override to the 'input value based on the minimum number of scrubber
S-7
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trains required. The minimum number of trains is calculated considering the
saturated flue gas velocity and volumetric flow rate at the scrubber outlet in
conjunction with the maximum cross-sectional area assumed for the scrubber
(1,370 ft2). Flue gas and slurry recirculation rates per train are calcu-
lated by dividing the total flow rates from the overall material balance model
by the number of operating scrubbing trains.
Scrubbers—
Scrubber cross-sectional area is calculated considering the outlet flue
gas rate per train in conjunction with the specified scrubber design gas
velocity. Number of scrubber grids, beds, and height of spheres per bed are
inputs to the program. The height of the scrubber is assumed to remain
constant for all scrubber sizes and internal configurations. A presaturator
compartment is included at the scrubber inlet for the TCA and spray tower, and
chevron-type mist eliminators are included near the outlet. Materials of
construction for the scrubbers and internals are listed below.
Venturi: Carbon steel with acid-resistant lining
Shell: Rubber-lined carbon steel
Grids: Type 316L stainless steel
Spheres: 1-1/2-inch-diameter, Nitrile foam
Mist eliminator, slurry header, and nozzles: Type 316L stainless steel
Tanks—
The size or specifications of tanks, agitators, and pumps for each of the
areas are determined by utilizing the following procedures. Tank volume is
calculated based on the residence time, which is either a program input or
assumed. An additional 10$ volume is added for freeboard. All tanks are
constructed of carbon steel and the slurry tanks are flake glass lined.
Except for the absorber bleed receiving tanks and the thickener overflow
tanks, each tank is designed with diameter equal to height up to a maximum
height of 60 feet. For tanks larger than 60 feet in diameter, tank height is
fixed at 60 feet and diameter is calculated. Absorber bleed receiving tank
height is equal to the effluent hold tank height and the diameter is calcu-
lated. Thickener overflow tank height is set equal to the height of the
thickener and the diameter is calculated. As an override to the calculated
diameter, a minimum diameter equal to one-half the height is fixed for all
tanks. The thickener and filter feed tanks are not used unless more than one
thickener or filter is required.
Agitators—
All slurry tanks are equipped with a 4-blade, pitched-blade, turbine
agitator. Agitator horsepower requirements are calculated on the basis of
total torque, which is a function of the degree of agitation required
(expressed as torque/unit volume), total tank volume, tank diameter, and the
S-8
-------
slurry specific gravity. Unit torque (torque/unit volume) for each tank is
determined as a function of the percent solids in the slurry.
Slurry Pumps—
All slurry pumps are rubber lined, centrifugal with water seals, and are
equipped with either a variable- or constant-speed drive. Pumps are usually
spared, with the number of operating pumps determined by the maximum available
pump size of 20,000 gpm.
Water Pumps-
Vertical, multiple-stage, turbine makeup water pumps capable of providing
a static head of 200 feet are provided for each 10,000 gpm of water required.
The pumps are carbon steel and spared.
Compressors—
The compressors are sized to provide sufficient air (oxygen) for oxi-
dizing the CaS03'1/2H20 to CaSOn*2H20. The stoichiometric
quantity of S02 absorbed is multipled by an input stolchiometry, usually
2.5, to determine the stoichiometric quantity of oxygen to be added. The
quantity of air is then determined for sizing the compressors.
Reheaters—
Reheater cross-sectional area is calculated based on the superficial gas
velocity (usually 20 to 25 ft/sec) which is input to the program and the
volumetric gas flow rate per train at scrubber outlet conditions. Reheater
surface area requirements are calculated in two steps: (1) surface area
requirements for reheat to 150°F and (2) requirements for reheat to the
specified reheat temperature. The portion of the reheater tubes required to
reheat to 150°F are Inconel and the remaining tubes are Cor-Ten. Reheater
design and costs are based on use of 1-inch tubes on a 2-inch square pitch.
Thickeners—
The thickeners are constructed of carbon steel tank walls coated with
epoxy paint and 1-foot-thick concrete conical basins. Thickeners are equipped
with rake mechanisms. A concrete underflow tunnel, including pumps and piping
for transferring the slurry, is included. Total thickener cross-sectional
area is calculated by the material balance portion of the model as a function
of the settling rate and settled solids density, which are Inputs into the
program, and the quantity of sludge in the effluent slurry calculated in the
material balance model. The number of thickeners required Is determined
assuming a maximum thickener diameter of 400 feet. Thickener height Is
calculated as a function of the diameter.
Filters-
Rotary drum vacuum filters constructed of carbon steel and equipped with
a vacuum pump, a filtrate pump, and a vacuum receiver are utilized. Filter
size is determined as a function of the filtration rate expressed In tons of
dry solids/ft2/day, which is a program input, in conjunction with the total
quantity of sludge. The minimum and maximum sizes of filters considered have
effective filtration areas of 50 and 900 ft2, respectively. Single filters
are used up to required filtration areas of 100 ft2. For total filtration
S-9
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areas between 100 and 1,800 ft*, two parallel filters are assumed. For
total filtration areas greater than 1,800 ft2, the number and size of
parallel filters required are determined based on the capacity of the largest
filter size.
Field Construction Materials Design Basis
Costs for field construction materials are based on the materials of
construction or specifications discussed below.
Piping—
Carbon steel pipe and gate valves are used for all waterlines including
pond supernate. For slurry lines less than 3-inch diameter, stainless steel
pipe is used; whereas, for all larger size lines, rubber-lined carbon steel
piping is used. Stainless steel strainers are used for pipes less than H-inch
diameter and rubber-lined strainers are used for 4-inch-diameter and larger
pipes. For slurry lines less than 3-inch diameter, stainless steel plug
valves are used. Eccentric plug valves are used for slurry lines between 3-
and 20-inch diameter, and knife gate valves are used for lines greater than
20-inch diameter. Handwheel operators are used for valves less than 12-inch
diameter and air cylinder actuators for larger valves. Typical piping layouts
are assumed as functions of flow capacities and the number of trains and costs
are correlated to flow rates in gal/min. Control valve costs are included in
instrumentation. Costs are included for a rubber-lined downcomer from the
scrubber to the effluent hold tank and a spare slurry disposal line to the
disposal site.
Ductwork—
Costs are included for the inlet plenum and all ductwork between the
inlet and stack plenums including insulation. Costs for the stack plenum are
not included since this plenum is required even if an FGD system is not
installed. Stack plenum elevation is set equal to effluent hold tank height
with a minimum elevation of 20 feet for small hold tanks. Each scrubber train
includes two guillotine dampers and costs for expansion joints.
Two partial scrubbing or emergency bypass ducts, each designed for a
minimum of 25% of the total gas flow rate from the boiler, are included in the
costs. Each duct includes two louver-type dampers and costs for expansion
joints.
Materials of construction for all ductwork is 3/16-inch Cor-Ten with the
exception of ductwork between the scrubber and reheater outlet which is 3/16-
inch type 316 stainless steel. All ductwork is insulated with 2-inch rock
wool. Duct size is based on a square cross section and a nominal design
velocity of 3,000 ft/min at local inlet conditions.
Foundations—
Concrete foundations for each equipment item are fixed according to
equipment sizes. Foundations for the structure are estimated on the basis of
the weight of the structure.
S-10
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Structures—
Structural estimates are based on the structure arrangement shown in the
body of the report. The total quantity of structure required for each
scrubber train and the corresponding costs are related to effluent hold tank
volume, scrubber cross-sectional area, and number of scrubbing trains.
Electrical—•
The electrical estimate is divided into four sections: (1) costs of
feeder cables from the power plant transformer yard to field modules for each
area; (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 module location, and individual motors for each area.
For each area, total connected motor horsepower is calculated for use in
establishing costs for (1) and (2). Costs for (3) and (4) are based on
individual motor sizes and number of connected motors. A typical layout is
assumed for each area in reference to the power plant transformer yard, remote
control center, and other areas.
Instrumentation—
Instrumentation costs are based on (1) fixed costs for instruments which
do not change In size and cost with equipment and pipe size variations and (2)
variable costs for Instruments which increase in size and cost as equipment
and pipe sizes increase. Each of these costs may be dependent upon number of
scrubbing trains, number of ball mills, number of pumps, etc. Costs are
included for control valves, graphic boards and panelboards, annunciator, air
dryers and piping, and instrument cable and wiring systems.
Buildings—
The control room and motor control center are integrated with the power
plant and prorated costs are included. Costs are included for a building to
house the limestone-grinding or lime slaking facilities. Buildings to house
the oxidation and/or disposal area equipment are included as appropriate. All
buildings are sized as a function of the equipment size and number of equip-
ment items and are constructed with concrete floors and corrugated aluminum
siding, supported by a steel frame. They are insulated to a value of R-19
using fiberglass insulation.
Pond Construction-
Disposal pond size is calculated based on a square configuration with a
diverter dike three-fourths the length of one side. A pond construction
diagram is shown in Appendix B. The pond model is based on either unlined,
clay-lined, or synthetic-lined design and includes the following options in
running the program:
Fixed-depth pond
Optimum-depth pond based on minimum pond Investment
Optimum-depth pond based on minimum pond investment with available
acreage and maximum excavation depth as overriding constraints
S-ll
-------
In addition to specifying pond design, the model also itemizes the break-
down of projected pond costs.
Landfill Construction— _. ., ...
Disposal landfill size is calculated based on a square configuration with
the cap sloping up to a point. A landfill construction diagram is shown in
Appendix B.
A separate model is included to design and cost the onsite landfill. The
landfill model is based on either unlined, clay-lined, or synthetic-lined
design.
MODEL USAGE
The Shawnee model can be of use to utility companies or architectural and
engineering firms involved in the selection and design of SC>2 removal
facilities. The model also has potential for use by environmental groups or
regulatory agencies. Although it is not intended to b*» used for projecting a
final design, it can be used to assist in the evaluation of system alterna-
tives prior to a detailed design. It should also be useful for evaluating the
potential impact of various process variables on economics as a guide for
planning.
Although the model was not meant to be used for comparing projected
lime-limestone economics with economics for alternate processes, these
comparisons should be valid as long as the bases for the alternate process
economics are comparable to those included in the computer model for lime and
limestone systems.
The body of this report contains information required to run the overall
computer model.
S-12
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SHAWNEE FLUE GAS DESULFURIZATION COMPUTER MODEL
USERS MANUAL
INTRODUCTION
The Shawnee flue gas desulfurization (FGD) computer model projects the
major design and operating conditions and the detailed economics of various
lime and limestone FGD process alternatives for coal-fired utility boilers
from user-supplied input data. Development of the model was sponsored by the
U.S. Environmental Protection Agency (EPA). The model is maintained by the
Tennessee Valley Authority (TVA), from whom the complete model or individual
runs are available. This manual provides a general description of the model
and its uses. It includes additions and revisions to the model that have been
made since publication of the previous users manual in 1981.
The model is general in nature and is capable of projecting conceptual
designs and economics for a range of power plant and FGD conditions. The
results are similar to those of preliminary conceptual design evaluations in
which absolute accuracies are about -15$ to +30$ and comparative accuracies
are about -10$ to +10$. The model is most useful for projecting preliminary
comparisons of FGD alternatives (type of absorbent, absorber design, and
operating conditions, for example) and evaluation of the effects of design
criteria [gas velocity, liquid-to-gas (L/G) ratio, S02 removal efficiency,
and stoichiometry, for example]. As such, it is most useful in preliminary
studies and screenings leading to detailed design studies and in planning
research and development activities.
-------
-------
GENERAL INFORMATION
BACKGROUND
From 1968 to 1980, EPA sponsored the development of lime and limestone
FGD technology at a test facility located at TVA's Shawnee Steam Plant near
Paducah, Kentucky. TVA was the constructor and operator of the facility and
Bechtel National, Inc., was the primary contractor. The test facility
consisted of three prototype FGD systems, each with a capacity of 30,000
aft3/min of flue gas (equivalent to 10 MW of generating capacity). One
system had a venturi-spray tower absorber and one had a mobile-bed absorber
[Turbulent Contact Absorber (TCA)]. The third system originally had a marble-
bed absorber that was operated only briefly and eventually converted to a
cocurrent absorber system.
Most of the test work involved operation of venturi, spray tower,
venturi-spray tower, and TCA absorbers. Initially, an extensive series of
lime and limestone FGD tests was made over a wide range of conditions. In
1976, forced-oxidation tests were begun and the use of magnesium oxide (MgO)
to enhance S02 removal efficiency was investigated. In 1979 and 1980, an
equally extensive series of tests using adipic acid to enhance S02 removal
efficiency was made. In all, over a decade of almost continuous assessment
and development of lime and limestone FGD technology was conducted, resulting
in a very large and comprehensive body of information.
The main phase of the testing at Shawnee was conducted from 197*1 through
1978 as the "Advanced Test Program," which has been reported in detail by
Bechtel (1). The adipic acid tests were conducted after this period (8).
Formal support of the test program by EPA ended in 1980. The facility is
still operated by TVA for various FGD evaluations, but the results of most of
these tests are not directly applicable to development of the Shawnee model.
The data developed during the tests sponsored by EPA were used to develop
a computer model to project conceptual designs and economics for lime and
limestone FGD processes. Bechtel developed computer procedures to project
material balances, flow rates, and stream compositions. TVA developed
computer procedures to project the economics of the processes. These were
based on premises and procedures developed by TVA, EPA, and others for the
evaluation of FGD economics. All of the computer procedures were combined
into an overall model composed of two computer programs. One program projects
the major equipment requirements and costs and the total capital investment.
The second program projects the annual revenue requirements.
-------
Since 1974, when development of the model began, the model has been
periodically updated to reflect current technology and economic conditions.
In 1979 and again in 1981 (9), users manuals were published for the model as
it existed then. Since that time, further revisions and additions have been
made. The major revisions consist of a refinement and expansion of the
forced-oxidation and adipic acid options, inclusion of a waste fixation option
and a landfill disposal option, and revision of the equipment and installation
cost models to reflect base costs obtained in 1983-
DOCUMENTATION
This manual provides the information and procedures necessary to use the
model but it does not describe the concepts and mathematics upon which it is
based. No fully comprehensive description of this basis has been published
because of the frequent revisions and additions that have been made during the
course of its development. The original chemical equilibrium model which was
developed by the Radian Corporation has been discussed (10), as have earlier
versions of the model (11). The Advanced Test Program reports by Bechtel (1)
discuss many aspects of the design and performance of the conceptual designs
used. Process flowsheets and layout drawings are included in Appendix A for
the alternative process and waste disposal options which are available in the
model. The design and economic premises in Appendix B provide additional
detail on the design basis and the economic calculations. Economic studies by
TVA (12), based in whole or part on the Shawnee computer model, discuss design
and economic aspects and provide examples of the economic evaluations and
comparisons.
SCOPE OF THE MODEL
There are three absorber options: spray tower, TCA, and venturi, each of
which can be used alone or as venturi-spray tower or venturi-TCA combinations
with either limestone or lime absorbent. Forced oxidation in various configu-
rations can be used with most of the absorber options. Adipic acid or MgO
additive options are also available with most absorber configurations.
Numerous design and operating condition options are available. Waste disposal
options include ponding, landfill, and fixation and landfill.
The equipment size and layout configurations are based on power units
between 100 MW and 1,300 MW in size and coal sulfur contents of 1$ to 5$. The
ranges of other critical variables are:
Absorber gas velocity 8-12.5 ft/sec
Absorbent liquid recirculation rate 25-120 gal/kaft3
Hold tank residence time 2-25 minutes
Number of absorber trains 1-10
Flue gas S02 concentration 600-4,000 ppm
-------
The validity of results for conditions outside these ranges has not been
determined. Results for intermediate-sized plants outside these ranges may be
valid, however.
Several model runs may be required to fully analyze the combined effects
of individual input conditions, especially if the ranges specified above are
exceeded. The effects of variations in inputs (such as absorber gas velocity,
L/G ratio, absorbent stoichiometry, 802 removal efficiency, and reheat
temperature) can be assessed individually or the cumulative effect can be
assessed by varying several conditions simultaneously.
AVAILABILITY
The model is available to the public through TVA under an information
exchange agreement between EPA and TVA. Upon receipt of a written request,
TVA provides a copy of the model suitable for loading onto an IBM-370-
compatible computer system, along with FORTRAN program listings and the
documentation required to execute the model. Under the same information
exchange agreement, TVA will make model runs based on user-supplied input
data. This allows users to analyze the capabilities of the model with a
minimum amount of investigation and investment.
The model is based on the requirements and specifications of the G1
compiler and FORTRAN66 language. The model is executed in FORTRAN66 on the VS
FORTRAN compiler using the FORTRAN66 option. It cannot be used with systems
based exclusively on FORTRAN?? or VS FORTRAN.
Model options and input variables are added and modified on a regular
basis. The latest version is usually supplied to users and is typically the
basis for user runs made by TVA. Model and documentation availability is
subject to limitations based on available funding and the costs that must be
incurred in connection with a user request.
A detailed list of all of the model inputs is included in Tables C-1 and
C-2 of Appendix C. These tables include a number of options for selecting
process design and controlling model output. Types of options are listed
below:
Variable Line Page
• Print - 1-3 9
• Particulate collection device XESP 5 9
removal
• Reheat XRH 5 13
• Bypass and partial scrubbing KEPASS, KPAS02 5 13-14
• Coal cleaning KCLEAN 5 m
-------
• Input composition
• Particulate removal
• S02 removal
• Operating parameter calculation
• Scrubbing absorbent (lime or
limestone)
• Chemical additive
• Forced oxidation
• Fan
• Absorber
• Redundancy
• Waste disposal
• Fixation
• Pond design
• Landfill design
• Disposal site liner
• Process economics
• Tax-freight
• Waste disposal economics
• Overtime
• Pond capacity
• Operating profile
Variable
INPOPT
IASH
IS02
ISR
XIALK
IADD
IFOX
IF AN
ISCRUB
NSPREP,NOREDN
ISLUDG
IFIXS
PSMAX.DISTPD
PDEPTH.PMXEXC
ILINER
IECON
ITAXFR
INDPND
IOTIME
PNDCAP
IOPSCH
Line
6
6
7
7
7
7
8
8
9
9
10
10
10
10
10
11
12
12
12
14
14
Page
17
18
20
22
24
24
29
34
34
37
37
42,64
42
50
54
54
56
62
56
62
66
Requests for copies of the computer model, model runs to be made by TV A,
or additional information should be made to the authors at the following
address: Division of Energy Demonstrations and Technology (ED&T), Tennessee
Valley Authority, Muscle Shoals, Alabama 35660, telephone number
(205) 386-2814 or (205) 386-2514.
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MODEL DESCRIPTION
INPUT
The model requires a minimum of 15 lines of input. Free-form format is
specified and blank spaces are required between variables except for the
CASEID (line 4) and the END or NEXT variable (last line of data set) which are
alpha-numeric format. Individual values may be specified to the desired
precision provided the total characters, including separators, do not exceed
72 per line. Additional input is required when a user-specified operating
profile is chosen instead of the built-in profiles. A detailed FORTRAN
variable list of the model input is shown in Table C-1 of Appendix C. The
variables are defined in Table C-2 of Appendix C. Ranges for key variables to
aid in establishing input data to the model are shown in Table 1.
TABLE 1. VARIABLE RANGES
'Item Description
Power plant New, 100-1,300 MW
Fuel sulfur content 1$-5$
Fuel S02 content 1.7-9.0 Ib S02
MBtu
Absorber gas velocity 8-12.5 ft/sec
Absorbent recirculation rate 25-120 gal/kft3
Hold tank residence time 2-25 minutes
Number of scrubbing trains 1-10
Number of spare scrubbing
trains 0-10
S02 removal efficiency 1$-100$
Fly ash removal efficiency 156-99.9$
TCA pressure drop 13 in. I^O/stage
Capital investment cost year Midpoint of construction
Annual revenue requirement
cost year First year of operation
Note: The variable ranges were established for model
development purposes. Values beyond these'ranges
are not necessarily invalid but the potential for
error is greater when these ranges are exceeded.
-------
As new options are incorporated, the required inputs are subject to
change. When this occurs, the list of variables and the associated
definitions will be updated and made available as necessary.
OUTPUT
The outputs of the Shawnee lime-limestone computer model provide a
complete conceptual design package for lime or limestone scrubbing. They
consist of: (1) a detailed material balance, including properties of the
major streams; (2) a detailed water balance itemizing water availability and
water required; (3) specifications of the scrubbing system design; (4) a
display of overall pond or landfill design and costs; (5) specifications and
costs of the process equipment by major processing area; (6) a detailed break-
down of the capital investment; (7) an itemized breakdown of the revenue
requirements for the first year of operation of the system; (8) a lifetime
revenue requirement analysis showing projected costs for each year of opera-
tion, as well as lifetime cumulative and discounted costs and equivalent unit
revenue requirements; and (9) a particulate removal cost table which lists
operating conditions and itemizes capital investment and annual revenue
requirements for a cold-side electrostatic precipitator (ESP), a hot-side ESP,
a baghouse, or a particulate scrubber. However, upstream particulate removal
is independent of the FGD process and costs are not included in the FGD eco-
nomic projections. These outputs are illustrated in the base case printout
shown in Appendix D.
In addition to the outputs listed above, a diagnostic message file is
generated each time the model is executed. This file contains informative
messages related to processing such as data case number and title, possible
conflicts between options, variable values that may be out of range, and fatal
conditions that terminate model execution. In typical model runs made by TVA,
the message file is listed between the printed output from the capital invest-
ment program and the printed output from the annual revenue requirements
program, but this depends on the control language procedures used for execu-
tion. An example message file is shown in the base case printout in
Appendix D.
OPTIONS
A detailed list of all of the model inputs is included in Tables C-1 and
C-2 of Appendix C. These tables include a number of options for selecting
process design and controlling model output. Some examples of the options are
shown on the pages that follow. For illustration purposes, the appropriate
input data line is shown and the particular option code is indicated. An
explanation of each option and sample output resulting from its use is
provided where necessary- Unless a value of zero is required, nonzero values
for all variables must be entered for each case even though a variable value
is being calculated by the model as a result of a user-specified option. In
this case, the calculated value will override the input value. A value of
zero may result in a zero divide operation in some cases. Spaces cannot be
used to take the place of variables which have a value equal to zero.
-------
Some user-specified input values result in the use of default values of
other variables for consistency in the calculations. For the options that
allow defaults, the option code that must be input and the default values that
are assumed are described. All model output listings used to illustrate
individual options are derived from the base case data shown in Appendix D.
Only the variables related to options being illustrated are changed from the
base case unless otherwise noted.
Print Options
Line No. Input data
1 11111
2 111111111111
3 11111
t *
IRPT IEQPR
The options on the first three lines of the input data control printed
output from the model. The first print option on line 3 (IRPT) requires
further explanation. This option controls the printout of the capital invest-
ment and annual revenue requirements. The short form printout is shown in
Table 2 and may be compared with the long printout of the base case example in
Appendix D. The other print option requiring further explanation is the third
option on line 3 (IEQPR). This option controls the printing of all or
selected portions of the equipment list. These options are described in the
input definition list in Table C-2 of Appendix C.
Particulate Collection Device Option
Line No. Input data
5 2 500 9500 11700 39 300 2 1 0 90 0 84.1 12.1 .3 175 470 751
XESP
The partlculate collection device option is controlled by the XESP
variable. The value of XESP may be 0, 1, or 2. A zero value is used if no
particulate removal device is to be considered. A value of 1 is used if a
mechanical collector (33$ efficient) is selected, and the code for upstream
removal (line 6, ASHUPS, see Table C-2) should have an input value of 33$ (%
removal). If an XESP value of 2 Is selected, a separate particulate removal
cost model (13) projects the capital investment and annual revenue require-
ments for particulate removal. The results are listed in the output but are
not included in the FGD costs. The percentage of particulate removal required
for this option is specified by the ASHUPS variable. Example output showing
the results of specifying mechanical collectors (XESP =1) is shown in
Table 3. Example output showing the results of using the built-in particulate
removal cost model is shown in the base case printout in Appendix D.
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TABLE 2. EXAMPLE RESULTS ILLUSTRATING SHORT-FORM PRINTOUT
LANDFILL DESIFN
LANDFILL COSTS
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TABLE 2. (Continued)
PROJECTED CAPITAL INVESTMENT REQUIREMENTS
INVESTMENT, THOUSANDS OF 1985 DOLLARS
HAT HAND FEED PREP GAS HAND S02 SCRU" OXID REHFAT SOLI^ SEP TOTAL PER Kw
SUBTOTAL DIRECT INVESTMEMT 2927. 5316. 1172?. 23561. 2797. 5077. 8129. 59525. 119.05
TOTAL CAPITAL INVESTMENT 5381. 9745. 21190. 13193. 5128. 93C7. 11575. 108818. 217.61
PKOJECTED FIRST YEAR REVENUE REQUIREMENTS - SHAHNEE COMPUTER USE" MANUAL
ANNUAL OPERATION KW-HR/KH = 5500
REVENUE
REPUIPEMENT, $
SUBTOTAL RAH MATERIAL 2220100
SUBTOTAL CONVERSION COSTS 11699200
SUBTOTAL INDIRECT COSTS 372COOO
FIRST YEAR OPERATING AND MAINTENANCE COSTS 17639600
LE.VELIZED CAPITAL COSTS 15996300
FIRST YEAR ANNUAL REVENUE REQUIREMENTS 33635 = 00
EQUIVALENT FIRST YEA» UNIT REVENUE REQUIREMENTS, MILLS/KWH (TOTAL MW) 12.23
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TABLE 3. EXAMPLE RESULTS ILLUSTRATING
MECHANICAL COLLECTOR PARTICIPATE REMOVAL
S02 SCRUBBING
INCLUDING 1 OPERATING AND 1 S^a"1" SCRUBBING TRAINS
ITEM DESCRIPTION NO. MATERIAL LABOP
MEC^MCAL ASH COLLECTOR
SMELL
NEOPRENE LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES
GRIDS
TOTAL SPRAY SCRUBBER COSTS
SOOTBLOWERS
EFFLUENT MOLD TANK
331 PARTICULAR REMOVAL
EFFLUENT HOLD TANK AGITATOR
COOLING SPRAY PUMPS
HECIRCULATION PUMPS
MAKEUP HATER PUMPS
AIR-FIXED
32?974.GAL, 'o.OFT D!A,
38.OFT HT, FL'TGLASS-
LINED CS
66 HP
13P9.GPM 100 FT HEAD,
61.HP, 4 OPER'TINC-
AND 6 SPARE
1P40S.GPM, 10? FT HEAD,
814.HP , P OPEO&TIHG
ANO 7 SPSCE
3473.GPM, 2C-.FT HFAD,
2^3.HP, 1 OPr'A^IMG
AMD 1 SPa»F
1
5
40
5
5
10
634081 .
2341328.
383686.
627930.
6220272.
174667.
410706.
457885.
113°11.
12°699
507083
27123
347464
1P9610
36076
15 20S5P46.
26754.
1673t'9.
4155.
TOTAL S02 SCRUBBING FTQUIPME^T COST
10133118. 140P60f.
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Reheat Potion
Line No. Input data
5 2 500 9500 11700 39 300 2 1 0 90 0 84.1 12.1 .3 175 470 751
I i *
XRH TSTEAM HVS
The reheat option (XRH) allows for either an inline steam reheater for
the scrubbed gas or for no reheating of the scrubbed gas. The inline steam
reheater is the only type of reheater available in the current version of the
model. When a reheater is specified (XRH = 2), the TSTEAM variable is used to
specify the temperature of the reheater steam and the HVS variable is used to
specify the heat of vaporization of the reheater steam. For the base case,
steam at 470°F and 500 psia is used; a steam table should be used to
determine the latent heat of steam for other steam conditions. Example output
showing the results of specifying an inline steam reheater is shown in the
base case in Appendix D. When no reheating is specified (XRH = 0), the
reheater section is omitted from the printout. If partial scrubbing/bypass is
used (variable KPAS02, line 5 below), the reheat requirements are determined
by the final temperature of the recombined flue gas, which includes the heat
contribution of the bypassed flue gas.
Emergency Bypass Option
Line No. Input data :
5 2 500 9500 11700 39 300 2 1 0 90 0 84.1 12.1 .3 175 470 751
f
KEPASS
The emergency bypass option (KEPASS) allows an emergency bypass around
the FGD system for one-half of the flue gas normally scrubbed as specified in
the premises (Appendix B). If only one operating scrubbing train is specified
(line 9, NOTRAN) then the emergency bypass is sized for all of the gas
normally scrubbed instead of only one-half. When both emergency bypass and
partial scrubbing/bypass (line 5, KPAS02 and PSS02X) are specified, the
emergency bypass is sized for 50$ of the gas normally scrubbed (100$ of the
gas normally scrubbed if only one operating train) plus the partial bypass
normally used for the unscrubbed gas (the total cannot exceed 100$). The
following values are used for the KEPASS option:
0 - No emergency bypass
1 - Emergency bypass
An example showing output when an emergency bypass is specified is shown in
the base case printout in Appendix D.
13
-------
Partial Scrubbing/Bypass Option
Line No. Input data
5 2 500 9500 11700 39 300 2 1 1 90 0 84.1 12.1 .3 175 470 751
/ t
KPAS02 PSS02X
The partial scrubbing/bypass option (KPAS02) allows FGD systems to be
projected for conditions in which all of the flue gas does not have to be
scrubbed to meet specified emission levels. The percent removal in the
absorber is specified with the PSS02X variable and the model will calculate
the percentage of flue gas that can be bypassed (if any) while still meeting
the emission limit or overall removal percentage specified (line 7, IS02 and
XS02)- The appropriate ductwork and reheater adjustments are made as
required, depending on the amount of bypassed gas. When the partial
scrubbing/bypass option is specified, the emergency bypass duct is also used
for the gas normally bypassed, as discussed above. Partial scrubbing/bypass
is not allowed when S02 removal is calculated from scrubber operating
conditions (line 7, ISR = 3). The following values are used for the KPAS02
option:
0 - No partial scrubbing/bypass
1 - Partial scrubbing/bypass
Example output showing partial scrubbing/bypass specified is shown in Table 4
based on an emission limit of 1.2 Ib S02/MBtu.
Coal—Cleaning Option
Line No. Input data
5 2 500 9500 11700 39 300 2 1 1 90 1 84.1 12.1 .3 175 470 751
/ / jf \
KCLEAN PREC SPASH WPRITE
5B 1.0 5.5 6.0 13000
If//
SMRW SMCL ASHCLN HVCLN
The coal-cleaning option (KCLEAN) allows the model to be used in conjunc-
tion with a coal-cleaning process. The model calculates the composition and
firing rate of cleaned coal based on the raw coal characteristics, the coal-
cleaning conditions, and the boiler megawatt rating and heat rate. The cor-
responding flue gas composition is used to determine the S02 removal
required in the FGD system.
In line 5, the variable PREC specifies the weight percent recovery in
pounds of cleaned coal per 100 pounds of raw coal, SPASH specifies the weight
14
-------
TABLE 4.- EXAMPLE RESULTS ILLUSTRATING
PARTIAL SCRUBBING/BYPASS
EMERGENCY BY-PASS
EMERGENCY BY-PASS DESIGNED FOR 53.?
HOT GAS FROM POILEP
MOLT PERCENT LP-MOLE/HR
C02
HCL
S02
02
N2
H20
12.317
0. 006
0.221
5.553
7"5.1"9
6.703
0.2255E*05
0.1115E+02
0.1012E*03
0.1017E»05
0.1377E»06
0.1227E*05
0.°923E + 06
C.*175E*03
0.2?"9E«05
0.3253E+06
0.3°57E«-07
0.22 HE* 06
FLYASH EMISSION = 10.325 LPS/MILLION BTU TO POILER
= 19013. LP/HR
HOT GAS FLOW RATE = .1156E+07 SCFM ( 60. DEG F, 11.7 PSIA)
= .1690E*07 ACFM (300. DEG F, 1«.7 PSIA)
CORRESPONDING COAL FIRING RATE = .1060E+06 LB/HR
HOT GAS HUMIDITY - 0.01? LR H20/LB DRY GAS
WET PULB TEMPERATURE = 121. DEG F
HOT GAS TO HY-PASS
MOLE PERCENT LB-MOLE/HR LP/"P
C02
HCL
SO 2
02
N2
H20
12. 317
0. 006
C.221
5.553
75. 199
6.703
0.1126E+01
0.7211E*00
0.2556E»02
0.6127E»03
0.8703E+01
0.775PE*03
0.6271E+05
0. 2£*OE»02
0.1637E*01
0.2C57E»05
0.2*;°E»06
0.139PE*05
HOT GAS BY-PASSED 6.3 *
FLYASH EMISSION = 0.001 LBS/MILLION BTU TO POILER
= 17. LB/HR
HOT GAS FLOW RATE - .7311E*05 SCFM ( 60. DEG F, 11.7 PSIA)
= .106BE*06 ACFM (300. DEG F, 11.7 PSIA)
CORRESPONDING COAL FIRING RATE = .2567E + 05 LP/HR
(Continued)
-------
TABLE 4. (Continued)
HOT GAS TO SCRUBBER
MOL17 PE°CENT LB-MOLE/HR L6/HR
CO 2
HCL
so a
02
N2
H20
12.317
0. 006
0.221
5.553
75.199
6.703
0.2112E+05
0.1073E+02
0.37B7E«03
0.9522E»04
0.1289^*06
0.11»9E>05
0.92°6E»C6
P. 31 11 E« 3 3
0.2426E-05
0.3047E»06
0.3613E«07
n.2071E»C6
S02 CONCENTRATION IN SCRUBBER INLET GAS = 22CB. "P"
= 5.45 L?S / MILLION BTU
FLYASH EMISSION =: 0.053 LBS/MILLION BTU TO BOILER
= 251. LB/HR
SOLUBLE CAO IN FLY ASH = 0. LB/HP
SOLUBLE MGO IN FLY ASH = 0.
HOT GAS FLOW RATE = .10«3E«07 SCF H < 60. DEC F, 11.7 PS1A)
= .15P3E»07 ACFH (300. DEC F, 1».7 P?!A)
h-«
CTv MW EQUIVALENT OF SCRJBBEP = »68 MEGAWATTS
CORRESPONDING COAL FIRING RATE = .?PC3E»06 LB/HR
MOT G»S HUMILITY = 0.013 LB H20/LB ^RY r-ss
WET HULB TEMPERATURE = 121. DEG F
WET GAS FRO" SCRUBBED
C02
HCL
S02
02
N2
H20
M.PLE PERCENT
11.722
0.000
0.010
5.101
70. 312
12.835
LB-MOLE/HR
0.2119E»05
0.5 364E »00
0.1893E»P2
O.^SSIE^O*
0.12S9f>06
0.2 35. IE* 05
LP/HR
0.94C9E»06
0.1956E»02
?.1213E»C»
0.2"'92E->C6
0.3613E*?7
0.4210E«06
S02 CONCENTRtTION IN SCRUBBER OUTLET GAS = 1P3. PPM
FLYASH EMISSION = 0.026 LBS/MILLION PTU TO "OILER
= 126. LB/HP
TOTAL WATER PICKUP = »»». GP«
INCLUDING 10.6 GPM ENT»flINMENT
WET GAS FLOW RATE = ,1158E«07 SCFM < 60. DEG F, 14.7 PSIA)
= .1301E»07 STFM (124. OEG F, 14.7 PSIt)
WET GAS SATURATION *jt«lDITY = 0.087 LP H20/LB nPY GAS
-------
percent of sulfur In the cleaned coal, and WPRITE specifies the weight percent
of pyritlc sulfur in the raw coal. In line 5B, which is required only if the
coal-cleaning option (KCLEAN =1) is specified, SMRW specifies the surface
moisture of the raw coal, SMCL specifies the surface moisture of the cleaned
coal, ASHCLN specifies the ash content of the cleaned coal, and HVCLN
specifies the heating value of the cleaned coal.
When the 1979 new source performance standards (NSPS) emission limit is
automatically calculated by the model (line 7, IS02 = 4), the appropriate
credit for coal cleaning will also be automatically calculated by the model on
a raw coal basis. In all other cases, the emission limit or removal percent-
age (line 7, IS02 and XS02) must be specified on a cleaned coal basis or must
be calculated by the model from FGD operating conditions (line 7, ISR = 3).
Coal cleaning is not allowed when the flue gas composition is specified
directly (line 6, INPOPT = 2). The following values are used for the KCLEAN
option:
0 - No coal cleaning
1 - Coal cleaning
Input Composition Option
Line
No. Input data
INPOPT
6A 1 66.7 3.8 5.6 1.3 3-36 .1 15.1 1.0 95 80 2 .06 .03
or
6B 2 12.338 .006 .214 5.560 75.227 6.654 1154000 47500 100 100 2 .06 .03
*
INPOPT
The input composition option (INPOPT) allows the flue gas composition to
be specified directly instead of being calculated by the model from a coal
composition. This allows the model to be used to project FGD systems for
other than coal-fired boilers. The variables described for line 6A (C, H, 0,
N, S, Cl, ash, H20, etc.; see Table C-2) should be used when the coal compo-
sition is specified; the variables described for line 6B (C02, HC1, S02,
02, N2, H20, etc.; see Table C-2) should be used when the flue gas
composition is specified directly. Coal cleaning (line 5, KCLEAN = 1) and the
automatic calculation of 1979 NSPS emission levels (line 7f IS02 = 4) are not
allowed when the flue gas composition is specified directly. The following
values are used for the INPOPT option:
17
-------
1 - Coal composition is specified (line 6A)
2 - Flue gas composition is specified (line 6B)
When a coal composition is specified, a "BOILER CHARACTERISTICS" section is
included in the output. Example output showing the results of specifying a
coal composition as input (INPOPT = 1) is shown in the base case printout in
Appendix D. When a flue gas composition is specified, a "HOT GAS ANALYSIS"
section is provided. Example output showing the results of specifying a flue
gas composition as input is shown in Table 5.
Particulate Removal Potion
Line No.
Input data
6 1 66.7 3.8 5.6 1.3 3-36 .1 15.1 4.0 95 80 2 .06 .03
IASH ASHUPS ASHSCR
The particulate removal variables are IASH, ASHUPS, and ASHSCR. The IASH
option identifies the method for specifying particulate removal, i.e., as
percent removal or as outlet emission in Ib/MBtu. IASH may take values of 0,
1, 2, or 3. If IASH is equal to 0, upstream particulate removal (ASHUPS) and
absorber particulate removal (ASHSCR) take default values of 33? and 99.2$
removal, respectively. If IASH equals 1, ASHUPS and ASHSCR are input as
percent removal. If IASH equals 2, ASHUPS and ASHSCR are input particulate
loadings in Ib/MBtu at the outlet of the upstream particulate collector and
the absorber, respectively. If IASH equals 3, ASHUPS is input as percent
removal and ASHSCR takes a default value of 75$. Regardless of the option
chosen, the output listing provides the equivalent particulate emission as
both percent removal and Ib/MBtu. A summary of the options is shown below.
IASH = 0 ASHUPS default value = 33$ removal
ASHSCR default value = 99.2$ removal
IASH = 1 ASHUPS input value as percent removal
ASHSCR input value as percent removal
IASH = 2 ASHUPS input value as Ib/MBtu to absorber
ASHSCR input value as Ib/MBtu from absorber
IASH = 3 ASHUPS input value as percent removal
ASHSCR default value equals 75$ removal
Example output showing the results of specifying particulate removal based on
Ib/MBtu (IASH = 2) is shown in the base case printout in Appendix D.
18
-------
TABLE 5. EXAMPLE RESULTS ILLUSTRATING
USER INPUT FLUE GAS COMPOSITION
«•• INPUTS ***
HOT GAS ANALYSIS MOLE PERCENT:
CO 2
12.3170
CL
n.0060
S02
0.2210
02 N2
5.5^30 75.1990
SULFUR OVERHEAD = 100.0 PERCENT
ASH OVERHEAT - 100.0 PERCENT
HEATING VALUE OF COAL = 11700. PTU/L B
EFFICIENCY,
50. 0
FLYASH REMOVAL
UPSTREAM OF SCRUBBED
WITHIN SCRUBBER
EMISSION STANDARD
SIP: 0.60 LEiS S02/1 BTU TO THE POILER
COST OF UPSTREAM FLYASH REMOVAL EXCLUDED
EMISSION.
LPS/M RTU
0.06
0.03
H20
6.7020
-------
S02 Removal Option
Line No. Jnput data
7 90 10 5 10 25 4 1.2 10 1 1.3 1 0 .15 0.0 1500 3 4.85 500
/ \
IS02 XS02
The model has five methods for specifying S02 outlet concentrations or
removal. The controlling variables are the IS02 option and the actual value
to be removed, XS02. If IS02 = 1, XS02 is input as the percentage of S02 to
be removed. (The percentage of S02 to be removed is used as the percent
removal by the absorber except when partial scrubbing is specified with the
KPAS02 option on line 5.) If IS02 = 2, XS02 is input as the absorber outlet
emission expressed as pounds S02/MBtu. If IS02 = 3, XS02 is input as ppm
S02 in the absorber outlet stream. If IS02 = 4, S02 removal is automati-
cally calculated by the model from the input coal composition based on the
1979 NSPS (14). Figure 1 illustrates the relationship between the S02
content of the raw coal and the controlled outlet emission levels used in the
model for the 1979 NSPS. The fifth method for specifying SC>2 removal, S02
removal calculated, is described in the operating condition options section
(line 7, ISR = 3). Regardless of the option chosen, the equivalent S02
removal in all three units is displayed in the model output. The input value
is shown as having been specified and the other values are shown as having
been calculated. A summary of the input options is shown below.
IS02 = 1 XS02 is input as percent removal
IS02 = 2 XS02 is input as pounds S02/MBtu at the absorber outlet
IS02 = 3 XS02 is input as ppm S02 in the absorber outlet stream
IS02 = 4 XS02 will be automatically calculated by the model based
on the 1979 NSPS
Example output showing the results of specifying emission limits based on the
1979 NSPS is shown in the base case printout in Appendix D.
An important concept related to SC>2 removal calculations in the model
should be emphasized here. The S02 removal options are based on long-term
average sulfur content of the coal and are not necessarily representative of
3-hour or 24-hour averages. When sizing an FGD facility, the raw material-
handling, feed preparation, and scrubbing areas should be based on the maximum
sulfur content of the coal rather than the long-term average. The waste
disposal area, however, should be sized on the long-term average sulfur
content. This can be done by entering the weight percent sulfur as the
maximum expected and then entering the waste disposal capacity factor (line
14, PNDCAP) to adjust the total amount of waste generated back to the
equivalent long-term average amount.
20
-------
90 90.8
pq
CSl
O
en
O
M
in
H
§
§
H
§
U
1.2-
1.0-
& 0.8-
s °'6 "
w
H
0.4 .
0.2 -
% SO Removal Required
70 80 85 88
5.0% S, 11,700 Btu/lb bit, coal
3.5% S, 11 700 Btu/lb bit, coal
2.0% S, 11,700 Btu/lb bit, coal
0.9% S, 6,600 Btu/lb lignite
0.7% S, 9,700 Btu/lb bit, coal
0.7% S, 9,700 Btu/lb subbit. coal
Q.7% S, 8,200 Btu/lb subbit. coal
10
12
EQUIVALENT SO CONTENT OF RAW COAL, Ib SO /MBtu
Figure 1. Controlled SO. emission requirements for 1979 NSPS. Premise coals, shown
underlined, are based on premise boiler conditions.
-------
Operating; Condition Calculation Potion
Line No. Input data
XLG XS02 ISR SRIN XIALK IADD AD
/ \ \ I /^ /
7 90 10 5 10 25 4 1.2 10 1 1.3 1 0 .15 0.0 1500 3 4.85 500
8 15 40 .2 40 0 30 2.5 85 1.2 7-0 0 9 0 14.7 1
PHLIME
Four options are available in the model to allow either user input or
model calculation of the major operating conditions which include L/G
(expressed as absorber liquid recirculation rate in gallons per 1,000 aft3
of flue gas at the absorber outlet), stoichiometry (expressed as mols CaCOg
or CaO added per mol of 803 + 2HC1 absorbed), and 803 removal. The
options differ slightly for the limestone system, the additive-enhanced
limestone system, and the lime-scrubbing system so the description is divided
into three sections.
For limestone scrubbing (line 7, XIALK =1), the variables used are ISR,
XLG, SRIN, and XS02. ISR is the controlling option and takes values from 0 to
3. If ISR has an input value of 0, the L/G (XLG), stoichiometry (SRIN), and
S02 removal (XS02, units depend on IS02) are all user input values. Speci-
fying ISR = 0 is referred to as "force-through" because no program checks are
made for validity or consistency among the three input variables to ensure
that specified L/G and stoichiometry can result in the input degree of
removal. If ISR is equal to 1, XLG and XS02 are input and the model calcu-
lates stoichiometry. If ISR is equal to 2, SRIN and XS02 are input and the
model calculates the L/G ratio. When ISR is equal to 3, XLG and SRIN are
input and the model calculates S02 removal. Values of 1.03 or greater
should be used for SRIN when it is specified as input because of logarithm
mathematical requirements. A summary of the various options for a limesttme-
scrubbing system is shown below.
ISR = 0 XLG is input
XS02 is input
SRIN is input
ISR = 1 XLG is input
XS02 is input
SRIN is calculated
ISR = 2 XLG is calculated
XS02 is input
SRIN is input
22
-------
ISR = 3 XLG is input
XS02 is calculated
SRIN is input
Example output showing the results of specifying ISR = 1 is shown in the base
case printout in Appendix D.
Similar options are available for the adipic acid-enhanced limestone
system (line 7, IADD = 2). The variable PHLIME is used to input the pH of
absorber recirculating liquid. The pH has a critical effect on the calcula-
tion of L/G ratio and S02 removal and the user must understand the system so
that anomalous results are not produced. The adipic acid option is discussed
in more detail in Appendix E. A summary of the options is shown below. The
PHLIME option specifies pH. The AD option specifies the quantity of adipic
acid in the system in ppm.
ISR = 0 XLG is input
XS02 is input
PHLIME is input
AD is input
ISR = 1 XLG is input
XS02 is input
PHLIME is input
AD is calculated
ISR = 2 XLG is calculated
XS02 is input
PHLIME is input
AD is input
ISR = 3 XLG is input
XS02 is calculated
PHLIME is input
AD is input
Similar options are available in the lime-scrubbing option (line 7,
XIALK = 2). 'The variable PHLIME replaces SRIN except when ISR = 0 because for
lime scrubbing the model calculates the pH of the recirculation liquid instead
of the lime stoichiometry. (When limestone is specified, the value of PHLIME
is ignored. Whe# lime is specified, SRIN is ignored except when ISR = 0, in
which case PHLIME* is ignored.) A summary of the options for a lime system is
shown below.
ISR = 0 XLG is input
XS02 is input
SRIN is input
23
-------
ISR = 1 XLG is input
XS02 is input
PHLIME is calculated
ISR = 2 XLG is calculated
XS02 is input
PHLIME is input
ISR = 3 XLG is input
XS02 is calculated
PHLIME is input
The output listing for the lime option is similar to that for the lime-
stone option shown in Appendix D except that the stoichiometry is printed out
for CaO instead of CaC03, as shown in Table 6. (An input value of 7.85 is
used for PHLIME in this example.) For both the lime and limestone options, if
input values are specified for the variables that are to be calculated by the
model, the input values are ignored.
Scrubbing Absorbent Option (Lime or Limestone)
Line No. Input data
7 90 10 5 10 25 H 1.2 10 1 1.3 1 0 .15 0.0 1500 3 *».85 500
XIALK
The absorbent option (XIALK) allows a choice of either lime or limestone.
If XIALK = 1, limestone slurry is selected as the scrubbing medium. If
XIALK = 2, lime slurry is selected. Example output showing the results of
specifying limestone scrubbing (XIALK = 1) is shown in the base case printout
in Appendix D. The scrubbing output and the raw material preparation area
equipment list from the lime option output are shown in Tables 7 and 8,
respectively.
Chemical Additive Option
Line No. Input data
7 90 10 5 10 25 4 1.2 10 1 1.3 1 0 .15 0.0 1500 3 4.85 500
IADD XMGOAD AD ADDC
The chemical additive option (IADD) provides for the addition of either
MgO or adipic acid to the slurry stream to improve scrubber efficiency and
S02 removal rates. The following values are used for the IADD option:
24
-------
TABLE 6. EXAMPLE RESULTS ILLUSTRATING
LIME-SCRUBBING INPUT
BOILER CHARACTERISTICS
MEGAWATTS = 500.
HOILEP HEAT PATE = 9500. PTU/KWH
EXCESS AIR = 39. PERCENT, INCLUDING LEAKAGE
HOT GAS TEMPERATURE r 300. DEG f
COAL ANALYSIS, WT * AS FIREP :
C H 0 N S CL A^H H20
66.70 3.80 5.60 1.30 3.36 0.10 15.10 4.00
SULFUR OVERHEAD = 95.0 PERCENT
ASH OVERHEAT = 80.0 PERCENT
HEATING VALUE OF COAL = 11700. BTU/LP
EFFICIENCY, EMISSION,
FLYASH REMOVAL X LCS/M BTU
UPSTREAM OF SCRUBBED 99.4 0.06
WITHIN SCRUBBER 50.0 0.03
EMISSION STANDARD
1979 NSPS
COST OF UPSTREAM FLYASH REMOVAL EXCLUDED
ALKALI
LIME :
CAO = 95.00 WT % DRY RASIS
SOLUBLE MGO = 0.15
INERTS = 4.85
MOISTURE CONTENT : 5.00 Lg H20/100 LPS DRY LIME
FLY ASH :
SOLUPLE CAO - 0.0 WT
SOLUBLE MGO = 0.0
INERTS = 100.00
RAW MATE"IAL HANDLIN3 APFA
NUMBER OF REDUNDANT A1.KALI PREPARATION UNITS =
-------
TABLE 7. EXAMPLE RESULTS ILLUSTRATING
LIME-SCRUBBING OUTPUT
SCRUBBER SYSTEM
TOTAL NUMBER OF SCRUBBING TRAINS (OPERAT ING*PEDUNDANT ) = 5
S02 REMOVAL = P9.0 PERCENT
PARTICULATE REMOVAL IN SCRUBBER SYSTM = 50.0 PERCENT
SPRAY TOWER DRE?SUR-: DROP = l.B IN. H20
TOTAL SYSTEM PRESSURE DROP = 7.0 IN. H20
SPECIFIED SPRAY TOWER L/G RATIO = 70. G£L/1030 ACF(SATD)
LIME ADDITION = 0.2370E*05 LB/HR DRY LIME
SPECIFIED LIME STOICHIOMETRY
= 1.10 MOLE CAO ADDED AS LIME
PFR "OLE (S02+2I-CL) ABSORBED
SOLUBLE CAO FRO" FLY ASH = 0.00 MOLE PER MOLE ABSORBED
TOTAL STOICHIOMETRY
MAKE UP WATER = 563. GPM
1.10 MOLE SOLUBLE (Ce**G>
PER MOLE APSORBED
OXIDATION AIR RATE r 0.4972E»05LB/HR
- 0.1083E»05 SCFM <6C DEC F,l«,7 PSIA)
CROSS-SECTIONAL AREA PER SCRUBBER r 577. SO FT
SOLIDS DISPOSAL SYSTEM
TOTAL CLARIFIER(S) CROSS-SECTIONAL AREA -
SYSTEM SLUDGE DISCHARGE
1551. SO FT
SPECIES
CAS03 .1/2 "20
CAS04 .2H20
CAC03
INSOLUBLES
H20
CA»*
"G**
S03 —
S04--
CL-
LP-MOLE/HR
0.17°7E*02
0.3417E«03
0.3P09E»02
0.6148F*03
0.4198E-»01
0.1635E*01
0.1B73E-01
0.1S24F»00
0.1088E:»02
LB/HR
0.2321E»04
0.5880F-* 05
O.^eiPTtOI
0 • 1 292F* 0*i
0.1682E+03
0 .3975T* 02
0.149°F»01
0.1560E»02
d-SSS^E*!!;
Ci U l_ i L
COMP,
WT X
3.5C
PP .79
5.76
IP ^
9^.
L 1 U U 1 L1
COMP,
PPM
14395.
3401.
12R.
1334.
33001.
TOTAL DISCHflRGE FLOW RATE = 0.77^1E+05 LB/HR
-------
TABLE 8. EXAMPLE RESULTS ILLUSTRATING LIME-SCRUBSING,
RAW MATERIAL-HANDLING, AND PREPARATION AREAS
ITEM
RAW MATERIAL HANDLING
DESCRIPTION
NO. MATEDIAL L6BP"
NJ
CAR SHAKER AND HOIST
CAR PULLER
UNLOADING HOPPER
UNLOADING VIBRATING FEEDER
UNLOADING BELT CONVEYOR
UNLOADING PIT DUST COLLECTOR
STORAGE SILO ELEVATOR
STORAGE BELT CONVEYOR
STORAGE CONVEYOR TRIPPER
CONCRETE STORAGE SILO
STORAGE SILO HOPPER BOTTOM
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOR
FEED BIN ELEVATOR
FEED BELT CONVEYOR
FEED CONVEYOR TRIPPFR
FEED BIN
LIME SYSTEM DUST COLLECTORS
20HP SHAKFR 7.5HP HOIST
25HP PULLER, 5HP RETURN
16FT DIA, 10FT STRAIGHT
INCLUDES 6 IN SQ GRATING
3.5 HP
20 FT HORIZONTAL, 5 HP
POLYPROPYLENE HAGTYPE,
INCLUDES DUST HOOD
125.FT HIGH 4" HP
133.FT HORIZONTAL. 5 HP
30FPM, 1 HP
10340*.FTT,4
-------
TABLE 8. (Continued)
RAH MATERIAL PREPARATION
INCLUDING 2 OPERATING AND 1 SPARE PREPARATION UNITS
ITEM DESCRIPTION NO. MATERIAL LABO°
N3
CD
BIN VIBRATING FEEDER
BIN WEIGH FEEDER
SLAKER
SLAKER PRODUCT TANK
3.5 HP
12FT, 12 IN SCREU, 1 HP
6. TPHt 11. HP
6000 GAL 10FT DIA, 10FT
HT, FLAKEGLASS LINED cs
SLAKER PRODUCT TANK AGITATOR 7.5 HP
SLAKER PRODUCT TANK SLURRY
PUMPS
SLURRY FEED TANK
SLURRY FEED TANK AGITATOR
SLURRY FEED TANK PUMPS
139.GPH, 60 FT HEAD,
4 HP, 2 OPERATING
AND 1 SPARE
146699.GAL, 29.2 FT DIA,
29.2 FT HT, FLAKEGLASS-
LINED CS
52 HP
69.GPM, 60 FT HEAD,
2.HP, 1 OPERATING ANC
4 SPARE
3
3
3
3
3
3
1
1
8
39038.
20010.
193160.
20207.
26200.
11190.
43742.
63961.
19211 .
4441.
2661.
35661.
15155.
2712.
3956.
36615.
5297.
8137.
TOTAL FEED PREPARATION EQUIP1ENT COST
436718.
11463ft.
-------
0 - No chemical additive
1 - MgO added
2 - Adipic acid added
If IADD = 1, variable XMGOAD is used to specify the quantity of MgO added
to the system (expressed as pounds of soluble MgO added per 100 pounds of
alkali feed). When IADD = 2, variable AD is used to specify the concentration
of adipic acid in the scrubber slurry [expressed as ppm (by weight) adiplc
acid] and variable ADDC specifies the degradation constant for adipic acid in
the scrubber slurry (expressed as pounds of adipic acid to be added per pound
of adipic acid remaining in the slurry after degradation).
Example output showing the results of adding adipic acid is shown in
Table 9-
Forced-Oxidation Option
Line No,
8 15 40
Inout data
.2 40 0 30 2.5 85 1.2 7.0 0 9 0 14.7
1
/ / t
RS IFOX OX
The forced-oxidation option (IFOX) provides for oxidation of the sulfite
slurry to gypsum by sparging air into one of the slurry tanks. Gypsum offers
better disposal options such as easier dewatering, a higher settling rate, and
a higher density. Variable RS is the thickener solids settling rate (ft/hr)
and may be user specified or will be automatically calculated based on the
percent oxidation of the scrubbing slurry by specifying a value of 0.0. The
following values are used for the IFOX option:
0 - No forced oxidation
1 - Forced oxidation in a single effluent tank (within the absorber loop)
2 - Forced oxidation in the first of two effluent tanks (within the
absorber loop)
3 - Forced oxidation in the disposal feed tank (bleedstrearn from the
absorber loop); the number of effluent tanks depends on the ISCRUB
variable (line 9)
The percent oxidation efficiency (0-99, in mol percent) in the system is
specified with the OX variable and should be specified in agreement with the
IFOX option. The number of tanks specified by the forced-oxidation option
must not conflict with the number of tanks indicated by the absorber option
29
-------
to
o
TABLE 9. EXAMPLE RESULTS ILLUSTRATING
THE ADDITION OF ADIPIC ACID
SCRUBBER SYSTEM
TOTAL NUMBER OF SCRU3BING TRAINS ABSORBED
SCRUBBER LIQUOR ADI»IC ACID CONCENT"AT ION r 1500. PPM
MAKE UP WATER = 531. GPM
MAKE-UP ADIPIC ACID = 0.5234E»02 LB/HR
OXIDATION AIR RATE =: 0. 1972E »05LB/HP
- 0.1083E»05 SCFM (60 DEG F,l*.7 PSIA)
CROSS-SECTIONAL AREA PER SC9UBBE" = 512. SO FT
SOLIDS DISPOSAL SYSTEM
TOTAL CLARIFIER(S) C^OSS-SECTIONAL AREA r
SYSTEM SLUDGF DISCHARGE
LB/HR
SPECIES
CAS03 .1/2 H20
CASOt .2H20
CAC03
INSOLUBLES
H20
CA»»
MG+*
SO3 —
so* —
CL-
AD —
LP
0.
0.
0.
0.
0.
0.
0.
0.
0.
0 -
-1.0LE/HR
1798E»P2
3117E*03
2£62E»02
S129E»03
3981E»01
1»87E»01
1851E-01
1582E»00
1019f:»02
1 195E*00
O.f 8fiOE»05
0.1520r»0?
15*3. SO FT
SOLID LIGUID
COMP, COMP,
WT X PPW
3.52
P9.21
t'.OI
1371P
127
J 307
31 061
1500
-------
TABLE 9. (Continued)
RAW MATERIAL HANDLING
ITEM
CAR SHAKER AND HOIST
CAR PULLFR
UNLOADING HOPPER
UNLOADING VIBRATING FEEDER
UNLOADING BELT CONVENOR
UNLOADING INCLINE BELT
CONVEYOR
UNLOADING PIT OUST C9LIECTW
UNLOADING PIT SUMP PI/HP
STORAGE BELT CONVEYOR
STORAGE CONVEYOR TRIPPER
MOBILE EQUIPMENT
RECLAIM HOPPER
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOR
RECLAIM INCLINE BELT CONVEYOR
RECLAIM PIT DUST COLLECTOR
RECLAIM PIT SUMP PUMP
RECLAIM BUCKET ELEVATOR
FEED BELT CONVEYOR
FEED CONVEYOR TRIPPER
FEED BIN
ADIPIC ACID ADD STO»AGE SILO
PNEUMATIC CONVEYOR SYSTEM
ADDITION FEED Bit
ADDITIVE DUST COLLECTOR
DESCRIPTION
20HP SHAKEP 7.5HP MCIST
25HP PULLE", ?H" CCTU"K
IfFT DIA, 10FT STRAIGHT
INCLUDES 6 IN SO COATING
3.5 HP
20 FT HORIZONTAL, 5 HP
310 FT, 50 HP
POLYPROPYLENE BA6TVPE.
INCLUDES DUST HOOO
60 GPN, 70 FT MEAD, 5 HP
200 FT, 5 HP
30 FPH, 1 HP
SCPAPPER TRACTOR
TFT WIDE, «.25FT HT, 2FT
WIDE BOTTO", C?
3.5 HP
200 FT, 5 HP
193 FT, »0 HP
POLYPROPYLENE BAG TYPE
60 GPM, 70 FT HEAD, 5 HP
90 FT HIGH, 25 HP
60.FT HORIZONTAL 7.5 HP
30 FPM, 1 HP
13FT DIA, 21FT STRAIGHT
SIDE HT, COVERED, CS
733. FT3, P.5FT DIA
19.9 FT HT 60 OE6 CONE
10. HP
RUBBER LINED
POLYPROPLENE BAG TYPE
450 CFM, 1.5 HP
NO.
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
3
1
1
1
1
MATERIAL
85232.
703
-------
TABLE 9. (Continued)
RAW MATERIAL PREPARATION
INCLUDING 2 OPERATING AND 1 SPARE PREPARATION UNITS
DESCRIPTION MO. MATERIAL LABO"
ITEM
BIN WEIGH FEEDER
GYRATORY CRUSHERS
BALL MILL DUST COLLECTORS
BALL MILL
MILLS PRODUCT TANK
MILLS PRODUCT TANK AGITATOR
MILLS PRODUCT TANK SLURRY
PUMP
SCREW FEEDER
SLURRY FEED TANK
SLURRY FEED TANK AGITATOR
SLURRY FEED TANK PUMPS
It FT PULLEY CENTERSt 2HP 5
75 HP
POLYPROPYLENE BIG TYPE
2200 CFM, 7.5HP
CYLINDRICAL 10.3TPH, 585. HP 3
5500 GAL 10FT 014, 10FT
HT, FLAKEGLASS LINED CS
7.5 HP
43. GPP,60 FT HEAD,
2.HPt 2 OPERATING
AND 1 SPAPE
30 FT LONG, 6 IN 0, SS
45623. GAL, 19.B FT DIA,
19.8 FT HT, FLAKEGLASS-
LINED CS
42 HP
22. GPM, 60 FT HEAD,
1 HP, 4 OPERATING AND
4 SPARES
3
3
3
3
3
3
3
1
1
1
&
63437.
402S25.
28620.
1363254.
17963.
38317.
7170.
6004.
20080.
42100.
1S709.
2661.
7374.
8883.
104992.
13257,
4069.
3051
593
168C9
3487
8137
TOTAL FEED PREPARATION EQUIPMENT COST
(Continued)
2008677. 173243.
-------
TABLE 9. (Continued)
LIMESTONE SLURRY PROCESS — 3ASIS: 468 «W SC°UBBING UNIT - 500 MW GENERATING UNITt 1987 STARTUP
PROJECTED REVENUE REQUIREMENTS - SHAWNEE CC^UTER USER MANUAL
"ISPLAY SHEET FOR YEAR =
AN'itAL OPERATION KW-HR/KW =
5500
DIRECT COSTS
RAW MATERIAL
32.99 TONS PED MOLID
TOTAL CAPITAL INVESTMENT
D°Y
97625000
A\NU*L QUANTITY
UNIT COST,*
TOTAL
ANNUAL
COST, I
UJ
LO
LIMESTONE
ADIPIC ACID
SUBTOTAL RAW MATERIAL
CONVERSION COSTS
OPERATING LABOR AND
SUPERVISION
LANDFILL LABOR AVD
SUPERVISION
UTILITIES
STEAM
PROCESS WATER
ELECTRICITY
DIESEL FUEL
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
INDIRECT COSTS
OVERHEADS
PLANT AND ADMINISTRATIVE (
112.9 K TONS
143.9 TONS
15.00/TON
1500.00/TON
£0.01 OF CONVERSION COSTS LESS UTILITIES)
FIRST YEAR OPERATING AND MAINTENANCE COSTS
LEVELIZED CAPITAL CHARGES* 1».TI PF TOTAL CAPITAL INVESTMENT)
FIRST YEAR ANNUAL REVENUE 'EOL' ID EVENTS
EQUIVALENT FUST YEAR UNIT "EVENUE R EC UIREMENT? , MILLS/KWH (VV SCRUBBED
EOUIV«LENT FIRST YEAR W." REVENUE REQUIREMENTS • "ILLS/KWH (TOTAL HW>
1693900
215900
1909*00
42970.0
29120.0
432220.0
179400.0
44469840.0
75480.0
3330.0
MAN-HR
MAN-HR
K LB
K GAL
KWH
GAL
HR
19.00/MAN-HR
24.00/MAN-HR
4.00/K LB
0.16/K PAL
0.055/KWH
1.60/GAL
26.00/HR
816400
698900
1728900
28700
?445»OP
120POO
4079^00
86600
111 005600
11915400
3408POO
1?3242CO
14351COO
29675200
11.5?
10.7<=
LEVELIZED OPERATING ANP MA INTtNAN1-1- ( 1.PC6 TI»FS FIRST YEAR OPER. t MAIN.)
LEVELIZED CAPITAL CHARGES! lt.7Ct OF TOTAL CAPITAL INVESTMENT)
LEVELIZED ANMJ«L REVENUE »EOUIRE»ENTS
EQUIVALENT LEVELIZED UNIT =EVfNUE a EQU IRECENTS , fILLS/KWH ( MW SCRUBBED)
EQUIVALENT LEVELIZED UNIT =EVENUE REOU I RE"E NTS . *ILLS/KWH (TOTAL MW)
2«901»00
143E10CO
43252*00
16.80
15.7J
HEAT RATE
9500. BTU/KWH
VALUE OF COAL
11700 5TU/LP
COAL RATE 1116500 'ONS/YR
-------
(ISCRUB, line 9). Example output showing the results of specifying forced
oxidation in the first of two effluent tanks (IFOX = 2) is shown in Table 10.
An example of one tank (IFOX = 1) is shown in Table 11.
Booster Fan Option
Line No. __ _ InPUt
8 15 40 .2 40 0 30 2.5 85 1.2 7.0 0 9 0 14.7 1
IFAN
The fan option (IFAN) allows either induced-draft (ID) fans or forced-
draft (FD) fans to be specified to compensate for the pressure drop in the FGD
system. The following values are used.
0 - Forced-draft fans
1 - Induced-draft fans
Example output showing the results of specifying ID fans is shown in the base
case printout in Appendix D. The format of the output is similar for the FD
fan option; however, the fan costs are different.
Scrubbing Option
Line No. _ Input data _
9 1 0 0 0 35 .0000005 3£ 10 5.70 1 4 1 .1
ISCRUB
The scrubbing option (ISCRUB) identifies one of the six absorber systems
that can be used. The ISCRUB values and the corresponding systems are as
follows:
ISCRUB = 1 Spray tower (one effluent tank unless two tanks are specified by
the forced-oxidation option, IFOX, on line 8)
ISCRUB = 2 TCA (one effluent tank unless two tanks are specified by the
forced-oxidation option, IFOX, on line 8)
ISCRUB = 3 Venturi-spray tower with two effluent tanks (if forced oxidation
is specified by IFOX on line 8, IFOX must be 2)
ISCRUB = 4 Venturi-spray tower with one effluent tank (if forced oxidation is
specified by IFOX on line 8, IFOX must be 1)
34
-------
TABLE 10. EXAMPLE RESULTS ILLUSTRATING
FORCED OXIDATION, TWO EFFLUENT TANKS
S02 SCRURPING
INCLUDING 1 OPERATING AND 1 SPAR? SCRUBBING TRAINS
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
Ln
SHELL
NEOPRENE LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES
GRIDS
TOTAL SPRAY SCRUBRER COSTS
SOOTBLOWERS
EFFLUENT HOLD TANK
EFFLUENT HOLD TANK AGITATOR
COOLING SPRAY PUMPS
RECIRCULATION PUMPS
MAKEUP WATER PUMPS
AIR-FIXED 10
323971.GAL, 38.OFT DIA, 5
38.0 FT HT, FLAKEGLASS-
LINED CS
66.HP 5
1389. GPM 100 FT HEAD, 10
61 .HP, 4 OPERATING
AND 6 SPARE
18108.GPM, 100 FT HEAD,
811.HP, fl OPERATING
AND 7 SPARE
3173.GPM, 200.FT HEAD, 2
293.HP, 1 OPERATING
AND 1 SPARE
2311328.
1928600.
383686.
938730.
627930.
6220272.
171667.
119706.
507083.
27123.
317161.
157885. 189610.
113911. 36076.
15 2085816. 167399.
1155.
TOTAL S02 SCRUBBING FQUIPME-JT COST
9199038. 1278907.
OXIDATION
INCLUDING 1 OPERATING AND 1 SPARE SCRUBBING TRAINS
ITEM DESCRIPTION NO. MATERIAL
LABOR
RECIRCULATION TANK
RECIRCULATION TANK AGITATOR
OXIDATION BLEED PUMPS
OXIDATION AIR BLOUEP
OXIDATION SPARGER
202181.GAL 30.1 FT DIA, 5
38.0 FT HT, FLAKEGLASS-
LINED CS
59.HP 5
168.GPM, 60 FT HEAD 8
12.HP, 1 OPERATING
AND 1 SPARE
2708 SCFM, 267.HP 6
19.0 FT DIA RING 5
TOTAL FORCED OXIDATION EQUIPMENT COST
319810.
312708.
17202.
201276.
66111.
980110.
261831.
111915.
17912.
5125.
12697.
172809.
-------
TABLE 11. EXAMPLE RESULTS ILLUSTRATING
FORCED OXIDATION, ONE EFFLUENT TANK
S02 SCRUBBING
INCLUDING 4 OPERATING AND 1 SPARE SCRUBBING TRAINS
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
SHELL
NEOPRENE LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES
GRIDS
TOTAL SPRAY SCRUBBER COSTS
SOOTBLOWERS
EFFLUENT-OX IDAT ION
HOLD TANK
EFFLUENT-OXIDATION
HOLD TANK AGITATOR
COOLING SPRAY PUMPS
ABSORBER RECYCLE PUMPS
MAKEUP HATE" PUMPS
AIR-FIXED
374595.GAL, 79.9FT DIA,
39.9 FT HT, FLAKEG LASS-
LINED CS
73 HP
5
to
1389.GPM ICO FT HEAD,
61.HP, 4 OPERATING
AND 6 SPARE
1P408.GPM, 100 FT HEAD,
81*.HP, fi OPERATING
ANO 7 SPARE
3173.GPM, 200 FT HEAD,
297.HP, 1 OPERATING
AND 1 SPARE
10
2311328.
1928600.
383686.
938730.
627930.
6220272.
174667.
462355.
500755.
113911,
15 2085846.
26754,
507083.
27123.
382772.
207362.
36076.
167399.
4155.
TOTAL S02 SCRUBBING EQUIPMENT COST
9584557. 1331967.
OXIDATION
INCLUDING 4 OPERATING AND 1 SPARE SCRUBBING TRAINS
ITEM DESCRIPTION NO. MATERIAL
LABOR
OXIDATION BLEED PUMPS
468.GPM, 60 FT HEAD
12.HP, 1 OPERATING
AND 4 SPARE
OXIDATION AIR BLOWER 2708.SC£V, 281.HP
OXIDATION SPARGER 20.0 FT DIS RING
TOTftL FORCED OXIDATION EQUIPMENT COST
8 47202.
6 204276-
5 69014.
17942.
5425.
42697.
6606»7
-------
ISCRUB = 5 Venturi-TCA with two effluent tanks (if forced oxidation is
specified by IFOX on line 8, IFOX must be 2)
ISCRUB = 6 Venturi-TCA with one effluent tank (if forced oxidation is
specified by IFOX on line 8, IFOX must be 1)
There are no specific material balance models for the venturi-TCA scrubbing
combination specified by options 5 and 6. These options are provided to allow
comparative cost estimates for analysis and should normally be used only in
"force-through" mode (see the operating condition calculation option, ISR, on
line 7) • Example output showing the results of specifying a spray tower is
shown in the base case printout in Appendix D. Example output showing the
results of specifying a venturi-spray tower with two effluent tanks is shown
in Table 12.
Spare Equipment Potions
Line No. Input data
9 1 0 0 0 35 .0000005 32 10 5.70 1 4 1 .1
/ X\
NSPREP NOTRAN NOREDN
Options for spare equipment in the model apply to the raw material
preparation area and the scrubbing area. The controlling input variables are
NSPREP, NOTRAN, and NOREDN. NSPREP specifies the number of spare preparation
units (ball mills for limestone or slakers for lime) and may be given any
realistic value, 0, 1, 2, 3, .... NOTRAN specifies the number of operating
absorbers. The model automatically overrides the value of NOTRAN if the
specified number requires an absorber larger than the maximum available size.
NOREDN indicates the number of spare absorber trains. The base case equipment
list in Appendix D shows the output for a limestone-scrubbing system designed
with spare ball mills and absorbers. For comparison, Table 13 shows similar
output for a limestone system with no spare absorbers.
Waste Disposal Option
Line No. Input data
10 50 0.0 9999 5000 25 25 5280 1 12 4.75
/ \^ /
ISLODG IFIXS SDFEE DISTPD
Six basic waste disposal options are available in the model (usually
these are based on a disposal site one mile from the FGD facility, as speci-
fied in feet by the variable DISTPD). The input variables are ISLUDG, IFIXS,
and SDFEE and are illustrated below. ISLUDG takes values of 1, 2, 3, 4, or
5. Options 1 through 4 specify variations of pond disposal. Option 5 speci-
fies dewatering and landfill disposal. IFIXS takes values of 0 or 1.
IFIXS = 1 can be used only with ISLUDG = 5 and specifies an additional
37
-------
TABLE 12. EXAMPLE RESULTS ILLUSTRATING
A VENTURI-SPRAY TOWER ABSORBER
S02 SCRUBBING
INCLUDING 1 OPERATING AND 1 SPARF SCRUBBING TRAINS
ITEM DESCRIPTION NO. MATERIAL
LABOR
U)
00
VENTURI
SHELL
NEOPRENE LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES
GRIDS
TOTAL SPRAY SCRUBBER COSTS
SOOTBLOUERS
VENTURI-OXIDATION HOLD TANK
797677.
111617.
AIR-FIXED
78615. GAL IB.8 FT DIA,
37.7FT HT,FL»KEGLASS-
LINED CS
VENTURI-OXIDATION TANK AGITATORS 16 HP
I/ENTURI-OXIDATION PUMPS
EFFLUENT HOLD TANK
EFFLUENT HOLD TANK AGITATOR
ABSORBER RECYCLE PUMPS
MAKEUP WATER PUMPS
6946.6PM 100 FT HEAD,
307.HP 1 OPERATING
AND 6 SPARE
5
55
5
234152R.
1028600.
383686.
922698.
627930.
6204240.
240167.
166075.
507083.
37295.
139076.
5
10
314805.GAL, 37.TFT DIA, 5
37.7FT HT, FLAKEGLASS-
LINED CS
65 HP 5
17887.GPM, 100 FT HEAD, 15
791.HP, B OPERATING
AND 7 SPARE
3473.GPM, 200.FT HEAD, 2
293.HP, 1 OPERATING
AND 1 SPARE
191263.
733826.
411750.
449B53.
2050555.
26754.
79201.
72893.
340878.
186283.
165311.
4155.
TOTAL S02 SCRUBBING EQUIPMENT COST
1127212S. 1643790.
-------
TABLE 13. EXAMPLE RESULTS ILLUSTRATING NO SPARE EQUIPMENT
RAW MATERIAL HANDLING
ITEM DESCRIPTION NO. MATERIAL LABOR
CAR SHAKER AND HOIST
CAR PULLER
UNLOADING HOPPER
UNLOADING VIBRATING FEEDER
UNLOADING BELT CONVEYOR
UNLOADING INCLINE BELT
CONVEYOR
UNLOADING PIT DUST COLLECTOR
UNLOADING PIT SUMP PUMP
STORAGE BELT CONVEYOR
STORAGE CONVEYOR TRIPPER
MOBILE EQUIPMENT
RECLAIM HOPPER
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOP
RECLAIM INCLINE RELT CONVEYOR
RECLAIM PIT DUST COLLECTOR
RECLAIM PIT SUMP PU«P
RECLAIM BUCKET ELEVATOR
hEED BIN
20HP SHAKER 7.5HP HOIST
25HP PULLEP» 5HP RETURN
16FT OIA, 10FT STRAIGHT
INCLUDES 6 IN SO GRATING
3.5 HP
20 FT HORIZONTAL, 5 HP
310 FTt 50 HP
POLYPROPYLENE BAGTYPEt
INCLUDES DUST HOOO
60 GPW , 70 FT HEAD, 5 HP
200 FT, 5 HP
30 FPM, 1 HP
SCRAPPER TRACTOR
7FT HIDE, 4.25FT HT, 2FT
WIDE BOTTOM, CS
3.5 HP
200 FT, 5 HP
19' FT, 40 HP
POLYPROPYLENE BAG TYPE
60 GPM, 70 FT HEAD, 5 HP
90 FT HIGH, 25 HP
11FJ DIA, 21FT STRAIGHT
SIDE HT, COVERED, CS
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
85232.
70391.
16566.
6987.
11*90.
85641.
10835.
1*76.
73387.
27264 .
166916.
2576.
13973.
42182.
60587.
7511 .
4476.
635CS.
30730 .
14392.
21586.
6837.
588.
1639.
5521.
5922.
870.
4521.
10443.
0.
1876.
1175.
3277.
3842.
2961 .
870.
7606.
18489.
TOTAL RAW MATERIAL HANDLING EQUIPMENT COST
(Continued)
784727.
112415.
-------
TABLE 13. (Continued)
ITEM
GAS HANDLING
DESCRIPTION
NO. MATERIAL LABOR
1.0. F»NS
7.9IN H20, WITH 661.
HP MOTOR AND DRIVE
TOTAL GAS HANDLING EQUIPMENT COST
4 2702017.
2792017.
50980.
50980.
ITEM
S02 SCRUBBING
DESCRIPTION
NO. MATERIAL LABOR
SHELL
NEOPRENE LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES
GRIDS
TOTAL SPRAY SCRUBPER COSTS
SOOT8LOWERS
tFFLUENT HOLD TANK
EFFLUENT HOLD TANK AGITATOR
COOLING SPRAY PU"PS
RECIRCULATION PUMPS
MAKEUP WATER PUMPS
AIR-FIXED
323971.GAL, 38.0 FT DIA,
3fl.O FT HT, FLAKEGLASS-
LINED CS
56 HP
13P9.GPM 100 FT HEAD,
61 HP, 4 OPERATING
AND 1 SPIRE
18108.GPM, 100 FT HEAD,
81« HP, B OPERATING
AND 1 SPARE
3473.GPM, 200 FT HEAD,
293.HP, 1 OPERATING
AND 1 SPARE
32
TOTAL S02 SCRUBBING EQUIPMENT COST
(Continued)
1R73062.
1512880.
706949.
750981.
502311.
4976217.
139733.
335765.
405667
21699
277971
366308.
91129.
12 1668677.
26754.
7604579.
121350.
28861.
133919.
4155.
993621.
-------
ITEM
TABLE 13. (Continued)
OXIDATION
DESCRIPTION
NO. MATERIAL
LABOR
RECIRCULATION TANK
RCCIRCULATION TANK AGITATOR
OXIDATION BLEED PUMPS
OXIDATION AIR BLOWER
OXIDATION SPARGER
202484.GAL 30.1FT DIAt
38.0 FT HTt FLAKEGLASS-
LINED CS
59 HP
468. GPM, 60 FT HEAD
12.HP, 4 OPERATING
AND 2 SPARE
2708 SCFH, 267 HP
19.0 FT OIA RING
TOTAL FORCED OXIDATION EQUIPMENT COST
255872.
274166.
35402.
204276.
53131.
"822~847T
211865.
90825.
13457.
5425.
34157.
"355729.
ITEM
REHEAT
DESCRIPTION
NO. MATERIAL
LABOR
REHEATERS
SOOTBLOUERS
AIR-RETRACTABLE
4 2371214. 147297.
16 262000. 160S2.
TOTAL REHEAT EQUIPMENT COST
2633213. 166009.
-------
fixation process which is described below. SDFEE is a user-specified fee in
$/ton Of dry waste that can be used to specify a fee for additional costs not
included in the model. It is normally used with ISLUDG values of 3 and 4 but
it can also be used with the other ISLUDG options. In all options that
involve dewatering, user-specified solids contents are used. These must be
within practical limits to attain accurate results. The use of ISLUDG = 5
normally requires either the use of IFIXS = 1 or one of the forced-oxidation
options because unoxidized sludge is not normally landfilled without fixation.
A summary of the basic options is shown below.
ISLUDG = 1 Onsite pond disposal of untreated waste.
ISLUDG = 2 Dewatering in a gravity thickener followed by onsite pond
disposal.
ISLUDG = 3 Dewatering in a gravity thickener with additional costs based on
SDFEE to cover fixation and/or disposal cost.
ISLUDG = 4 Dewatering in a gravity thickener and a rotary vacuum filter with
additional costs based on SDFEE to cover fixation and/or disposal
costs.
ISLUDG = 5 Dewatering in a gravity thickener and a rotary vacuum filter
followed by disposal in an onsite landfill.
ISLUDG = 5 Dewatering with a gravity thickener and a rotary vacuum filter,
and followed by fixation by blending the filter cake with an equal
IFIXS = 1 quantity of dry fly ash and 3-5% lime (both based on dry waste)
for disposal in an onsite landfill.
The base case printout in Appendix D is an example of the forced-
oxidation, landfill option (ISLUDG = 5, IFIXS = 0). Sample equipment lists
corresponding to the output for the other waste disposal options are shown in
Tables 14-16. Annual revenue requirements corresponding to fixation using the
model and landfill disposal (ISLUDG = 5, IFIXS = 1) are shown in Table 17.
Pond Disposal Option
Line No.
Input data
10 1 0 0.0 9999 5000 25 25 5280 1 12 6.00
XEXC DISl
PSAMAX PDEPTH PMXEXC
TPD
The design of the disposal ponds used in the model is described in
Appendix B. The model has three options for defining the relationships
between pond land area, excavation depth, and depth of waste in the filled
pond.
42
-------
TABLE 14. EXAMPLE RESULTS ILLUSTRATING POND WASTE DISPOSAL
SOLIDS SEPARATION
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
POND FEED SLURRY PUMPS
POND SUPERNATE PUMPS
80905.GAL» 19.0 FT DIA,
38.0 FT HT, FLAKGLASS-
LINED CS
ABSORBER BLEED TANK AGITATOR *1.HP
187*.GPH, 1JO. FT HEAD 2
107.HP, 1 OPERATING
AND 1 SPARE
1672.GPM, 192. FT HEAD. 2
135.HP, 1 OPERATING
AND 1 SPARE
33857.
37036.
3070*.
162**.
28353.
3067.
8223.
2522.
TOTAL EQUIPMENT COST
1178*1.
*2165.
-------
TABLE 15. EXAMPLE RESULTS ILLUSTRATING
THICKENER - FILTER - POND WASTE DISPOSAL
SOLIDS SEPARATION
ITCH
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATOR
THICKENER FEED PUMP
THICKENER
THICKENER UNDERFLOW SLURRY
PUMPS
THICKENER OVERFLOW PUMPS
THICKENER OVERFLOW TANK
FILTER FEED TANK
FILTER FEED TANK
AGITATOR
FILTER FEED SLURRY PUMP
FILTER
FILTRATE PUMP CPER FILTER)
FILTRATE SURGE TANK
FILTRATE SURGE TANK PUMP
FILTER CAKE CONVEYOR
DESCRIPTION
NO. MATERIAL
80905.GAL. 19.0 FT DIA, 1 33*57.
38.OFT HT, FLAKGLASS-
LINED CS
41 HP 1 37036.
1873.GPH, 60 FT HEAD, 2 23293.
50 HP, 1 OPERATING
AND 1 SPARE
1843.SO.FT., 48. FT DIA, 1 88611.
5.5FT HT TANK
1. HP RAKE
293.GPM, 9.4 FT HEAD, 2 9657.
2.HP , 1 OPERATING
AND 1 SPARE
1525.GPM, 75.0 FT HEAD, 2 10517.
48.HP, 1 OPERATING
AND 1 SPARE
25169.GAL, 28.0 FT DIA, 1 7223.
5.5 FT HT
4832. GAL, 9.4 FT DIA, 1 4496.
9.4 FT HT, FLAKEGLASS-
LINED CS
7 HP 1 8443.
146.GPM, 50 FT HEAD, 3 11201.
4. HP, 2 OPERATING
AND 1 SPARE
393.SO FT FILTDATION I 511ftfc7.
AREA, 49. VACUUM HP
2 OPERATING AND 1 SPARE
101.GPM, 20.0 FT HEAD, 4 13939,
l.HP, 2 OPEBATING
AND 2 SPARE
3131. GAL,
8.3 FT HT
9.3 FT OIA,
202. GPM, 85.0 FT HEAD,
7. HP, 1 OPERATING
AND 1 SPARE
75 FT. HORIZONTAL
100 FT. INCLINE
1.5 HP
1848.
LABOR
28353.
3067,
8221.
69845.
3654.
1631.
5475.
3763.
699.
4049.
77905.
2165.
1400.
1164.
3592.
-------
SOLIDS DISPOSAL FIXATION - LANDFILL
ITEM
SOLIDS SEPARATION
DESCRIPTION
NO. MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATO*
THICKENER FEED PUMP
THICKENER
THICKENER UNDERFLOW SLURRY
PUMPS
THICKENER OVERFLOW PUMPS
THICKENER OVERFLOW TANK
FILTER FEED TANK
FILTER FEED TANK
AGITATOR
FILTER FEED SLURRY PUMP
FILTER
FILTRATE PUMP (PER FILTER)
FILTRATE SURGE TANK
FILTRATE SURGE TANK PUMP
FILTER CAKE CONVEYOR
TOTAL EQUIPMENT COST
R0905. GALi 19.0 FT DIA, 1
38.0 HT HT, FLAKGLASS-
LINEO CS
01.HP 1
1P73. GPM. 60 FT HEADt 2
50. HP, 1 OPERATING
AND 1 SPARE
1843.SO.FT., 48.FT DIA, 1
5.5 FT HT TANK
1. HP RAKE
293.GPK, 9.* FT HEAD, 2
2. HP , 1 OPERATING
AND 1 SPARE
1525.GPM, 75.0 FT HEAD »' 2
48.HP, 1 OPERATING
AND 1 SPARE
25169.GAL, 28.0 FT DIA, 1
5.5 FT HT
4832.GAL, 9.4 FT DIA, 1
9.4 FT HT, FLAKEGLASS-
LINED CS
7 HP 1
146.GPM, 50 FT HEAD,
4.HP, 2 OPERATING
AND 1 SPARE
393.SO FT FILTRATION
AREA, 49. VACUUM HP
2 OPERATING AND 1 SPARE
101.GPM,. 20.0 FT HEAD,
l.HP, i OPERATING
AND 2 SPARE
3331. GAL,
8.3 FT HT
8.3 FT DIA,
202.GPM, 85.0 FT HEAD,
7.HP, 1 OPERATING
AND- 1 SPARE
75 FT. HORIZONTAL
100 FT. INCLINE
1.5 HP
33857.
37036.
23293.
88611.
9657.
10517.
7223.
4496.
8443.
11201.
511867.
13939.
1848.
7496.
42066.
28353.
3067.
8221.
69845.
3645.
1633.
5475.
3763.
699.
4049.
77905.
2165.
1400.
1164.
3592.
811550. 214986.
(Continued)
-------
TABLE 16. (Continued)
FIXATION
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
PNEUMATIC CONVEYOR SYSTEM
LIME CONCRETE STORAGE SILO
LIME SILO HOPPER BOTTOM
ASH CONCRETE STORAGE SILO
ASH SILO HOPPER BOTTOM
LIME SCREW CONVEYOR
ASH SCREW CONVEYOR
LIME/ASH SCREW CONVEYOR
PUG MILL
PUG MILL DUST COLLECTORS
PUG MILL DISCHARGE CONVEYOR
RADIAL STACKER
TOTAL FIXATION EQUIPMENT COST
10.HP
29196. FT3 29.2 FT DIA,
43.7 FT STRAIGHT SIDE
STORAGE HT
60 DEGREE. CS
23404. FT3 27.1 FT DIA,
40.6 FT STRAIGHT SIDE
STORAGE HT
60 DEGREE, CS
30 FEET LONG, 6 IN D,CS
30 FEET LONG, 14 IN D,CS 1
47 FEET LONG, 16 IN D,CS 1
72.9 TPH 75. HP
1 OPERATEING AND 1 SPARE
POLYPROPLENE BAG TYPE
2200 CFM, 7.5 HP
50 FEET HORTI20NAL
JP INCH BELT, 2.5 HP
185.FT LENGTH(?6 INCH BELT 1
50. HP, MOTOR TRAVEL
1
1
1
1
1
1
1
1
2
2
1
1965.
56780.
8760.
49367.
7579.
1747.
4885.
8133.
73447.
14847.
14279.
746.
102354.
6640
88948
5744
147
452
746
8702
5922
1492
4803^.
11366.
289P27.
23325P.
(Continued)
-------
TABLE 16. (Continued)
LANDFILL DISPOSAL
LANDFILL EQUIPMENT ESTIMATED INCLUDING FIXATION PROCESS VOLUME
ITEM
TRUCKS
WHEEL LOADER
TRACK-DOZER
COMPACTOR
WHEEL LOADER
WATER TRUCK
SERVICE TRUCK
TRAILER
WATER TREATMENT SYSTEM
TOTAL EQUIPMENT COST
DESCRIPTION
NO.
26.0 CU YD. 1 SPARE
5.3 CU YDS-BUCKET
167.HPtSTRAIGHT-BLADE
SHEEP-FOOT
2.6 CU YDS BUCKET.CLEANUP 1
1500 GALLON TANK A NO
SPRAY HEADERS
WRECKER RIG, TOOLS
12 FT X 30 FT, OFFICE,
BREAKROOM,FACTLI TIES
PU*PS, TANKS
MATERIAL
LABOR
3
2
1
1
1
1
1
1
232689.
461864.
197307.
283082.
107169.
37990.
70511.
10917.
10033.
0.
0.
0.
0.
0.
0.
0.
1130.
31610.
1441560.
32740.
-------
TABLE 17. EXAMPLE REVENUE REQUIREMENTS TABLE ILLUSTRATING FIXATION COSTS
00
LIMESTONE SLURRY PROCESS — BASIS: 500 *W SCRUBBING UNIT - 500 MH GENERATING UNIT, 19P7 STARTUP
PROJECTED REVENUE REQUIREMENTS - SHAWNEE COMPUTER USER MANUAL
DISPLAY SHEET FOR YEAR: 1
ANNUAL OPERATION KW-HR/KW r 5500
39.38 TONS PEP HOUR DRY SLUDGE
TOTAL CAPITAL INVESTMENT 113053000
DIRECT COSTS
RAW MATERIAL
LIMESTONE
LIME
SUBTOTAL RAW MATERIAL
CONVERSION COSTS
ANNUAL QUANTITY
1*8.0 K TONS
12.3 K TONS
UNIT COST,*
15.00/TON
90.00/TON
OPERATING LABOR AND
SUPERVISION
LANDFILL LAROR AND
SUPERVISION
UTILITIES
STEAM
PROCESS UATEP
ELECTRICITY
DIESEL FUEL
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
INDIRECT COSTS
OVERHEADS
PLANT AND ADMINISTRATIVE <
60.Or OF CONVERSION COSTS LESS UTILITIES)
FIRST YEA" OPERATING AND MAINTENANCE COSTS
LEVELIZED CAPITAL CHARGESC 1*.70X OF TOTAL CAPITAL INVESTMENT)
FIRST YEAR ANNUAL REVENUE REQUIREMENTS
EQUIVALENT FIRST YEAR UNIT REVENUE REQUIREMENTS, MILLS/KWH (MW SCRUBBED)
TOTAL
ANNUAL
COST,!
2220*00
110*-JOC
5*810.0
33280.0
5*26*0.0
195920.0
57629390.0
121020.0
5750.0
MAN-HR
MAN-MR
K LB
K GAL
KUH
GAL
HR
19.
2*.
4.
g.
0.
i.
26.
00/MAN-HP
00/MAN-HR
00/K LB
16/K GAL
055/KWH
60/GAL
00 /HR
10*1*00
798700
2170500
313CO
3169P CO
193fOC
«657100
1*96CO
12211700
15536100
3988000
If618RCO
3S1*2°00
13.1*
LEVELIZED OPERATING AND MAINTENANCE < 1.886 TIMES FIRST YEAR OPER. 5 MAIN.) 36822500
LEVELIZED CAPITAL CHARGES< 1«.70X PF TOTAL CAPITAL INVESTMENT) 16618POO
LEVELIZEO ANNUAL REVENUE REQUIREMENTS 5?**13f>P
EQUIVALENT LEVELIZED UNIT REVENUE REQUIREMENTS, MILLS/KWH (MW SCRUBBED) 19.*3
HEAT RATE 9500. 9TU/KWH - HE/IT VALUE OF COAL 11700 RTU/LP - COAL RA7
1116EOO TONS/YR
-------
Three variables, PSAMAX, PDEPTH, and PMXEXC are required inputs. The
PSAMAX variable specifies the maximum land area in acres available for the
pond, the PDEPTH variable specifies the final depth of waste in the filled
pond, and the PMXEXC variable specifies the maximum depth of topsoil and
subsoil (clay) that can be excavated and used for dike construction (excava-
tion and dike construction calculations are based on the assumption that the
excavated material compacts to 85% of the original volume). For a fixed depth
pond, PSAMAX should be zero, PDEPTH should be set to the desired depth, and
PMXEXC should be set to zero. For a pond based on minimum capital investment
costs but subject to area and excavation limits, PSAMAX should be set to the
maximum area in acres available for pond construction, PDEPTH should be set to
zero, and PMXEXC should be set to the maximum excavation depth allowed. The
pond based on minimum capital investment costs (with no area and excavation
limits) is essentially the same as the second option except that the values
specified for the area and excavation limits should be high enough not to
realistically limit the optimized values; for example, PSAMAX = 9999 and
PMXEXC = 25.
In all three options below, the pond is designed to minimize the sum of
construction cost and land cost.
Fixed depth pond
PSAMAX =0.0
PDEPTH = desired depth, feet
PMXEXC =0.0
Optimum pond cost, sub.iect to limits of area and excavation depth
PSAMAX = Maximum area available for disposal site, acres
PDEPTH =0.0
PMXEXC = Maximum allowable excavation depth, feet
Optimized capital investment, assuming unlimited area and excavation
depth
PSAMAX = Maximum area available for pond construction (maximum =
9999 acres)
PDEPTH = Maximum pond depth, feet
PMXEXC = Maximum excavation depth, feet
49
-------
When the restricted area pond design option is used and calculations
indicate that the total waste volume cannot be contained within the specified
area and excavation limits, an error message is issued and the case la
terminated. Example output showing the results of specifying a pond based on
minimum capital investment costs and the available area constant is shown in
Table 18.
The pond portion of the model can also be executed separately in an
interactive mode. Execution of the pond portion of the model in this manner
is discussed in Appendix F.
Landfill Disposal Potion
Line No.
10
Input data
5 0 0.0 9999 75 85 5280 1 12 6.00
/ \
PDEPTH PMXEXC
The design of the landfill used in the model is described in Appendix B.
Based on this design and the volume of waste to be disposed of, the transpor-
tation and landfill requirements are determined. The variable names used in
executing the landfill model are the same as those used in executing the pond
model, but are defined differently. In the landfill model, PDEPTH specifies
the uncompacted waste bulk density in Ib/ft3 (for transportation require-
ments) and PMXEXC specifies the compacted bulk density in Ib/ft3 (for land-
fill volume determination). If bulk density values are unknown, the model
will choose default values for FGD wastes as shown below. Example output
showing the results of specifying a landfill based on minimum capital invest-
ment costs with a synthetic liner is shown in Table 19. As with the pond
option, the liner is specified separately, as discussed below.
DEFAULT VALUES OF WASTE BULK DENSITIES
Bulk density. Ib/ft3
Waste Sludge
Sulfite (filtered)
Gypsum (filtered)
Fixed sulfite (filtered)
Fixed sulfate (filtered)
In-process waste
70
75
90
85
Compacted
85
95
106
100
The landfill portion of the model can also be executed separately in an
interactive mode. Execution of the landfill portion of the model in this
manner is discussed in Appendix G.
50
-------
TABLE 18. EXAMPLE RESULTS ILLUSTRATING
POND SITE ACREAGE CONSTRAINT
OQNO DESIGN
OPTIMIZED TC MINIMIZE TOTAL COST PLUS OVERHEAD
WITH POND SITE ACREAGE CONSTRAINT
POND DIMENSIONS
DEPTH OF POND
DEPTH OF EXCAVATION
LENGTH OF DIVIDER PIKE
LENGTH OF POND PERIMETER DIKE
LENGTH OF POND PERIMETER FENCE
SURFACE AREA OF BOTTOM
SURFACE AREA OF INSIDE WALLS
SURFACE AREA OF OUTSIDE WALLS
SURFACE AREA OF RECLAIM STORAGE
LAND AREA OF POND
LAND AREA OF POND SITE
LAND AREA OF POND SITE
VOLUME OF EXCAVATION
VOLUME OF RECLAIM STORAGE
VOLUME OF SLUDGE TO BE
DISPOSED OVER LIFE OF PLANT
21.86 FT
4.80 FT
1735. FT
9655. FT
10605. PT
545.
98.
71.
66.
637.
817.
175.
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
ACRES
0£8. THOUSAND YD3
362. THOUSAND YD3
4333. THOUSAND YD3
2686. ACRE FT
POND COSTS (THOUSANDS Oc DOLLARS)
TOTAL DIRECT POND INVESTMENT
LABOR
MATERIAL
6411 .
190.
ENGINEERING DESIGN AND SUPERVISION ( 2.0 )
ARCHITECT AND ENGINEERING CONTRACTOR 1.0 )
CONSTRUCTION EXPENSES ( 8.0 )
CONTRACTOR FEES ( 5.0 )
CONTINGENCY (10.0 )
TOTAL
CLEARING LAND
EXCAVATION
DIKE CONSTRUCTION
LININGC 12. IN. CLAY)
SEEDING DIKE WALLS
ROAD CONSTRUCTION
PERIMETER COSTS. FENCE
RECLAMATION EXPENSE
MONITOR WELLS
SUBTOTAL DIRECT
TAX AND FREIGHT
386.
1914.
2090.
1287.
130.
15.
64.
SI''.
•-.
6411 .
77.
21.
74.
5.
177.
13.
386.
1914.
2090.
1287.
207.
36.
138.
519.
10.
6588.
13.
6601.
132.
66.
528.
330.
766.
TOTAL FIXED INVESTMENT
LAND COST
9189.
1050.
-------
TABLE 19. EXAMPLE RESULTS ILLUSTRATING
LANDFILL DISPOSAL BASED MINIMUM COSTS WITH SYNTHETIC LINER
LANDFILL DESIGN
LANDFILL DIMENSIONS
01
NJ
HEIGHT OF LANDFILL
HEIGHT OF LANDFILL CAP
SLOPE OF LANDFILL CAP
LENGTH OF LANDFILL DISPOSAL SIDE
LENGTH OF LANDFILL TRENCH
LENGTH OF PERIMETER FEN:E
SURFACE AREA OF LANDFILL
FILL AREA LAND FXPOSED TO RAIN
SURFACE AREA OF RECLAIM STORAGE
DISPOSAL LAND AREA OF LANDFILL
LAND AREA OF LANDFILL SITE
LAND AREA OF LANDFILL SITE
VOLUME OF EXCAVATION
VOLUME OF RECLAIM STORAGE
VOLUME OF SLUDGE TO BE
DISPOSED OVER LIFE OF PLANT
DENSITY OF DISCHARGE CAKE
DENSITY OF COMPACTED CAKE
DEPTH OF CATCHMFNT POND
LENGTH OF CATCHMENT POND
VOLUME OF CATCHMENT POND
112.27 FT
92.27 FT
6. DEGREES
1B56. FT
7569. FT
9657. FT
7495.
3f73.
515.
4930.
113.
301.
297.
3691.
THOUSAND FT2
THOUSAND FT2
THOUSAND FT2
THOUSAND FT2
THOUSAND FT2
ACRES
THOUSAND YD^
THOUSAND YD3
THOUSAND YD3
ACRE FT
75.00 LBS/FT3
95.00 LRS/FT3
24.44 FT
373.33 FT
96. THOUSAND YD3
(Continued)
-------
TABLE 19. (Continued)
Ol
UJ
LANDFILL COSTS (THOUSANDS OF DOLLARS)
LANDFILL EQUIPMENT
TAX AND FREIGHT
LANDFILL EQUIPMENT TOTAL
LABOR
MATERIAL
1189.
87.
1277.
TOTAL
CLEARING LAND 24°. 24".
EXCAVATION 596. 596.
DISCHARGE TRENCH 25. 25.
LINING(SYNTHETIC) 7*6. 2184. 2929.
DRAINAGE LANDFILL 0. 0. 0.
SEEDING LANDFILL SITE 89. 53. 112.
ROAD CONSTRUCTION 81. 47. 12R.
PERIMETER COSTS. FENCE 66. 74. 140.
RECLAMATION EXPENSE 281. 281.
RECLAMATION SYNTHETIC COVER 752. 1526. 2278.
MONITOR WELLS 6. 5. 11.
SUBTOTAL DIRECT 2891. 3889. 6780.
TAX AND FREIGHT 292. 292.
TOTAL DIRECT LANDFILL INVESTMENT 2891. 4181. 7071.
ENGINEERING DESIGN AND SUPERVISION I 2.0 ) 141.
ARCHITECT AND ENGINEERING CONTRACTOR 1.0 ) 71.
CONSTRUCTION EXPENSES ( 8.0 ) 566.
CONTRACTOR FEES ( 5.0 ) 354.
CONTINGENCY (20.0 ) 1896.
TOTAL FIXED INVESTMENT 11375.
LAND COST 67°.
REVENUE QUANTITIES
LANDFILL LABOR
DIESEL FUEL
ELECTRICITY
WATER
ANALYSIS
29120.
103596.
145178.
38f7.
42.
MAN-HRS
GALLONS
KHH
K-GALLONS
1AN-HRS
-------
Disposal ,S;ite Liner Potion
Line No. Input data
10 1 0 0.0 9999 5000 0 25 528CM 12 6.00
**^^S< 1
ILINER XLINA XLINB
The liner option allows a choice of an unlined, clay-lined, or synthetic-
lined disposal site. The input variables are ILINER, XLINA, and XLINB.
ILINER specifies the type of lining as illustrated below.
1 = Clay liner
2 = Synthetic liner
3 = No liner
For a clay lining (ILINER =1), XLINA specifies the depth of clay in
inches and XLINB specifies the clay lining installation cost (or the costs for
reworking the clay subsoil into a lining) in $/yd3. For a synthetic lining
(ILINER = 2), XLINA specifies the liner material cost in $/yd2 and XLINB
specifies the installation cost in $/yd2- For no liner (ILINER = 3), XLINA
and XLINB should be set to zero. Example output showing the results of
specifying a synthetic liner is shown in Table 20.
Economic Premjses Option
Line No. Input data
11 7 2 16 5 10 8 15.6 10 8 3 JM 60 1.886 14.7 0.0
IECON PCTOVR XLEVEL CAPCHG PCTMKT
or or or
PCTADM UNDCAP PCTINS
The economic premises option (IECON) allows cost projections based on
either the current EPA-TVA economic premises adopted December 5, 1979 (and
expanded and amplified in March 1981), or the old premises that were used
before December 5, 1979. Appendix B contains a description of the current
premises. Four variables are used in conjunction with the economic premises
option. The meaning of these variables depends on which set of premises is
selected. If the current premises are specified (IECON =1), the PCTOVR
variable specifies the plant administrative overhead rate, applied as a
percent of conversion costs less utilities; the XLEVEL variable specifies the
levelizing factor to be applied to first-year operating and maintenance costs
to develop levelized operating and maintenance costs for the total life of the
54
-------
TABLE 20. EXAMPLE RESULTS ILLUSTRATING
SYNTHETIC POND LINER OUTPUT
POND DESIGN
OPTIMIZED TO MINIMIZE TTTAL COST PLUS OVERHEAD
POND DIMENSIONS
DEPTH OF POND 29.83 FT
DEPTH OF EXCAVATION 7.57 FT
LENGTH OF DIVIDER DIKE 1485. FT
LENGTH OF POND PERIMETER DIKE 8435. ^T
LENGTH OF POND PERIMETER FENCE 9505. FT
SURFACE AREA OF BOTTOM 385.
SURFACE AREA OF INSIDE HALLS 108.
SURFACE AREA OF OUTSIDE HALLS 78.
SURFACE AREA OF RECLAIM STORAGE 56.
LAND AREA OF POND 485.
LAND AREA OF POND SITE 683.
LAND AREA OF POND SITE 141.
VOLUME OF EXCAVATION 1082.
VOLUME OF RECLAIM STORASE 288.
VOLUME OF SLUDGE TO BE 4333.
DISPOSED OVER LIFE OF PLANT 2686.
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
THOUSAND Y02
THOUSAND YD2
ACRES
THOUSAND YD3
THOUSAND Y03
THOUSAND YD3
ACRE FT
POND COSTS (THOUSANDS OF DOLLARS)
LABOR
MATERIAL
TOTAL
CLEARING LAND
EXCAVATION
DIKE CONSTRUCTION
LINING(SYNTHFTIC)
SEEDING DIKE HALLS
ROAD CONSTRUCTION
PERIMETER COSTSi FENCE
RECLAMATION EXPENSE
MONITOR WELLS
SUBTOTAL DIRECT
TAX AND FREIGHT
311 .
2141.
2739.
790.
74.
13.
5P.
401.
5.
6532.
2394.
44.
18.
67.
5.
2527.
190.
311.
2141.
2739.
3184.
118.
31.
124.
401.
10.
9059.
190.
TOTAL DIRECT POND INVESTMENT
6532.
2717.
ENGINEERING DESIGN AND SUPERVISION < 2.0 )
ARCHITECT AND ENGINEERING CONTRACTOP( 1.0 >
CONSTRUCTION EXPENSES ( 8.0 )
CONTRACTOR FEES ( 5.0 )
CONTINGENCY (10.0 )
9249.
1R5.
92.
740.
462.
1073.
TOTAL FIXED INVESTMENT
LAND COST
11801.
847.
-------
plant; the CAPCHG variable specifies levelized annual capital charges applied
as a percent of total capital investment; and the PCTMKT variable specifies
marketing costs applied as a percent of byproduct credit (applies only to
processes with a salable byproduct). If the levelizing factor (XLEVEL) is set
to zero then a lifetime revenue sheet is printed showing annual revenue
requirements for each year of plant operation.
If the old premises are specified (IECON = 0), the PCTOVR variable speci-
fies the plant overhead rate applied as a percent of conversion costs less
utilities, the PCTADM variable specifies the administrative research and
service overhead rate applied as a percent of operating labor and supervision,
the UNDCAP variable specifies the annual capital charge basis for undepreci-
ated investment, and the PCTINS variable specifies the rate for insurance and
interim replacements applied as a percent of total capital investment.
Example output showing the results of specifying the current economic
premises (IECON = 1) and a nonzero levelizing factor (XLEVEL = 1.886) is shown
in the base case printout in Appendix D. The results of specifying a zero
levelizing factor are shown in the example revenue requirements in Table 21.
The results of specifying the old economic premises are shown in the example
revenue requirements in Table 22.
Sales Tax and Freight Option
Line No. Input data
12 1 4 3-5 6 0 1 1.5 1 2 1 8 5 10 0
ITAXFR TXRAT FRRAT
The sales tax and freight option (ITAXFR) allows capital investment sales
tax and freight to be applied as a percentage of material costs. The sales
tax rate is specified with the variable TXRAT and the freight rate is speci-
fied with the FRRAT variable. When ITAXFR is 1, the specified rates are
applied to material costs and included in the capital investment summary
printout; when ITAXFR is zero1, sales tax and freight are excluded. Example
output showing the results of specifying sales tax and freight is shown on the
capital investment summary sheet in the base case printout in Appendix D. An
example investment summary sheet showing sales tax and freight excluded is
shown in Table 23.
Overtime Option
Line No. Input data
12 1 4 3.5 6 0 1 1.5 1 2 1 8 5 10 0
IOTIME OTRATE
56
-------
TABLE 21. EXAMPLE REVENUE REQUIREMENTS USING
THE ECONOMIC PREMISES WITH NO LEVELIZING FACTORS
LIMESTONE SLURRY PROCESS — BASIS: 500 MW SCRUBBING UNIT - 5CO MW GENERATING UNITi 1987 STARTUP
Ln
PROJECTED REVENUE REQUIREMENTS - SHAWNEE COMPUTER USER MANUAL
DISPLAY SHEET FOR YEA"= 1
ANNUAL OPERATION KW-HR/KW = 5500
39.38 TONS PER HOUR DRY
TOTAL CAPITAL INVESTMENT 108818000
UNIT COST.J
DIRECT COSTS
RAW MATERIAL
LIMESTONE
SUBTOTAL RAW MATERIAL
CONVERSION COSTS
ANNUAL QUANTITY
1*8.0 K TONS
UNIT COSTt*
15.00/TON
OPERATING LABOR AND
SUPERVISION
LANDFILL LABOR AND
SUPERVISION
UTILITIES
STEAM
PROCESS WATER
ELECTRICITY
DIESEL FUEL
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
INDIRECT COSTS
OVERHEADS
PLANT AND ADMINISTRATIVE (
60. OX OF CONVERSION COSTS LESS UTILITIES)
COST,J
SLUDGE
FIRST YEAR OPERATING AND MAINTENANCE COSTS
LEVELIZED CAPITAL CHARGES( 14.70X OF TOTAL CAPITAL INVESTMENT)
FIRST YEAR ANNUAL REVENUE REQUIREMENTS
EQUIVALENT FIRST YEAR UNIT REVENUE REQUIREMENTS? MILLS/KWH (MW SCRUBBED)
TOTAL
ANNUAL
COST,*
2220400
2220400
43860.0
29120.0
542640.0
194000.0
56943180.0
103600.0
4990.0
MAN-HR
MAN-HR
K LB
K GAL
KWH
GAL
HR
19
24
4
0
0
1
26
,00/HAN-HR
.00/MAN-HP
.00/K LB
.16/K GAL
.055/KWH
.60/GAL
,00/HR
833400
698900
2170500
31000
3131900
165POO
4538000
129700
11699200
13919600
3720000
17639600
15996300
33635900
12. 21
HEAT RATE 9500. BTU/KWH
HEAT VALUE OF COAL
11700 BTU/LB
(Continued)
COAL RATE 1116500 TONS/YR
-------
L/l
00
TABLE 21. (Continued)
LIMESTONE SLURRY PROCESS — B«SIS: 500 "W SCRUBBING UMT - 500 MW GENERATING UNIT. 19P7 STARTUP
PROJECTED LIFETIME REVENUE PI 3UI P.EMENTS - SHtWNEE COMPUTER USER MANUAL
TDTAL CAPITAL INVESTMENT:
1CP819000
ADJUSTED GROSS
YEARS ANNUAL
AFTER OPERA-
POWER TION,
UNIT KU-HR
START /KW
1 5500
2 5500
3 5500
4 5500
5 5500
6 5500
7 5500
8 5500
9 5500
10 5500
11 5500
12 5500
13 5500
14 5500
15 5500
16 5500
17 5500
18 5500
19 5500
20 5500
21 5500
22 5500
23 5500
24 5500
25 5500
26 5500
27 5500
28 55?0
29 5500
30 5500
TOT 165000
LIFETIME
SU LF UP
REMOVED
POWER UNIT POWER UNIT PY
HEAT FUEL POLLUTION
REQUIREMENT, CONSUMPTION, CONTROL
MILLION BTU TONS COAL PROCESS,
/YEAR /YEAR TONS/YEAR
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
2612*000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
2612*000 1116503 31700
26125000 1116500 31700
26125000 1116500 31700
26125COO 1116500 31700
2612*000 1116500 31700
26125000 1116500 317CO
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
2612fOOO 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31750
26125000 1116500 317CO
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31703
26125000 1116500 31700
783750000 3349*000 951000
AVERAGE INCREASE IN UMT REVENUE REQUIREMENT
DOLLABS PEP TON OF COAL "URNED
"ILLS PER KILOWATT-HOUR
CENTS PEP MILLION PTU HE«T INPUT
DOLLARS °EP TON OF SULFUP REMOVED
REVENUE REQUIREMENT DISCOUNT£3 AT 10.0)1 TO INITIAL YEAR
LEVELIZED
BYPRODUCT
PATE,
EQUIVALENT
TONS/YEAR
DRY
SLUDGE
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
6498000
, DOLLARS
ANNUAL REVENUE
SLUDGE
FIXATION FEE
I/TON
PRY
SLUDGE
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
c.o
0.0
0.0
0.0
0.0
REQUIREMENT
EXCLUDING
SLUDGE
FIXATION
COST,
J/YEA"
33635900
34694100
35P.16100
37005400
3B265900
39601900
41018400
42519700
44111100
45797800
47585900
49481200
51490500
53620200
55B77700
5P270300
f 9P07200
63495400
66745300
693.66500
7256P400
75963000
79561000
83374700
P7417600
S17027CO
9624E2CO
1C1C60200
1061641CO
111573900
1874437300
55. °6
22.72
239.16
1°71.02
446631930
TOTAL
ANNUAL
SLUDGE
FI»«TION
COET,
t/YEAO
0
0
0
0
0
c
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
c
c
0
c
c
0
G
0
0.0
~ . c
: .0
I • G
c
INCREASE IN UNIT REVENUE REQUIREMENT EQUIVALENT TO DISCOUNTED REQUIREMENT OVR LIFE "c COUER
DOLLARS PER TON OF COAL BURNED
MILLS PE* KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUP «E"OVE?
42.43
17.23
181.35
1*94.75
: .0
c.o
- . C
r . r
NET ANNUAL
INCREASE
IN TOTAL
REVENUE
REQUIREMENT.
*
33635900
34694100
35816100
37005400
38265900
39601900
41018400
42519700
44111100
45797800
47585900
49481200
51490500
53620200
55877700
58270300
60807200
63495400
66345300
69366500
7256P400
75963000
79561000
83374700
P.7417600
91702700
96245200
101060200
106164100
111573900
1874437300
55.96
22.72
23°. 16
1971.02
446631900
UNIT
42.43
17.23
181.35
1494.75
CUMULATIVE
NET INCREASE
IN TOTAL
REVENUE
REGUIREMEM,
t
3363S9CO
68330CCC
1041 461 CO
1411E150C
1794174CO
219019300
260037700
302557400
34666P5CO
3924663CO
4400*2230
489533400
5410239CO
594644100
65052180C
70879210C
7695993CC
833094700
899440CCC
96880650G
10413745CC
11173394GC
1196898900
12802736:0
13676912CC
1459393?CC
15556391GC
16566993CC
1762S634:C
18744373::
UMT COSTS INFLATED «T t.COl PER YEAR
-------
TABLE 22. EXAMPLE REVENUE REQUIREMENTS USING THE OLD ECONOMIC PREMISES
LIMESTONE SLURRY PROCESS — BASIS! 500 MM SCRUBBING UNIT - 500 MW GENERATING UNIT, 19P7 STARTUP
PROJECTED REVENUE REQUIREMENTS - SHAWNEE COMPUTER USER MANUAL
DISPLAY SHEET FOR YEA"= 1
ANNUAL OPERATION KW-HR/KW r 5500
39.38 TONS PER HOUR DRY SLUDGE
TOTAL CAPITAL INVESTMENT 105529000
ANNUAL QUANTITY
UNIT COST,*
TOTAL
ANNUAL
COST,t
Ui
DIRECT COSTS
RAW MATERIAL
LIMESTONE
SUBTOTAL RAW MATERIAL
CONVERSION COSTS
OPERATING LABOR AND
SUPERVISION
LANDFILL LABOR AID
SUPERVISION
UTILITIES
STEAM
PROCESS WATER
ELECTRICITY
DIESEL FUEL
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
INDIRECT COSTS
1*8.0 K TONS
43860.0 MAN-HR
25810.0 MAN-HR
542640.0 K LB
193170.0 K GAL
56912080.0 KUH
81400.0 GAL
4420.0 HR
15.00/TON
19.00/MAN-HR
24.00/MAN-HR
4.00/K LP
0.16/K GAL
0.055/KWH
1.60/GAL
2S.OO/HR
DEPRECIATION
COST OF CAPITAL AND TAXES, 17.20X OF UNDEPRECIATED INVESTMENT
INSURANCE < INTERIM REPLACEMENTS, 1.17X OF TOTAL CAPITAL INVESTMENT
OVERHEAD
PLANT, 50.OX OF CONVERSION COSTS LESS UTILITIES
ADMINISTRATIVE, RESEARCH, AND SERVICE,
10.OX OF OPERATING LABOR AND SUPERVISION
SUBTOTAL INDIRECT COSTS
TOTAL ANNUAL REVENUE REQUIREMENT
2220400
2220400
833400
619500
2170500
30°00
313020C
130200
3926700
114KOO
10956200
13176600
3401900
1815100C
1234700
2747200
£2000
25596800
38773400
EQUIVALENT UNIT REVENUE REQUIREMENT, MILLS/KWH
HEAT RATE 9500. 3TU/KWH - HEAT VALUE OF COAL
14.10
COAL RATE 1116500 TONS/YR
11700 BTU/LB
(Continued)
-------
TABLE 22. (Continued)
LIMESTONE SLURRY PROCESS — BASIS: 500
PROJECTED LIFETIME REVENUE REQUIREMENTS
W SCRUBBING UMT - 5 DC "M GENES£TING UNIT, 19H7 STfTL'P
SH1WNEE COMPUTE? USER "4NU4L
TOTAL CA°ITAL INVE'TMECT: I 105529000
SULFUR
REMOVED
YEARS ANNUAL POWER UNIT POWER UNIT PY
AFTER OPERA- HEAT FUEL POLLUTION
POUER TION, REQUIREMENT, CONSUMPTION, CONTROL
UNIT KW-HR MILLION BTU TONS COAL PROCESS,
START /KW
1 5500
2 5500
3 5500
4 5500
5 5500
6 5500
7 5SCO
8 5500
9 5500
10 5500
11 5500
12 5500
13 5500
14 5500
15 5500
16 5500
17 5500
18 5500
19 5500
20 5500
21 5500
22 5500
23 5500
24 5500
25 5500
26 5500
27 5500
28 5500
29 5500
30 5500
TOT 165000
LIFETIME
/YEAR /YEAR TONS/YEAR
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 1116500 31700
26125000 11165CO 31700
26125000 1116500 31700
783750000 33495000 °51000
AVERAGE INCREASE IN UNIT REVENUE »E OU IPE»«ENT
DOLLARS PER TON OF COAL BURNED
"ILLS PER KILOWATT-HOUR
CENTS PEP MILLION BTU HEt T INPUT
DOLLARS TR TON OF SULFU" REMOVED
RLVENUE REQUIREMENT DISCOUNTED AT 10.01 TO INITIAL YEAP
ADJUSTED GROSS
BYPRODUCT ANNUAL REVENUE
PATE, SLUDGE RECUI REMENT TOTAL
EQUIVALENT FIXATION FEE EXCLUDING ANNUAL
TONS/YEAR J/TON TLUCGE SLUDGE
FIXATION FIXSTION
DRY PRY COST, COST,
SLUDGE
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
21660C
216600
216600
216600
216600
216SOO
216600
216600
216600
216600
216600
216600
216600
216600
216600
216600
64°f>COC
, DOLLAPS
LEVELIZED INCREASE IN UMT REVENUE REQUIREMENT EQUIVALENT TC 0 ISCCUISTED
UMT COSTS
"PLLARS PER TON OF CO«L " UR NE D
"ILLS PFR KILOWATT-HOI1"
CENTS PE' MILLION BTU HE«T INPUT
COLLARS PSP TON OF SUL^U" REMCVET
INFLATED AT 6.00X PER YEAR
SLUDGE
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
c.o
0.0
0.0
0.0
g.o
0.0
0.0
c.o
0.0
0.0
0.0
0.0
o.o
0.0
c.o
0.0
c.o
G.O
P.O
0.0
c.o
1/YEAP I/YFAR
38773400
39147600
395790CO
40071700
4C6289CO
41?547PO
41°53200
42728400
4?5»5500
44529200
45564300
466970CO
«7932700
49277200
5073P3CO
52321400
54035200
55886500
57884000
60036600
62353500
64844500
67520400
70391400
73469800
76768300
00299600
"4C77800
P01181CO
9C435900
1602°041PO
REQUIREMENT
50.54
20.52
2i5.ro
1780.1 ;
4'7P18f CO
rvTR LIFE OF
41.60
16.99
177.77
1065.26
0
0
0
0
0
c
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
c.o
c.o
r.o
0
COUE P
c.o
o.c
c.o
c.c
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
IN TOTAL IN TOTAL
REVENUE REVEHUE
REQUIREMENT, REQUIREMENT,
I
38773400
39147600
39579000
40071700
4062H900
41254700
41953200
42728400
43585500
4452=200
45564300
46697000
47932700
49277200
50738300
52321400
54035200
55886500
57884000
60036600
62353500
64844500
67520400
70391400
73469800
7676P300
80299600
84077800
88118100
92435900
1692904100
50.54
20.52
216.00
1780. 13
437818600
UNIT
41.60
It. 89
177.77
1465.26
1
38773400
77921000
117500000
157571700
19P2G060C
239455300
281408500
324136900
367722400
412251600
457815900
504512900
552445600
601722800
652461100
704782500
758817700
81470420C
8725882CO
932624800
9949783CO
1059822800
1127343200
1197734200
12712C4400
134T9727CO
1428272300
1512350100
160C468200
1692904100
-------
TABLE 23. EXAMPLE INVESTMENT SUMMARY TABLE WITH SALES TAX AND FREIGHT EXCLUDED
LIMESTONE SLURRY PROCESS — BASIS: 500 MW SCRUBBING UNIT - 500 MU GENERATING UNIT, 1987 STARTUP
PROJECTED CAPITAL INVESTMENT REQUIREMENTS - SHAWNEE COMPUTER USER "ANUAL
INVESTMENT, THOUSANDS Of 1985 DOLLARS
DISTRIBUTION
HAT HAND FEED PREP
EQUIPMENT
MATERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTWORK
MATERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
BUILDINGS
MATERIAL
LABOR
TOTAL PROCESS CAPITAL
SERVICES AND MISCELLANEOUS ( £.0 *)
TOTAL DIRECT PROCESS INVESTMENT
LANDFILL EQUIPMENT
LANDFILL CONSTRUCTION
TOTAL DIRECT INVESTMENT
ENGINEERING DESIGN AND SUPERVISION ( 7.0 X)
ARCHITECT AND ENGINEERING CONTRACTOR < 2.0 XI
CONSTRUCTION EXPENSES (16.0 X)
CONTRACTOR FEES ( 5.C X)
CONTINGENCY (10.0 X)
LANDFILL INDIRECTS ( 2.0, 1.0, 8.0, 5.0, 20.0 X)
SUBTOTAL FIXED INVESTMENT
STARTUP S MODIFICATION ALLOWANCE « 8.0, 0.0 X)
INTEREST DURING CONSTRUCTION (15.6 X)
ROYALTIES ( 0.0 X)
LAND I » 6000. ACRE )
WORKING CAPITAL
P39.
134.
37.
17.
C.
C.
215.
524.
142.
36.
177.
540.
1.
0.
0.
0.
2656.
159.
2816.
0.
0.
2816.
197.
56.
451.
141.
366.
0.
4026.
322.
628.
0.
15.
187.
2376.
1P7.
416.
192.
0.
P.
114.
219.
67.
124.
178.
365.
167.
24.
161.
166.
4754.
285.
5040.
0.
0.
5040.
353.
101.
806.
-252.
''655.
0.
7206.
577.
1124.
0.
1.
335.
GAS HANC
3490.
64.
0.
0.
2918.
2424.
49.
88.
0.
0.
338.
1103.
60.
12.
0.
0.
10545.
633.
11176.
0.
0.
11178.
782.
224.
1788.
559.
1453.
0.
15985.
1279.
2494.
0.
2.
744.
S02 SCRUB
949°.
1279.
5723.
735.
0.
0.
1C?.
208.
393.
722.
437.
780.
942.
127.
0.
0.
20948.
1257.
22205.
0.
0.
22205.
1554.
444.
355?.
1110.
2B87.
0.
31753.
2494.
4«?53.
P.
1.
1478.
OXID
580.
47?.
25.
57.
102.
182.
45.
90.
0.
0.
202.
226.
69.
10.
34.
34.
2530.
152.
2681.
0.
0.
26P1.
1PP.
54.
429.
1?4.
J49.
0.
3«J4.
?07.
C9P.
r.
i.
178.
REHEAT SOLID SEP
3292.
20P.
559.
26?.
0.
0.
C.
0.
0.
p.
66.
67.
32.
7.
0.
C.
4494.
270.
4764.
o.-
0.
4764.
333.
95.
762.
23*.
61°.
0.
6812.
545.
1063.
P.
P.
317.
812.
215.
851.
271.
0.
0.
35.
69.
0.
0.
250.
529.
55.
72.
61.
61.
3280.
197.
3476.
1189.
3177.
7843.
243.
70.
556.
174.
452.
14P3.
10821.
398.
1688.
0.
6P4.
522.
TOTAL
21287.
2558.
7611.
1536.
3020.
2606.
561.
1197.
602.
882.
1641.
3610.
1325.
252.
256.
260.
49207.
2952.
52159.
1189.
3177.
56526.
3651.
1043.
8345.
2608.
6781.
1483.
80437.
5967.
12548.
0.
704.
3761.
DOLLARS
PER KWH
42.57
5.12
15.22
3.07
6.04
5.21
1.12
2.39
1.20
1.76
3.28
7.22
2.65
0.50
0.51
0.52
98.41
5.90
104.32
2.38
6.35
113. Of
7.30
2.0 =
16.69
5.22
13.56
2.97
160.87
11.53
25.10
0.0
1.41
7.52
TOTAL CAPITAL INVESTMENT
5179
9244.
20503.
40725.
4«18.
8737.
14112.
103417.
206.83
-------
The overtime option (IOTIME) allows an overtime labor rate (OTRATE) to
be applied to 7$ of total capital investment labor as defined in the premises
in Appendix B. When IOTIME is 1, the specified overtime rate is applied to J%
of all applicable labor costs; when IOTIME is zero, no overtime labor adjust-
ments are made. The added costs for overtime labor are not shown separately
in the model output, but a message is printed in the listing of the model
inputs to indicate if overtime is specified. An example printout with over-
time specified is shown in the base case printout in Appendix D.
Separate Waste Disposal Site Construction Indirect Investment Factors Qptiop
Line No. Input data
12 1 4 3.5 6 0 1 1J51,2 1 8 5 10^0,.
PARCH PFLDEX FFE
INDPND PENGIN PARCH PFLDEX PFEES PCONT PSTART
The separate waste disposal indirect investment option (INDPND) allows
the indirect capital investment for the waste disposal site construction to be
calculated separately from the process indirect investment. The waste
disposal site construction is usually less complicated than the FGD process
construction and its indirect investment factors are usually lower. If INDPND
is zero, the waste disposal site construction indirect investment is calcu-
lated using the same factors (ENGIN, ARCTEC, FLDEXP, FEES, CONT, -and START)
specified in line 11. If INDPND =1, the factors specified by PENGIN
(engineering design and supervision), PARCH (architectural and engineering
contractor), PFLDEX (field expenses), PFEES (contractor fees), PCONT (contin-
gencies), and PSTART (allowance for startup and modifications) are used to
determine the waste disposal site indirect investment. All but PCONT and
PSTART are calculated as a percentage of waste disposal site direct invest-
ment. If the current economic premises are used (IECON = 1 in line 11), the
contingencies are a percentage of the sum of the waste disposal site direct
investments plus each of the four preceding waste disposal site indirect
investments. If the old economic premises are used (IECON = 0 in line 11),
the contingency is calculated as a percentage of the waste disposal site
direct investment only. The allowance for startup and modification is calcu-
lated as a percentage of the total fixed investment for waste disposal site
construction. An example of output showing the use of separate indirect
investment factors for landfill construction is shown in the example printout
in Appendix D. An example of the use of a common indirect investment factor
(INDPND = 0) for both the FGD process and the waste disposal site is shown in
Table 24.
If the user wishes to specify an oversized waste disposal site to cover
contingencies, or to specify an undersized site for applications in which the
initial site is not designed for the full life of the plant, an appropriate
PNDCAP factor, i.e., greater than or less than 1.0, can be specified.
The PNDCAP factor is also used automatically by the model to adjust the
landfill size when fixation (ISLUDG = 5, IFIXS = 1 in line 10) is specified to
account for the additional volume of the fly ash and lime. An example is
shown in Table 25.
62
-------
TABLE 24. EXAMPLE INVESTMENT SUMMARY TABLE WITH COMMON INDIRECT INVESTMENT FACTORS FOR PROCESS AND LANDFILL
LIMESTONE SLURRY PROCESS — BASIS: 500 "W SCRUBBING UNIT - 500 MW GENERATING UNIT, 1987 STARTUP
PROJECTED CAPITAL INVESTMENT REQUIREMENTS -
CO«PUTEe USER MANUAL
INVESTMENT, THOUSANDS OF 1985 DOLLAPS
DISTRIBUTION
EQUIPMENT
MATER IAL
LABOR
PIPING
MATERIAL
LABOR.
DUCTWORK
MATERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
BUILDINGS
MATERIAL
LABOR
SALES TAX (4. OX) AND FREIGHT ( 3.5*1
TOTAL PROCESS CAPITAL
SERVICES AND MISCELLANEOUS ( 6.0 X)
TOTAL DIRECT PROCESS INVESTMENT
LANDFILL EQUIPMENT
LANDFILL CONSTRUCTION
LANDFILL SALES TAX (A. OX) AN3 FREIGHT ( 3.5X )
TOTAL DIRECT INVESTMENT
ENGINEERING DESIGN AND SUPERVISION < 7.0 X)
ARCHITECT AND ENGINEERING CONTRACTOR ( 2.0 X)
CONSTRUCTION EXPENSES (16.0 X)
CONTRACTOR FEES ( 5.0 X)
CONTINGENCY (10.0 X)
SUBTOTAL FIXED INVESTMENT
STARTUP t MODIFICATION ALLOWANCE ( 8.0, 0.0 X)
INTEREST DURING CONSTRUCTION (15.6 X)
ROYALTIES < 0.0 X)
LAND ( * 6000. ACRE )
WORKING CAPITAL
X4T HAND 1
839.
134.
37.
17.
S.
G.
215.
524.
142.
36.
177.
540.
1.
0.
0.
0.
105.
2762.
166.
2927.
0.
0.
c.
2927.
205.
59.
469.
146.
381.
4186.
335.
653.
0.
15.
192.
FEED PREP
2376.
187.
416.
192.
0.
0.
114.
219.
67.
124.
178.
365.
167.
24.
161.
166.
261.
5015.
301.
5316.
0.
C.
0.
5316.
372.
1P6.
.851.
266.
6°1.
7602.
608.
1106.
0.
1.
348.
GAS HAND
3490.
64.
0.
0.
2918.
2424.
49.
88.
0.
0.
338.
1103.
60.
12.
0.
0.
514.
11059.
664.
11723.
0.
0.
0.
11723.
821.
234.
1876.
586.
1524.
16764.
1341.
2615.
0.
2.
768.
S02 SCRUB
9499.
1279.
5723.
735.
0.
0.
103.
208.
393.
722.
437.
780.
942.
127.
0.
0.
1282.
22230.
1334.
23564.
0.
0.
0.
23564.
1649.
471.
3770.
1178.
3063.
33697.
2696.
5257.
0.
1.
1543.
OXI"
9PC.
173.
2?.
?7.
102.
182.
45.
90.
P.
0.
202.
22f.
69.
10.
34.
34.
109.
2639.
158.
2797.
0.
P.
P.
2797.
196.
56.
448.
140.
364.
40GO.
32C.
624.
n.
1.
IP?.
REHEAT
3292.
208.
55".
263.
0.
0.
0.
0.
0.
n.
66.
67.
32.
7.
0.
0.
296.
4790.
287.
5077.
o. •
C.
".
5077.
355.
102.
812.
254.
660.
7261.
581.
1133.
0.
0.
333.
SOLID SEP
812.
215.
851.
271.
0.
0.
35.
69.
0.
0.
250.
529.
55.
72.
61.
61.
155.
3434.
206.
3640.
1189.
3177.
113.
8120.
479.
105.
1095.
342.
1014.
11155.
790.
1740.
0.
684.
532.
TOTAL
21287.
2558.
7611.
1536.
3020.
2606.
561.
1197.
602.
882.
1641.
3610.
1325.
252.
256.
260.
2723.
51930.
3116.
5504*.
1189.
3177.
113.
59525.
4077.
1133.
9320.
2912.
7697.
84664.
6671.
13208.
0.
704.
3898.
DOLLARS
PER KWH
42.57
5.12
15.22
3.07
6.04
5.21
1.12
2.39
1.20
1.76
3.28
7.22
2.65
0.50
0.51
0.52
5.45
103.86
6.23
110.09
2.3P-
6.35
0.23
119.05
8.15
2.27
18.64
5.82
15.39
169.33
13.34
26.42
0.0
1.41
7.RO
TOTAL CAPITAL INVESTMENT
5381.
9745.
21490.
43193.
512P.
9307.
14901.
109145.
218.29
-------
TABLE 25. EXAMPLE RESULTS ILLUSTRATING
THE EFFECTS OF FIXATION ON LANDFILL DESIGN
LANDFILL DESIGN
ON
(LANDFILL DESIGNED FOR 157.49 X OF PROJECTED LIFETIME CAPACITY)
(LANDFILL VOLUME INCLUDES SLUDGE FIXATION PROCESS VOLUME)
LANDFILL DIMENSIONS
HEIGHT OF LANDFILL
HEIGHT OF LANDFILL CAP
SLOPE OF LANDFILL CAP
LENGTH OF LANDFILL DISPOSAL SIDE
LENGTH OF LANDFILL TRENCH
LENGTH OF PERIMETER FENCE
SURFACE AREA OF LANDFILL
FILL AREA LAND EXPOSED TO RAIN
SURFACE AREA OF RECLAIM STORAGE
DISPOSAL LAND AREA OF LANDFILL
LAND AREA OF LANDFILL SITE
LAND AREA OF LANDFILL SITE
VOLUME OF EXCAVATION
VOLUME OF 'RECLAIM STORAGE
VOLUME OF SLUDGE TO BE
DISPOSED OVER LIFE OF =>LANT
VOLUME OF FLYASH TO BE
DISPOSED OVER LIFF OF »LANT
DENSITY OF DISCHARGE CAKE
DENSITY OF COMPACTED CAKE
DEPTH OF CATCHMENT POND
LENGTH OF CATCHMENT POND
VOLUME OF CATCHMENT POND
127.83 FT
107.8? PT
6. DEGREES
2152. FT
8754. FT
11030. FT
4694.
675.
4631.
6448.
148.
THOUSAN'D FT2
THOUSAND FT2
THOUSAND FT2
THOUSAND FT2
THOUSAND FT2
ACRES
402. THOUSAND YD3
401. THOUSAND YD3
8909. THOUSAND YD3
5-522. ACPE FT
2980.
1P47.
THOUSAND YD?
ACRE FT
85.00 LBS/FT3
100.00 L"S/FT3
25.18 FT
420.59 FT
129. THOUSAND YD?
(Continued)
-------
TABLE 25. (Continued)
LANDFILL COSTS (THOUSANDS OF DOLLARS)
LANDFILL EQUIPMENT
TAX AND FREIGHT
LANDFILL EQUIPMENT TOTAL
CLEARING LAND
EXCAVATION
DISCHARGE TRENCH
GRAVEL
LINING( 12. IN. CLAY)
DRAINAGE LANDFILL
SEEDING LANDFILL SITE
ROAD CONSTRUCTION
PERIMETER COSTSt FENCE
RECLAMATION EXPENSE
RECLAMATION CLAY COVER
MONITOR WELLS
SUBTOTAL DIRECT
TAX AND FREIGHT
LABOR
326.
795.
2P.
68.
12*1.
13.
11*.
87.
75.
378.
58".
6.
?721.
MATERIAL
80.
132.
68.
52.
8*.
5.
»20.
32.
1*74.
108.
1582.
TOTAL
326.
795.
28.
1*7.
12*1.
1*5.
182.
139.
160.
378.
589.
11.
*1*2.
32.
TOTAL DIRECT LANDFILL INVESTMENT 3721.
ENGINEERING DESIGN AND SUPERVISION ( 2.0 )
ARCHITECT AND ENGINEERING CONTRACTORC 1.0 )
CONSTRUCTION EXPENSES < 8.0 )
CONTRACTOR FEES ( 5.0 )
CONTINGENCY (20.0 )
TOTAL FIXED INVESTMENT
LAND COST
REVENUE QUANTITIES
«52.
LANDFILL LABOR
DIESEL FUEL
ELECTRICITY
WATER
ANALYSIS
33280.
121021.
181303.
5785.
59.
MAN-HRS
GALLONS
KWH
K-GALLONS
MAN-HRS
*173.
83.
*2.
33*.
20".
1285.
7708.
888.
-------
Operating Profile Option
Line No.
14
Input data
3 .6 30 1 5 .8 1.0 3 .65 1 1 1.10 1985 363.4
/ \ ^
IOPSCH ONCAP IYPROP
One of the most important variables affecting the economics of a power
plant and an associated FGD system is the operating profile (number of years
of operation and the hours of operation per year) over the life of the unit.
The effects of the year-by-year profile on capital investment and annual
revenue requirements are determined by the economic premises option (line 11,
IECON), the operating and maintenance cost levelizing factor (line 11, XLEVEL)
used with the current economic premises, and the waste disposal option
(line 10, ISLUDG). The model provides five options for specifying this
profile. The input variable for these options is IOPSCH. If IOPSCH = 1, the
model uses the operating schedule shown in Figure 2 which is based on a
profile developed by TVA for several past economic evaluations (15). If
IOPSCH = 2, the operating schedule is based on historical Federal Energy
Regulatory Commission (FERC) data (16) as shown in Figure 3. If IOPSCH = 3,
the user must input the operating profile as shown below. If IOPSCH = 4, a
levelized operating profile of 5,500 hours per year is used (see Appendix D).
If IOPSCH = 5, the user supplies a fractional capacity factor, UNCAP, and the
hours of operation each year are calculated by multiplying the fractional
capacity factor by 8,760 hours per year. The cumulative hours of operation
over the life of the plant are obtained by multiplying the resulting annual
hours of operation by the number of years of operation, IYROP, which is also
an input. A 30-year operating life is assumed for IOPSCH = 1, 2, or 4. The
operating life in years must be specified by the variable IYROP when using
IOPSCH options 3 and 5. When the operating profile is specified by the user
(IOPSCH = 3), the projected operating life in years cannot exceed 50. Begin-
ning on line 16, the total number of hour-per-year entries must be equal to
the value of IYROP. The number of entries per line must be equal to 10. Less
than 10 entries are allowed on the last line only, depending on the number of
years required. An example using 25 years is shown below.
Line No.
14
15
16
17
18
19
Input data
3 1 5 .8 1.0 3 .65 1 1 1.10 1985 363-4
25
5000 5000 5000 5000 5000 6000 6000 6000 6000 6000
6250 6250 6250 6250 6250 6250 6250 6250 6250 6250
4500 4500 3500 2500 1000
END
66
-------
80
60
OS
o
gs
E 40
u
w
o
g 20
I T
I
10
I
20
30
I
40
r
50
I T
60
70
BOILER AGE, YEARS
Figure 2. Operating profile assumed for IOPSCH = 1 based on old TVA premises.
-------
00
o
H
O
CJ
w
w
I T]j III I j I I
BOILER AGE, YEARS
Figure 3. Operating profile assumed for IOPSCH = 2 based on historical Federal Energy
Reeulatorv Coirnnissinn r1a*-a j-ncigy
-------
If levelized operating and maintenance costs under the current premises are
used, a levelizing factor (line 11, XLEVEL) that corresponds to the operating
profile should be used.
Example output resulting from the Figure 2 operating profile (IOPSCH = 1)
is shown in Table 26. Table 27 illustrates the results of the Figure 3 FERC
data operating profile (IOPSCH =s 2). Example output resulting from a user-
supplied operating profile (IOPSCH = 3) is shown in Table 28. The base case
printout in Appendix D shows the results of specifying a levelized operating
profile of 5,500 hours per year. Example output resulting from a user-
specified operating capacity factor in conjunction with a 26-year operating
profile is shown in Table 29.
69
-------
TABLE 26. EXAMPLE LIFETIME REVENUE REQUIREMENTS USING THE OLD TVA PREMISES OPERATING PROFILE
..1MESTONE SLURRY PROCESS — BASIS: 500 MW SCRUBBING UNIT - 500 MW GENERATING UNIT, 1987 STARTUP
PROJECTED LIFETIME REVENUE REQUIREMENTS - SHAHNEE COMPUTER USER MANUAL
TOTAL CAPITAL INVESTMENT:
108153000
ADJUSTED GROSS
SULFUR PYPRODUCT ANNUAL REVENUE
REMOVED PATE, SLUDGE REQUIREMENT TOTAL
YLARS ANNUAL POWER UNIT POWER UNIT BY EQUIVALENT FIXATION FEE EXCLUDING ANNUAL
AFTER OPERA- HEAT FUEL POLLUTION TONS/YEAR S/TON SLUDGE SLUDGE
POWER TIOM, REQUIREMENT, CONSUMPTION, CONTROL FIXATION FIXOTION
UNIT KW-HR MILLION BTU TONS COAL PROCESS, DRY PRY COST, COST,
START /KW
1
2
3
4
5
6
7
8
9
10
11
12
13
1"
15
16
17
18
19
20
21
22
23
24
25
it:
27
28
29
30
TOT
7000
7000
7000
7000
7000
7000
7000
7000
7000
70QO
5000
5000
5000
5000
5000
3500
3500
35 CO
3500
3500
1500
1500
1500
1509
1500
1500
1500
1500
1500
1500
127500
LIFETIME
/YEAR
33250000
33250000
33250000
33250000
33250000
33250000
33250000
33250000
33250000
33250000
23750000
23750000
23750000
23750000
23750000
16625000
16625000
16625000
16625000
16625300
7125000
7125000
7125000
7125000
7125000
7125000
7125000
712500 0
7125000
7125000
605625000
AVERAGE INCREASE
/YEAR
1*20900
1120900
1420900
1120900
1420900
1420900
1420900
1420900
1420900
1420900
1015000
1015000
1015000
10150CO
1015000
710500
710500
710500
710500
710500
30«500
304500
304500
304500
3C1500
301500
304500
304500
304500
304500
25881500
TONS/YEAR SLUDGE
40300
40300
40300
40300
40300
40300
4030C
40300
40300
40300
28800
28800
28800
28ROO
28800
20200
20200
20200
20200
20200
8600
8600
8600
8600
8600
8600
8600
8600
8600
8600
734000
275700
275700
275700
275700
275700
275700
275700
275700
275700
275700
196900
196900
196900
106900
196900
1 J7800
137800
137800
137800
137800
59100
59100
59100
59100
59100
59100
59100
59100
59100
59100
5021500
SLUDGE
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
.0
.0
.0
.0
.0
.0
.0
.0
.0
. 0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
. 0
.0
.0
.0
i/YEAP T./YFAR
35769100
36^61200
38224900
39564900
40984500
4249000 0
44085300
45776600
47569000
49469200
43264700
44906800
46647200
48492000
50447700
43781200
15454300
4722770 0
49107500
51099900
35882100
37081800
78352200
39699400
41127500
42641100
44245700
45°46600
47749300
49660400
1313709000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
n
0
0
0
0
0
0
0
0
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
IN TOTAL IN TOTAL
REVENUE REVENUE
REQUIREMENT, REQUIREMENT,
$
35769100
36961200
38224900
39564900
40984500
42490000
44085300
45776600
47569000
49469200
43264700
44906800
46647200
48492000
50447700
43781200
45454300
47227700
49107500
51099900
35882100
37081800
38352200
3969°400
41127500
42641100
44245700
45946600
47749300
49660400
1313709000
1
35769100
72730300
110955200
150520100
191504600
233994600
278079900
323856500
371425500
420894700
464159400
509066200
555713400
604205400
654653100
698434300
743888600
791116300
840223800
891323700
927205800
964286600
1002639700
1042338400
1083465900
1126107000
1170352700
1216299300
1264048600
1313709000
IN UNIT REVENUE REQUIREMENT
DOLLARS PEP TON OF
MILLS PER
CENTS PE»
COAL BURNED
KILOWATT-HOUR
MILLION
DOLLARS =>ER TON OF
REVENUE REQUIREMENT DISCOUNTED AT 10.
LEVELIZED
INCREASE IN UNIT
HOLLARS P
MILLS PER
CENTS PER
REVENUE
ER TON OF
BTU HEAT INPUT
SULFUR REMOVED
0% TO INITIAL YEAR,
DOLLARS
REQUIREMENT EQUIVALENT TO DISCOUNTED
COOL PUR NED
50.76
20.61
216.92
1789.79
399442600
REQUIREMENT OVER LIFE OF
KILOWATT-HOUR
MILLION
DOLLARS PER TON OF
BTU HEAT INPUT
SULFUP REMOVED
35.87
14.56
153.27
1264.46
0.0
0.0
0.0
0.0
0
POWER
n.o
0.0
0.0
0.0
50.76
20.61
216.92
1789.79
399442600
UNIT
35.87
14.56
153.27
1264.46
UNIT COSTS INFLATED AT 6.00X PER YEAR
-------
TABLE 27. EXAMPLE LIFETIME REVENUE REQUIREMENTS USING THE HISTORICAL FERC/FPC OPERATING PROFILE
LIMESTONE SLURRY PROCESS -- 3ASIS! 500 MW SCRUBBING UNIT - ?00 MH GENERATING UNIT, 1987 STARTUP
PROJECTED LIFETIME REVENUE REQUIREMENTS - SHAWNEE COMPUTER USER MANUAL
TOTAL CAPITAL INVESTMENT:
108190000
YEARS ANNUAL POWER UNIT POWER UNIT
AFTER OPERA- HEAT FUEL
POWER TION, REQUIREMENT, CONSUMPTION
UNIT KW-HR MILLION BTU TONS COAL
START /KW
1
2
3
1
5
6
7
8
9
10
11
12
13
11
15
16
17
18
19
20
21
22
23
21
25
26
27
28
29
30
TOT
4512
1613
1775
1906
5037
5169
5300
5132
5563
5691
5695
5695
5695
5695
5695
5537
5379
5221
5061
1906
1718
1591
1133
1275
1118
3960
3802
3615
3117
3329
116001
LIFETIME
/YEAR
21132000
22051300
22681300
23303500
23925800
21552POO
25175000
25802000
26121300
27016500
27051300
27051700
27051300
27051300
27051300
26300ROO
25550300
21799800
21051000
23303500
22553000
21807300
21056800
2030630 0
19560500
18810000
18059500
17313800
16563300
15812ROO
693505700
AVERAGE INCREASE
DOLLARS P
MILLS PER
CENTS PER
/YEAR
915900
912500
96°300
995900
1022500
1010300
1075900
1102600
1129200
1155800
1156000
1156000
1156000
1156000
1156000
1121000
1091900
1059800
1027900
9°5900
96^800
931900
899900
867800
835900
803800
771800
739900
707800
675800
29636800
ADJUSTED GROSS
SULFUR BYPRODUCT ANNUAL REVENUE
REMOVED RATE, SLUDGE REQUIREMENT TOTAL
BY EQUIVALENT FIXATION FEE EXCLUDING ANNUAL
POLLUTION TONS/YEAR t/TON SLUDGE SLUDGE
, CONTROL FIVATION FIXATION
PROCESS, DRY DRY COST, COST,
TONVYEAR SLUDGE
26000
26700
27500
28300
29000
29800
30500
31300
32000
32800
32800
32POO
32800
32800
32800
31900
31000
30100
29200
2P300
27100
26100
25500
21600
23700
22800
21900
21000
20100
19200
811000
177700
1R2ROO
188000
1=3200
198100
203500
208700
21 3900
219100
221200
221300
221300
221300
221300
221300
218000
211800
205600
199100
193200
187000
180800
171600
168300
162200
155900
119700
113500
137300
131100
5719100
SLUDGE
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
I/YEAR
32P30300
33368200
31809300
36355100
38016100
39P01600
"1721700
13781500
15=95300
1P368300
50320900
52385900
51571700
56895000
59?51500
60989600
62659100
61361100
66099800
67857100
69637100
71113100
73253100
75069700
76895800
7P.702600
R0191100
P2261100
S3H83500
P5618000
1767111000
t/YFAR
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
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
IN TOTAL IN TOTAL
REVENUE REVENUE
REQUIREMENT, REQUIREMENT,
$
32030300
33368200
31809300
36355100
36016100
39801600
11721700
13781500
15995300
18368300
50320900
52385900
51571700
56895000
59351500
60989600
62659100
61361100
66099800
67857100
69637100
71113100
73253100
75069700
7689f800
78702600
80191100
82261100
83983500
85618000
1767111000
I
32030300
65398500
100207800
136563200
171579600
211381200
256015900
299890100
315885700
391251000
111571900
196960800
551535500
608130500
667785000
728771600
791131000
855795100
921891900
989752300
1059389100
1130832800
1201086200
1279155900
1356051700
1131751300
1515215100
1597509500
1681193000
1767111000
IN UNIT REVENUE REQUIREMENT
ER TON OF
KILOWATT
MILLION
HOLLARS PER TON OF
REVENUE REQUIREMENT DISCOUNTED AT 10.
LEVEL1ZED INCREASE IN UNIT
REVENUE
DOLLARS PER TON OF
UNIT COSTS
"ILLS PER
CFNTS PER
DOLLARS '
COAL BURNED
-HOUR
BTU HE«T INPUT
SULFUR REMOVED
OX TO INITIAL YEAR,
DOLLARS
REQUIREMENT EQUIVALENT TO DISCOUNTED
COAL BURNED
REQUIREMENT
KILOWATT-HOUR
MILLION
ER TON OF
BTU HEAT INPUT
SULFUR REMOVED
59.63
21.21
251.81
2101.21
11C918100
OVFR LIFE
15.62
18.52
191.91
1607.51
0.0
0.0
0.0
0.0
0
OF POWER
0.0
0.0
0.0
0.0
59.63
21.21
251. Rl
2101.21
110918100
UNIT
15.62
18.52
191.91
1607.51
INFLATED AT 6.00* PER YEAR
-------
N)
TABLE 28. EXAMPLE LIFETIME REVENUE REQUIREMENTS USING A USER-SUPPLIED OPERATING PROFILE
PROJECTED LIFETIME REVENUE REQUIRFMENTS - SHAWNEE COMPUTER USER MANUAL
LIMESTONE SLURRY PROCESS — BASIS: 500 MW SCABBING UNIT - 500 MW GENERATING UNIT, 1987 STARTLP
TOTAL CAPITAL INVESTMENT! t 107981000
SULFUR
REMOVED
YEARS ANNUAL POWER UNIT POWER UNIT PY E
AFTER OPERA- HEAT FUEL POLLUTION
POWER TION, REQUIREMENT, CONSUMPTION, CONTROL
UNIT KW-HR MILLION 8 TU TONS COAL PROCESS,
ADJUSTED GROSS
PYPRODUCT ANNUAL REVENUE
"ATE, SLUDGE "EnillREMETNT TOTAL
QUIVALENT FIXATION FEE EXCLUDING ANNUAL
TONS/YEAR S/TON SLUDGE SLUDGE
FIXATION FIXATION
DRY DRY COST, CCST,
START /KU /YEAR /YEAR TONS/YEAR SLUDGE
1 5000 23750000 1015000 28800
2 5000 23750000 1015000 28800
3 5000 23750000 1015000 28800
* 5000 23750000 1015000 28800
5 5000 23750000 1015000 28800
6 6000 28500000 1217900 34600
7 6000 28500000 1217900 34600
8 6000 28500000 1217900 34600
9 6000 28500000 1217900 34600
10 6000 28500000 1217900 34600
11 6250 29687500 1268700 36000
12 6250 29687500 1268700 36000
13 6250 29687500 1268700 36000
14 6250 29687500 126R700 36000
15 6250 29687500 1268700 36000
16 6500 30875000 1319400 37400
17 6500 30875000 1319400 37400
18 6500 30875000 1319400 37400
19 6500 30875000 1319400 37400
20 6500 30875000 1319400 37400
21 4500 21375000 913500 25900
22 4000 19000000 812000 23000
23 3500 16625000 710500 20200
24 2500 11875000 507500 14400
25 1000 4750000 203000 5POO
TOT 134250 637687500 27251500 773300
LIFETIME AVERAGE INCREASE IN UNIT REVENUE REQUIREMENT
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFU" REMOVED
REVENUE REQUIREMENT DISCOUNTED AT 10. OX TO INITIAL YEAR,
1^6900
196900
196900
196900
196900
236300
236300
236300
236300
236300
246100
246100
246100
246100
246100
256000
256000
256000
256000
256000
177200
157500
137800
98400
39400
5286800
DOLLARS
LEVELIZED INCREASE IN LNIT REVENUE REQUIREMENT EQUIVALENT TC DISCOUNTED
DOLLARS PER TON OF COAL BURNED
MILLS PER K:LOWATT-HPUR
CENTS PER MILLION BTU HE»T INPUT
DOLLARS =ER TON OF SULFUR REMOVED
UNIT COSTS INFLATED AT 6.00X PER YEAR
SLUDGE
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
S/YEAP I/YEAR
32735000
33746750
34819000
35956000
37160900
"1798600
4?354300
45003300
46750800
48603500
51670300
53818000
56C94800
58507900
61066000
65243100
6P205700
71345700
74674000
7B201900
65816200
64337000
62384400
54386400
37218800
1322«984PO
REQUIREMENT
48.54
19.71
207.45
1710.72
4154557CO
OVR LIFE OF
40.98
16.64
175.12
1444.de
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.0
0.0
0.0
0.0
0
POWER
0.0
0.0
c.o
P.O
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
IN TOTAL IN TOTAL
REVENUE REVENUE
REQUIREMENT, REQUIREMENT,
t
32735000
33746700
34819000
35956000
37160900
41798600
43354300
45003300
46750800
48603500
51670300
53818000
56094800
58507900
61066000
65243100
68205700
71345700
74674000
78201900
65816200
64337000
62384400
54386400
37218800
1322898400
4H.54
11.71
207.45
1710.72
415455700
UNIT
40.98
16.64
175.12
1444.06
$
32735000
66481700
101300700
137256700
174417600
216216200
259570500
304573800
351324600
399928100
451598400
505416400
561511200
620019100
681085100
746328300
814534000
885879700
96055370C
1038755600
1104571800
1168908800
1231293200
1285679600
1312289840
-------
u>
TABLE 29. EXAMPLE LIFETIME REVENUE REQUIREMENTS USING A USER-SUPPLIED
PLANT LIFETIME PROFILE AND OPERATING CAPACITY FACTOR
IHESTONE SLURRY PROCESS — HASIS! «OC «W SCBUBBING UNIT - 500 Mw GEN EPATl«:s UMT, 19P7 STA<=TLP
ROJECTED LIFETIME REVENUF RE3JIREMENTS - SHAWNEE CCTUTE0 USER MANUAL Cic£C!TY FACTOR
TCTiL CAPITAL INVESTMENT: J 108C86000
SULFUR
REMOVED
VLARS ANNUAL POWER UNIT FOWER UNIT PY
AFTER OPERA- HEAT FUEL POLLUTION
POWER TION, REQUIREMENT CONSUMPTION, CONTROL
UNIT Ky-HR MILLION BTU TONS CO»L PROCESS,
START /KU /YEAR /YEAR TONS/YEAR
1 5256 24966000 1066900 3 03 CO
2 5256 24966000 1066900 30300
3 5256 24966000 1066900 30300
4 5256 24966000 1066900 303CC
5 5256 24966000 106690C 30300
6 5256 24966000 1066900 3030C
7 5256 24966000 106690G 30300
8 5256 24966000 1066900 30300
9 5256 24966000 106690P 30300
10 5256 24966000 1066900 30300
11 5256 24966000 1066900 30300
12 5256 24966000 1066900 30300
13 5256 24966000 1066900 30300
14 5256 24966000 10669DG 30300
15 5256 24966000 1066900 30300
16 5256 24966000 1066900 30300
17 5256 24966000 10669CO 30300
18 5256 24966000 1066900 J0300
19 5256 24966000 10669CC 30300
20 5256 24966000 1066900 3030C
21 5256 24966000 10669CC 30300
22 5256 24966000 106S9CC 30300
23 5256 24966000 106690C 3030C
24 5256 24966000 10669CC 30300
25 5256 24966000 1066900 30300
Zb 5256 24966000 10669CC 30300
TOT 136656 649116000 277394CC 787800
LIFETIME AVERAGE INCREASE IN UNIT PEVEMUE REQUIREMENT
DOLLARS =>ER TON Cf COAL BURNEP
MILLS PER KILOWtTT-wPUR
CENTS PER MILLION ?TU HE«T INPUT
COLLARS PiP TON T* SULFUR REMCVET
REVENUE REQUIREMENT DISCOUNTED AT 1C.:* TO INITIAL YEA"
ADJUSTED GROSS
BYPRODUCT ANNUAL REVtNUE
RATEt SLUOGE PECUIREMENT TOTAL
EQUIVALENT FIXATION FEE
TONS/YEAR
D«Y
SLUDGE
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
207000
297000
207000
207000
207000
53P2000
, DOLLARS
LEVELIZED INCREASE IN UNIT REVENUE =EOUIRE»ENT EQUIVALENT TO DISCOUNTED
DOLLARS PER TON OF COAL BURNED
"ILLS PER KILOUiTT-'-OUR
CENTS PER MILLION BTU HE»T INPUI
DOLLARS "ER TON 0* SULFUP REMOVE?
UMT COSTS INFLATED «T 6. OCX PER YE*0
«/TON
P°Y
SLUPGE
0.0
0.0
c.o
0.0
c.o
c.o
c.o
C.O
c.o
r.o
c.o
C.O
D.O
0.0
c.o
3.0
0.0 '
c.o
0.0
c.c
c.o
s.c
c.o
:.o
c.o
c.o
EXCLUDING
SLUOGT
FIXATION
COST,
J/YEAP
33140-500
34175400
J5272700
36435700
37668500
3P975500
40360700
41P28900
43385500
45035100
46784000
•8637700
50602500
•^2685300
54893200
572334CO
597141"0
62343500
65130900
6P0854CC
71217200
74536900
78056000
P1786000
P57397PO
B9931000
1433655300
BECUIREVENT
51.68
20.98
220. »6
1P19.P2
4122160CO
OVER LIFE
42.18
17.12
180.23
1484.03
ANNUAL
SLUDGE
FIXATION
CO-^T,
J/YEAR
0
0
0
0
0
0
c
0
0
0
0
0
0
0
0
n
0
0
0
0
0
0
0
0
0
c
0
0.0
0.0
0.0
0.0
0
OF POWER
0.0
0.0
0.0
0.0
SET ANNUAL
CUMULATIVE
INCREASE NET INCREASE
IN TOTAL
PE VENUE
PTCUIREMENT,
1
33140500
34175400
35272700
36435700
37668500
38975500
40360700
41828900
43385500
45035100
46784000
48637700
50602500
52685300
54893200
57233400
59714100
62343500
65130900
68085400
71217200
74536900
78056000
"1786000
P5739700
99931000
:«33655300
51.68
20.98
22G.86
1819.82
'12216000
U'.:T
42.18
17.12
180.23
1484.93
IN TOTAL
REVENUE
REQUIREMENT,
$
33140500
67315900
102588600
139024300
176692800
215668300
256029000
297857900
341243400
386278500
433062500
481700200
532302700
584988000
639881200
697114600
756828700
8191722CO
884303100
952388500
1023605700
1C98142600
1176198600
1257964600
1343724300
1433655300
-------
74
-------
USING THE MODEL
As previously discussed, a copy of the model can be made available for
independent user execution; or TVA, under an information-exchange agreement
with EPA, can make specific runs of the model based on user-supplied input
data. This section is provided for potential users who wish to obtain the
model for independent use.
The model was developed for, and is executed on, the TVA in-house IBM
370-compatible computer system. The current model consists of two FORTRAN
programs written in FORTRAN66 that are compiled using either the IBM G1 or H
extended compiler. The first program, which calculates investment costs, is
relatively large; it contains over 14,000 lines of source code. The second
program, which calculates revenue requirements, contains about 2,000 lines.
Core storage requirements for the first program are about 375,000 bytes;
the use of overlays can reduce this requirement to about 200,000 bytes. The
second program executes within 150,000 bytes of core storage with no overlays.
In addition to the core storage required for program execution, temporary
online storage (disk) is also required for intermediate files and the transfer
of data between the two programs. The only input data required for model
execution are the user input data; all other data for default assumptions and
option-related calculations are assigned the necessary values internally
within the program. Temporary online storage requirements depend on the
number of cases run but typically do not exceed 200,000 bytes.
The model is executed in both interactive and batch modes. The input
data can be provided in three ways, depending on the mode of execution. For
batch execution (typically remote batch), the input data variables are punched
on cards and inserted in a model execution run deck. The second method of
providing data applies to interactive model execution. Input is solicited at
the terminal during actual model execution and the user must respond with the
appropriate values. The third method is used for both interactive and batch
execution. A data file is created interactively (typically using ^i text
editor); all variable values (including the options selected) are examined and
corrected if necessary, then the model is executed (either interactively or a
batch run is submitted from the interactive terminal) and the input is
processed as a standard data file.
The third method of providing input data has been found to be preferable
in most cases. When separate but similar model runs are required, the data
file containing the input is copied to a second file, variables and options
are modified as necessary, and a second model run is submitted. This reduces
both input preparation time and the number of input data errors because only
the variables and options that differ from a previous run must be modified.
75
-------
The Job control language (JCL) required to execute the model in batch
mode is stored in a catalogued procedure file. An example procedure file is
shown in Table 30. The catalogued procedure uses a system utility program,
IEBGENER, which can be replaced if necessary by a user program to copy from
input card data to disk storage and from disk storage to an output print file.
The overall procedure consists of four steps to (1) copy the input data to a
temporary online storage file (disk), (2) copy the input data to an output
print file, (3) execute the first program of the model, and (4) execute the
second program. The programs are executed from load modules to avoid
recompiling each time they are executed.
The remaining JCL required to execute the model in batch mode is shown in
Table 31. If the input data have been prepared on cards, a card deck similar
to example 1 in Table 31 would be submitted with the data cards following the
//LOAD.DATA DD » ... card. In example 2, the catalogued procedure (Table 31)
is executed and the required input is read from a previously created data
file. The JCL examples shown in Tables 30 and 31 generally apply whether the
job is submitted interactively or with a card deck.
Table 32 shows two example interactive procedures for model execution.
Example 1 in Table 32 shows an example procedure for directly entering the
data during model execution. Example 2 shows a procedure for interactive
execution using a previously created data file.
The amount of computer time required for model execution is a function of
the number of cases of input data and the particular computer system. On the
TV A system (AMDAHL V8 with JES3), the average CPU time required per case is
about 0.5 second but some cases have exceeded 2 seconds.
The model is usually distributed on magnetic tape for independent usage.
A fairly wide range of tape format options is available but typically the tape
is unlabeled; the density is 1600 bpi; the block size is 4,000 characters (50
records, 80 characters per record); and the tape contains two files, one for
each program.
76
-------
TABLE 30. EXAMPLE PROCEDURE FOR EXECUTING THE MODEL IN BATCH MODE
//SHAWNEE
//LOAD
//SYSPRINT
//SYSIN
//SYSUT1
//SYSUT2
II
//LIST
//SYSPRINT
//SYSIN
//SYSUT1
//SYSUT2
//INVEST
//STEPLIB
//FT02F001
II
//FT08FJ801
II
//FT03FJ001
//FT05F001
//FT06F001
//FT09FJ001
//REVENUE
//STEPLIB
//FT02FJ001
//FT08FJ001
//FT06F/001
PROC
EXEC
DD
DD
DD
DD
EXEC
DD
DD
DD
DD
EXEC
DD
DD
DD
DD
DD
DD
DD
EXEC
DD
DD
DD
DD
PRTFMS=A
PGM=IEBGENER
SYSOUT=A
DUMMY
DDNAME=DATA
UNIT=SYSCR,SPACE=(TRK,(1,1),RLSE),DISP=(NEW,PASS),
DCB= ( RECFM=FB , LRECL= 80 , BLKSIZE=400)
PGM=IEBGENER
SYSOUT=A
DUMMY
DSN=*. LOAD. SYSUT2,DISP=(OLD, PASS)
SYSOUT=&PRTFMS, DCB=( RECFM=F,LRECL=80 , BLKSIZE=80)
PGM=INV,REGION=400
DSN=CHM . SHAWNEE . LOAD , DISP=SHR
UNIT=SYSCR>SPACE=(TRKf(1,1)fRLSE),DISP=(NEW,PASS)f
DCB=(LRECL=404,BLKSIZE=408,RECFM=VBS)
UNIT=SYSCR, SPACE=(TRK, ( 1,1), RLSE) ,DISP=( NEW, PASS) ,
DCB= ( LRECL=404 , BLKSIZE=40 8 , RECFM=VBS)
SYSOUT=A
DSN=«. LOAD. SYSUT2,DISP=(OLD, DELETE, DELETE)
SYSOUT=&PRTFMS
DSN=$LALQ01.FGDPB2.DATA,DISP=SHR
PGM= REV, TIME=( ,1jO),(0, LT, INVEST)
DSN=CHM. SHAWNEE . LOAD, DISPsSHR
DSN=». INVEST. FT02FJB01,DISP=( OLD, DELETE, DELETE)
DSN=$LALQ01.FGDPB2.DATA,DISP=MOD
SYSOUT=&PRTFMS
00000010
00000020
00000030
00000040
00000050
00000060
00000070
00000080
00000090
00000100
00000110
00000120
00000130
00000140
00000150
00000160
00000170
00000175
00000180
00000190
00000200
00000210
00000220
00000230
00000240
00000250
00000260
77
-------
TABLE' 31. EXAMPLE JCL TO EXECUTE THE MODEL USING A PROCEDURE FILE
(Example 1)
//TXSHAWNE JOB 123456,PRGMER.R501CEBM.2513,MSGLEVEL=1,CLASS=K,
// NOTIFY=CHM 00000020
/•MAIN ORG=RGROUPj03 00000030
//PROCLIB DD DSN=CHM.PROCLIB,DISP=SHR 00000040
//SHAWNEE EXEC SHAWNEE,PRTFMS=A 00000050
//LOAD.DATA DD » (INPUT DATA CARDS FOLLOW THIS CARD)
(Example 2)
//TXSHAWNE JOB 123^56.PRGMER.R501CEBM.2513,MSGLEVEL=1,CLASS=K,
// NOTIFY=CHM 00000020
/•MAIN ORG=RGROUP/)3 00000030
//PROCLIB DD DSN=CHM.PROCLIB,DISP=SHR 00000040
//SHAWNEE EXEC SHAWNEE,PRTFMS=A 00000050
//LOAD.DATA DD DISP=SHR,DSN=CHM.PART2.DATA 00000060
78
-------
TABLE 32. SAMPLE COMMAND PROCEDURE FOR EXECUTING THE MODEL INTERACTIVELY
00010
00020
00030
00043
00045
00050
00060
00070
00080
00090
00100
00010
00020
00030
00040
00050
00053
00055
00060
00070
00080
00090
00100
00110
(Example 1)
FREEALL
TERM LINESIZE(132)
FREE FILE (FT02F001,FT08F001,FT03F001.FT05F001,FT06F001,FT09F001)
ALLOC FKFT02F001) NEW BLOCK(13030) SPACE(10,5)
ALLOC FKFT08F001) NEW BLOCK( 13030) SPACE(10,5)
ALLOC FKFT09FJ001) NEW BLOCK( 13030) SPACE(10,5)
ALLOC FKFT03F001) DA(«)
ALLOC FI(FT05F001) DA(»)
ALLOC FKFT06FJ001) DA(«)
CALL 'CHM.SHAWNEE.LOAD(INV)'
CALL * CHM.SHAWNEE.LOAD(REV)«
FREEALL
(Example 2)
FREEALL
TERM LINESIZE(132)
FREE DA('CHM.PART2.DATA«)
FREE FILE(FT02FJB01.FT08F001,FT03F001,FT05F001.FT06F001,FT09F001
ALLOC FKFT02F001) NEW BLOCK( 13030) SPACE(10,5)
ALLOC FKFT08F001) NEW BLOCK( 13030) SPACE(10,5)
ALLOC FKFT09F001) NEW BLOCK( 13030) SPACE(10,5)
ALLOC FKFT03F001) DA(»)
ALLOC FKFT05F001) DA( »CHM.PART2.DATA')
ALLOC FKFT06F0JD1) DA(»)
CALL 'CHM.SHAWNEE.LOAD(INV)'
CALL 'CHM.SHAWNEE.LOAD(REV)'
FREEALL
79
-------
80
-------
MODEL STRUCTURE
As described previously, the overall model consists of two FORTRAN
programs. The first program which calculates investment costs consists of a
main program and 101 subroutines. An alphabetical listing of the subroutines
in this program with a general description of their function is shown in
Table 33- The second program which calculates revenue requirements consists
of a main program and 10 subroutines. An alphabetical listing of the sub-
routines in this program with a general description of their function is shown
in Table 34. Since the subroutines are not executed in either alphabetical
order or the order in which they occur in the two programs, hierarchy charts
showing the sequence for calling the various subroutines during batch program
execution and identifying the main program and subroutines from which they are
called are shown in Tables 35 and 36.
Further documentation of the overall model is beyond the scope of this
manual.
81
-------
TABLE 33. ALPHABETICAL LISTING OF THE SUBROUTINES IN THE INVESTMENT PROGRAM
IDENTIFYING THE FUNCTION OF EACH SUBROUTINE
Investment
program
subroutines —
Function
ACTIVE
ADAMGO
ADIPID
ADIPMD
BECHTL
BEQ
BEQPRT
BYPASS
CAS03
CAS04
CASOX
CLARIF
CLEAN
CSA
CSAFIL
DUCWRK
DUST
EDIT
EDIT1
ELECTR
EQCALL
EQPSUM
EQUIPR
EQUIPT
EQUPR1
EQUPR2
EQUPR3
Allows investment program to be run interactively
Calculates costs for adipic acid or MgO addition equipment
Calculates stoichiometry, L/G, S02 removal efficiency, and pH
for adipic acid addition option
Calls ADIPID when' adipic acid model is run interactively
Initializes variables and calls subroutines used for calcu-
lating material balance
Calculates aqueous equilibrium constants
Prints modified Radian equilibrium program results (not
activated by Shawnee model)
Used in projecting material balance and bypass design for
partial scrubbing options
Calculates aqueous concentration of CaS03«1/2H20 at
equilibrium
Calculates aqueous concentation of CaSOl(>2H20 at equilibrium
Calculates aqueous concentration of CaSOx at equilibrium
Calculates size of the thickener-clarifier
Calculates composition and heating value of physically
cleaned coal
Calculates cross-sectional area of scrubber
Calculates required filtration area for dewatering FGD sludge
Calculates design and costs for all ductwork, including
dampers and expansion joints
Calculates fly ash contained in combustion products
Checks validity of input data and determines which flags are
set
Checks to determine if the correct number of variables are
input when running in the batch mode
Calculates design and costs of electrical motors, wire, and
conduit
Initializes equilibrium variables and coefficients
Calculates sum of all FGD equipment costs
Calls subroutines for printing equipment costs
Calls subroutines for sizing all equipment
Initializes equipment sizing-costing arrays
Prints equipment lists for raw material and feed preparation
areas
Prints equipment lists for gas-handling, scrubbing, oxida-
tion, and reheat areas
(Continued)
82
-------
TABLE 33. (Continued)
Investment
program
subroutines
Function
EQUPR4
EQUPR5
EQUPR6
FANS
FILTER
FIXIT
FOROXD
FOONDT
H20BAL
H20PMP
HOTGAS
INSTRM
KCALC
LAND
LANDC
LANDP
LANFIL
LIMEPR
LSPREP
MATBAL
MBCON
MECOLL
NSPS
PARTIC
PDROP
PIPES
PNDCP
PNDCST
PNDDEP
Prints equipment list for solids separation area
Prints equipment list for landfill area
Prints equipment list for fixation area
Calculates equipment costs for ID and FD fans
Calculates equipment costs for drum filters
Calculates design and costs for the fixation area
Calculates equipment costs for forced-oxidation air compres-
sors and spargers
Calculates design and costs for foundations
Calculates overall water balance considering H20 added
through alkali and rainfall, and H20 losses from evapora-
tion, seepage, and entrainment
Calculates costs of makeup water and supernate return pumps
Calculates flow rate, composition, and wet bulb temperature
of flue gas exiting the boiler
Calculates design and costs for instrumentation
Calculates activity coefficients
Calculates land area required for FGD equipment and waste
disposal
Calculates design of the landfill
Prints material balance, design, and cost of the FGD landfill
Allows landfill option to be run interactively
Calculates costs of the lime raw material receiving and
preparation equipment
Calculates costs of the limestone raw material receiving and
preparation equipment
Calculates the material balance based on equilibrium models
and the Radian program
Initializes coefficients for calculating pressure drop
Calculates costs for the mechanical collector
Calculates allowable emissions based on 1979 NSPS
Calculates costs of particulate removal equipment based on
Argonne models
Calculates flue gas pressure drop attributed to the FGD
system
Calculates design and costs for piping
Prints pond cost versus capacity table (available only with
interactive pond model)
Calculates cost of waste disposal pond
Prints pond cost versus depth table (available only with
interactive pond model)
(Continued)
83
-------
Investment
program
subroutines
TABLE 33. (Continued)
Fupctipn
PNDEXC Calculates cost for pond excavation
PNDOPT Calculates cost for optimum size-depth pond
PNDPRT Prints design and costs for pond
PNDSGN Calculates design for pond
PNDSZE Calculates dimensions of pond
PONDS Allows pond model to be run interactively
PREPSM Calculates ancillary investment costs for the raw material-
handling and feed preparation areas
PRIN Calls other subroutines for printing input data
PRIN01 Prints short version of program inputs
PRIN02 Prints boiler inputs, composition of raw coal, allowable
emissions, and required removal
PRIN03 Prints composition and physical properties of the scrubbing
alkali
PRIN04 Prints scrubber, forced-oxidation, and adipic acid inputs
PRIN05 Prints waste disposal, reheat, and water balance inputs
PRIN06 Prints economic premises inputs
PRINTI Prints all FGD investment costs
PROUT Calls subroutines for printing program outputs
PROUT1 Prints boiler design and hot gas to scrubber outputs
PROUT2 Prints wet gas from scrubber and flue gas to stack outputs
PROUT3 Prints steam reheater and water balance outputs
PROUT4 Prints scrubber system and system sludge discharge outputs
PROUT5 Prints flow rates of individual species and total flow rate
for all liquid streams
READIN Reads all inputs from unit 5 when model is run in the batch
mode
REHEAT Calculates design for oil-fired reheater option (option not
available)
REHETR Calculates costs for inline steam reheater
SCLAND Initializes variables for landfill design model
SCRUBB Calculates design and costs for the S02 absorber
SLPUMP Calculates costs for rubber-lined slurry pumps
S02ELM Calculates SC-2 removal as % removed, equivalent emission
in Ibs S02/MBtu, or ppm S02 in outlet gas
SOOTBL Calculates costs of sootblowing
SPRINT Prints short-form FGD investment costs
SRMOD(ICR) Calculates L/G, stoichiometry, or S02 removal when other
scrubber parameters are input
STKGAS Calculates flow rate and composition of flue gas exiting the
stack
(Continued)
84
-------
TABLE 33. (Continued)
Investment
program
subroutines
Function
STMRHT
STREAM
STRUCT
TANKS
TCON
THICK
TOTALS
TVAIN
VPDROP
WETGAS
WORKCP
WRITDS
ZERO
Calculates design and costs for inline steam reheater
Calculates composition of liquid FGD system streams
Calculates design and costs of structures
Calculates costs for tanks and agitators
Initializes temperature dependent constants
Calculates costs for thickener
Sums costs for all components of the FGD system
Calls subroutines for calculating FGD investment costs
Calculates pressure drop or throat velocity for the venturi
scrubber
Calculates flow rate and composition for gas exiting the
scrubber
Calculates working capital component of FGD investment cost
Writes investment cost to a file for transfer to the revenue
requirement model
Initializes all major variables to zero
85
-------
TABLE 34. ALPHABETICAL LISTING OF THE SUBROUTINES IN THE REVENUE REQUIREMENT
PROGRAM IDENTIFYING THE FUNCTION OF EACH SUBROUTINE
Revenue
requirement
program
subroutines Function
PHOGM2 Initializes arrays for lifetime cost projections
PRTALF Prints first-year annual revenue requirements table
PRTASF Prints short form of first-year annual revenue requirements
table
PRTBLF Prints titles for lifetime revenue requirements table
PRTBSF Prints short-print titles for lifetime revenue requirements
table
PRTCLF Prints lifetime revenue requirements projections
PRTCSF Prints short-print lifetime revenue requirements projections
PRTDLF Prints summation of lifetime revenue requirements
PRTDSF Prints short-print lifetime revenue requirements summation
tables
RVHEAD Creates revenue requirements table headings
86
-------
TABLE 35. HIERARCHY CHART FOR EXECUTION OF THE INVESTMENT PROGRAM OF THE
OVERALL COMPUTER MODEL IN THE BATCH MODE
MAIN DRIVER (INVESTMENT PROGRAM)
CALL EDIT1
CALL ZERO
CALL READIN
CALL EDIT
CALL BECHTL
CALL VPDROP
IF(KCLEAN.GE.I) CALL CLEAN
IF(IS02.EQ.4) CALL NSPS
CALL DUST
CALL HOTGAS
CALL S02ELM
CALL BYPASS
CALL S02ELM
CALL PRIN
CALL PRIN01
CALL PRIN02
CALL PRIN03
IF(JSSVAR.EQ.I) CALL PRINOM
IF(JINPUT.GT.O) CALL PRIN05
IF(JINPUT.GT.O) CALL PRIN06
CALL MBCON
CALL MATBAL
CALL EQCALL
CALL BEQ
CALL SRMOD(2)
CALL SRMODC1)
CALL BEQ
CALL TCON
CALL KCALC
CALL CAS03
CALL CASOU
CALL CASOX
IF (IP.NE.O) CALL BEQPRT
CALL SRMOD(1)
CALL TCON
CALL KCALC
CALL CAS03
CALL CAS04
CALL CASOX
IF (IP.NE.O) CALL BEQPRT
(Continued)
87
-------
TABLE 35. (Continued)
CALL SRMOD(2)
CALL SRMODO)
CALL MATBAL
CALL EQCALL
CALL BEQ
CALL ADIPID
CALL MATBAL
CALL EQCALL
CALL BEQ
IF (ICLAR.EQ.1) CALL CLARIF
CALL WETGAS
CALL CSA
CALL PDROP
IF (IRH.EQ.1) CALL REHEAT
IF (IRH.NE.1) CALL STMRHT
CALL STKGAS
CALL PNDSGN
CALL PNDOPT
CALL PNDEXC
CALL PNDSZE
CALL PNDCST
CALL PNDSZE
CALL PNDEXC
CALL PNDSZE
CALL PNDSZE
CALL PNDCST
CALL PNDSZE
CALL PNDEXC
CALL PNDSZE
CALL PNDCST
CALL PNDSZE
CALL STREAM
CALL EQCALL
CALL BEQ
CALL H20BAL
CALL CSAFIL
CALL PROOT
CALL PROUT1
CALL PROOT2
CALL PROOT3
CALL PROUTlJ
CALL PROUT5
(Continued)
88
-------
TABLE 35. (Continued)
IF (ISLUDG.LE.2) CALL PNDPRT
IF (ISLUDG.EQ.5) CALL SCLAND
CALL LANDC
CALL LANDP
CALL TVAIN
CALL EQUIP!
IF (IALK.EQ.1) CALL LSPREP
IF (IALK.EQ.2) CALL LIMEPR
IF (IADD.GT.O) CALL ADAMGO
IF (ISLUDG.GT.1) CALL THICK
IF (ISLUDG.GE.10 CALL FILTER
CALL TANKS
IF (IFOX.GT.O) CALL FOROXD
CALL SLPUMP
CALL PREPSM
CALL MECOLL
CALL PARTIC
CALL FANS
CALL SCRUBS
IF (IRH.GT.O) CALL REHETR
CALL SOOTBL
CALL H20PMP
CALL EQPSUM
IF (IEQPR.GE.1) CALL EQUIPR
IF (IEQPR.GE.1) CALL EQUPR1
CALL FIXIT
IF (IEQPR.EQ.1.0R.IEQPR.EQ.2) CALL EQUPR2
IF (IEQPR.EQ.1.0R.IEQPR.EQ.3) CALL EQUPR3
IF (IEQPR.EQ.1.0R.IEQPR.EQ.M) CALL EQUPRM
IF (IFIXS.GT.O) CALL EQUPR6
IF (IEQPR.EQ.1.0R.IEQPR.EQ.5) CALL EQUPR5
CALL STRUCT
CALL FOUNDT
CALL PIPES
CALL DUCWRK
CALL INSTRM
CALL LAND
CALL ELECTR
CALL TOTALS
CALL WORKCP
CALL PRINTI
CALL SPRINT
CALL WRITDS
89
-------
TABLE 36. HIERARCHY CHART FOR EXECUTION OF THE REVENUE REQUIREMENT
PROGRAM OF THE OVERALL COMPUTER MODEL
MAIN DRIVER (REVENUE REQUIREMENT PROGRAM)
CALL RVHEAD
CALL PRTALF
CALL PRTASF
CALL PROGM2
CALL PRTBLF
CALL PRTBSF
CALL PRTCLF
CALL PRTCSF
CALL PRTDLF
CALL PRTDSF
90
-------
REFERENCES
1. Epstein, M., EPA Alkali Scrubbing Test Faoilltv! Advanced Program.
First Progress Report. EPA-600/2-75-050, U.S. Environmental Protection
Agency, Washington, D.C.; Head, H. N., 1976, EPA Alkali Scrubbing Test
Facility: Advanced Program. Second Progress Report,. EPA-600/7-76-008,
U.S. Environmental Protection Agency, Washington, Die.; Head, H. N.,
1977* EPA Alkali Scrubbing Test Facility: Advanced Program, Third
Progress Report, EPA-600/7-77-105, U.S. Environmental Protection Agency,
Washington, D.C.; Head, H. N., and S.-C. Wang, 1979, EPA Alkali Scrub-
bing Test Facility; Advanced Program, Fourth Progress Report. 2
volumes, EPA-600/7-79-244a and -2Mb, U.S. Environmental Protection
Agency, Washington, D.C.; and Burbank. D. A., and S.-C. Wang, 1980,
EPA Alkali Scrubbing Test Facility: Advanced Program - Final Report
(October 197 4-June 1978).
2. Zenz, F. A., 1963f Absorption, In; Kirk-Othmer Encyclopedia of
Chemical Technology, 2d Ed., Vol. 1, pp. M-77.
3. Danckwerts, P. V., 1970, Gas-Liquid Reactions. McGraw-Hill. New York.
4. Wen, C.-y., and L. S. Fan, 1975, Absorption of Sulfur Dioxide in Spray
Column and Turbulent Contacting Absorbers. EPA-600/2-75-023 (NTIS
PB 24733*0, U.S. Environmental Protection Agency, Washington, D.C.
5. Rochelle, G. T., and C. J. King, 1977, The Effect of Additives on Mass
Transfer in CaCO^ or CaO Slurry Scrubbing of S02 from Waste Gases,
Industrial and Engineering Chemistry, Fundamentals, Vol. 16, No. 1,
pp. 67-75.
6. Chang, C. S., and G. T. Rochelle, 1981, S02 Absorption Into Aqueous
Solutions, American Institute of Chemical Engineers Journal, Vol. 27,
No. 2, pp. 292-298.
7. Wen, C.-y, W. J. McMichael, and R. D. Nelsen, Jr., 1975, Scale Control
in Limestone Wet Scrubbing Systems. EPA-650/2-75-031, U.S. Environmental
Protection Agency, Washington, D.C.
8. Burbank, D. A., S.-C. Wang, R. R. McKinsey, and J. E. Williams, 1980,
Test Results on Adipic Acid-Enhanced Limestone Scrubbing at the EPA
Shawnee Test Facility - Third Report. In; Proceedings: Symposium on
Flue Gas Desulfurization - Houston, October 1980, Vol. I, EPA-600/7-81-
019a, U.S. Environmental Protection Agency, Washington, D.C.,
PP. 233-280.
91
-------
9. Anders, W. L., and R. L. Torstrick, 1981, Computerized Shawnee Tt^0/
Limestone Scrubbing Mo^el Users Manual. EPA-600/8-81-008, U.S.
Environmental Protection Agency, Washington, D.C.
10. Lowell, P. S., D. M. Ottmers, Jr., K. Schwitzgebel, T. I. Strange, and
D. W. DeBerry (Radian Corp.), 1970, A Theoretical Description of the
Limestone injection - Wet Scrubbing Process. Final report to the
National Air Pollution Control Administration, NTIS PB 193029.
11. Torstrick, R. L., 1976, Shawnee Limestone-Lime Scrubbing Process Com-
puterized Design Cost Estimates Program; Summary Description Report,
Prepared for presentation at Industry Briefing Conference, Raleigh,
North Carolina, October 19-21, 1976. Torstrick, R. L., L. J. Benson, and
S. V. Tomlinson, 1978, Economic Evaluation Techniques. Results, and
Computer Modeling for Flue Gas Desulfurization. In: Proceedings,
Symposium on Flue Gas Desulfurization, Hollywood, Florida, November 1977
(Vol. 1), Ayer, F. A., ed., EPA-600/7-78-058B, U.S. Environmental
Protection Agency, Washington, D.C., 1978, pp. 118-168. Stephenson,
C. D., and R. L. Torstrick, 1978, Current Status of Development of the
Shawnee Lime-Limestone Computer Program. Prepared for presentation at
Industry Briefing Conference, Raleigh, North Carolina, August 29, 1978.
Stephenson, C. D., and R. L. Torstrick, 1979» The Shawnee Lime-Limestone
Computer Program, prepared for presentation at Industry Briefing
Conference, Raleigh, North Carolina, December 5, 1979. Stephenson,
C. D., and R. L. Torstrick, 1979, Shawnee Lime/Limestone Scrubbing
Computerized Design/Cost-Estimate Model Users Manual.
12. Burnett, T. A., C. D. Stephenson, F. A. Sudhoff, and J. D. Veitch, 1983>
Economic Evaluation of Limestone and Lime Flue Gas Desulfurization
Processes, EPA-600/7-83-029, U.S. Environmental Protection Agency,
Washington, D.C.
13. Argonne, 1979. The model that sizes and costs particulate removal
devices was provided by Paul S. Farber of Argonne National Laboratory,
Argonne, Illinois.
14. Code of Federal Regulations, Standards for Performance for New Station-
ary Sources, Title 40, part 60. Subpart Da contains standards for
utility power plants upon which construction was, or will be, started
after September 18, 1978.
15. Tomlinson, S. V., F. M. Kennedy, F. A. Sudhoff, and R. L. Torstrick,
1979, Definitive SOx Control Process Evaluations; Limestone, Double-
Alkali, and Citrate FGD Processes, EPA-600/7-79-177, U.S. Environmental
Protection Agency, Washington, D.C.
16. Federal Energy Regulatory Commission, 1968, Hydroelectric Power Evalua-
tion. FPC P-35 and Supplement No. 1, FPC P-38 (1969). Federal Energy
Regulatory Commission, U.S. Government Printing Office, Washington, D.C.
92
-------
17. Cavallaro, J. A., M. J. Johnson, and A. W. Deubrouck, 1976, Sulfur Reduc-
tion Potential of the Coals of the United States, Bureau of Mines Report
of Investigation RI 8118, U.S. Bureau of Mines, Washington, D.C.
18. Hamersima, J. W., and M. L. Kraft, 1975, Applicability of the Meyers
Process for Chemical Desulfurization of Coal; Survey of Thirty-Five
Coals. EPA-650/2-74-025-A, U.S. Environmental Protection Agency,
Washington, D.C.
19. Bureau of Mines, 1946, Bureau of Mines Information Circular 7346t
Department of the Interior, Washington, D.C. Describes Rosin and Rammler
chart.
20. National Coal Association, 1979, Steam-Electric Plant Factors, 1979f
National Coal Association, Washington, D.C. National Electric Reliabil-
ity Council, 1980, 19flQ Summary of Projected Peak Demand. Generating
Capability, and Fossil Fuel Requirements, National Electric Reliability
Council, Princeton, New Jersey. Department of Energy, 1978, Steam-
Electric Plant Construction Cost and Annual Production Expenses 1977.
DOE/EIA-0033/3 (77), U.S. Department of Energy, Washington, D.C., DOE,
1979, Steam-Electric Plant Air and Water Quality Control Data, for the
Year Ended December 31, 1976,. DOE/FERC 0036, U.S. Department of Energy,
Washington, D.C. These are Issued annually.
21. Singer, J. G., ed., 1981, Combustion. Fossil Power Systemsf Combustion
Engineering, Inc., Windsor, Connecticut.
22. Babcock & Wilcox, Steam/Its Generation and Use. Babcock & Wilcox Co.,
New York, 1975.
23. Friedlander, G. D., 1978, 15th Steam Station Design Survey. Electrical
World, Vol. 190, No. 10, November 1978, pp. 73-87; Friedlander, G. D.,
1980, 16th Steam Station Design Survey. Electrical World, Vol. 194,
No. 8, November 1980, pp. 67-82; and Friedlander, G. D., and M. C. Going,
1982, 17th Steam Station Design Survey. Electrical World, Vol. 196,
No. 11, November 1982, pp. 71-79.
24. Code of Federal Regulations, Title 40, Part 60, Standard of Performance
for New Stationary Sources. Subparts D and Da.
25. Federal Register, 1971, Standards of Performance for New Stationary
Sources. Vol. 36, No. 247, December 23, pp. 24876-24895.
26. Federal Register, 1979, New Stationary Sources Performance Standards:
Electric Utility Steam Generating Units. Vol. 44, No. 113, June 11,
pp. 33580-33624.
27. Chemical Engineering, Economic Indicators.
93
-------
28. Uhl, V. W., 1979, ft Standard Procedure for Cost Analysis of
Control Operations. Vols. I and II, EPA-600/8-79-Ol8a and -Ol8b,
Research Triangle Park, North Carolina.
29. The Richardson Rapid System, Process Plant Estimation Standards,
Vols. I, III, and IV, 1978-1979 edition. Richardson Engineering
Services, Inc., Solano Beach, California.
30. Grant, E. L., and W. G. Ireson, 1970, Principles of Engineering
Economy. Ronald Press, New York.
31. Unpublished data for 200 utility boilers compiled by PEDCo Environmental,
Inc., Cincinnati, Ohio (T. C. Ponder to R. L. Torstrick, TVA,
February 25, 1976). Retrofit factors vary widely from near unity to
almost two times the cost of a new installation. Most are in the range
of about 1.1 to 1.5.
32. EPRI, Technical Assessment Guide. EPRI, Special Report, Electric Power
Research Institute, Palo Alto, California.
33. Jeynes, P. H., 1968, Profitability and Economic Choicef First Edition,
The Iowa State University Press, Ames, Iowa.
34. McGraw, M. G., 1980, Metrication in the Electric Utility Industry,
Electrical World, Vol. 194, No. 7, October 1980, pp. 69-100.
35. ASTM E 380 79, 1980, Annual Book of ASTM Standards, Part 41, American
Society for Testing and Materials, Philadelphia, Pennsylvania.
94
-------
Appendix A
PROCESS FLOWSHEETS AND LAYOUTS
A-l
-------
EMERGENCY BYPASS
STEAM FROM
STEAM PLANT
I.D. FAN
CONDENSATE
2' MAKEUP T0 STEAM PLANT
"WATER
LIQUID RETURN
(SEE SOLIDS SEPARATION
AREA FLOW DIAGRAM)
TO THICKENER
FEED TANK
HOPPERS, FEEDERS, AND CONVEYORS
Figure A-l. Limestone-scrubbing process utilizing a spray tower and forced oxidation.
-------
EMERGENCY BYPASS
COAL
LIQUID RETURN
TO POND
HOPPERS, FEEDERS, AND CONVEYORS
Figure A-2. Limestone-scrubbing process utilizing TCA absorber with natural oxidation.
-------
j" ELECTROSTATIC
[ECONOMIZER] PRECIPITATOR
EMERGENCY BYPASS
STEAM FROM
STEAM PLANT
HOPPERS,FEEDERS, AND CONVEYORS
Figure A-3. Limestone-scrubbing process utilizing a venturi-spray tower.
TO THICKENER
FEED TANK
-------
STEAM
Ul
Figure A-4. Limestone-scrubbing process utilizing a spray tower with forced oxidation and adipic acid
addition.
-------
EMERGENCY BYPASS
STORAGE CONVEYOR
=£3
s
'OR/1GE SIL
3S
T t T
RECLAIM CONVEYOR
CLEAR LIQUID
RETURN
BUCKET
ELEVATOR
NO I
(SEE SOLIDS SEPARATION
AREA FLOW DIAGRAM )
TO THICKENER
FEED TANK
Figure A-5. Lime-scrubbing process utilizing a venturi-spray tower with MgO addition.
-------
ELECTROSTATIC
PRECIPITATORS
PLAN
(SEE NOTES)
UT"PRESATURATOR -
PUMPS
TO
- SPARE SCRUBBING
I TRAIN
S-J'
-EMERGENCY BYPASS
EXPANSION JOINT _
(TYP WHERE SHOWN)
i-h ABSORBER
W~- SYSTEM ' —.
D I.D. FAN p~K~.
FROM
SPARE SCRUBBING
TRAIN
EMERGENCY BYPASS -
•kJ
OXIDATION J ABSORBER
TANK SYSTEM
SLURRY ' D- FAN
RECIRCULATION
PUMP
ELEVATION^
A. EMERGENCY BYPASS ON EACH SIDE.
B. SPARE SCRUBBING TRAIN ON ONE SIDE ONLY
Figure A-6. Plan and elevation for a spray tower with forced oxidation.
A-7
-------
ELECTROSTATIC
PRECIPATATORS
J-- STACK PLENUM
POWER PLANT
I 0. FAN
POWER PLANT
I 0 FAN
PLAN
(SEE NOTES)
POWER PLANT
I 0 FAN
/ PRESATURATOR7
-- PUMP /
SLURRY J
RECIRCULATION PUMP
ABSORBER SYSTEM_
I 0 FAN
ELEVATION
NOTES
A EMERGENCY BYPASS ON EACH SIDE.
B SPARE SCRUBBING TRAIN ON ONE SIDE ONLY
Figure A-7. Plan and elevation for a TCA without forced oxidation.
A-8
-------
ELECTROSTATIC
PRECIPITATORS
PLAN
SEE NOTES
EXPANSION JOINT
(TYP WHERE SHOWN)"^,
INDIRECT STEAM
REHEATER ~"
DAMPER it
(TYP WHERE SHOWN)/ ENTRAPMENT
/ SEPARATOR ^
FLUE GAS DUCT — x / SO.
ABSORBER^,
ELEVATION
NOTES
A EMERGENCY BYPASS ON EACH SIDE
8 SPARE SCRUBBING TRAIN ON ONE
SIDE ONLY.
Figure A-8. Plan and elevation for a venturi-spray tower with forced oxidation.
A-9
-------
UNOXIOIZED
FROM
FCO SYSTEM
Figure A-9. Fixation waste disposal option.
-------
ABSORBER
SLURRY 68
BLEED
SETTLING POND
Onsite ponding (Option 1)
Thickener ponding (Option 2)
Figure A-10. Fixation waste discosal option.
-------
TO SO2
ABSORBER
AREA
ABSORBER
BLEED
RECEIVING
TANK
FILTER CAKE
TO FIXATION/
DISPOSAL
Thickener - filter (Option 4)
ABSORBER
BLEED
RECEIVING
TANK
Thickener - fixation fee (Option 3)
Figure A—11. Waste disposal options 3 and f\.
-------
LIMESTONE PILE
LO
COAL STORAGE
LIMESTONE
PREPARATION
AREA
g
O
o
PUMP
STATION
>
cc.
0 A D
Figure A-12. Limestone slurry scrubbing process plant layout.
-------
A-14
-------
Appendix B
DESIGN AND ECONOMIC PREMISES FOR EMISSION CONTROL EVALUATIONS
B-l
-------
B-2
-------
DESIGN AND ECONOMIC PREMISES FOR EMISSION CONTROL EVALUATIONS
INTRODUCTION
These premises provide criteria for economic evaluations of emission
control and related processes for electric utility power plants fired with
pulverized coal. The design premises define representative coal and power
unit conditions and emission control design practices. The economic premises
are based on regulated utility economics; they prescribe procedures for
determining capital investments and annual revenue requirements. The premises
are directly applicable to economic evaluations of coal cleaning; flue gas
desulfurization (FGD), nitrogen oxides (NOX), and fly ash control; bottom
ash handling; and ponding or landfill disposal of nonhazardous wastes.
The economic evaluations are based on a conceptual design based on the
design premises and developed from engineering data such as flow diagrams,
material balances, and equipment costs. Depending on the degree of accuracy
specified, some costs are either scaled or developed from detailed design and
operating data.
A new 500-MW power unit is used as a base case. Seven coals, repre-
senting typical steam coals used in the United States, are defined. Normally
an eastern bituminous coal containing 3.5$ sulfur and 16$ ash (moisture-free
basis) is used as the base case coal. The other coals represent eastern
bituminous coals with different sulfur contents, western bituminous and
subbituminous coals, and lignite.
These premises, updated in late 1983, are based on 1985 costs for capital
investment and 1987 costs for annual revenue requirements. The cost basis and
other premise criteria are updated periodically; usually the entire premise
criteria are updated at one time rather than on a piecemeal basis to maintain
the comparability of evaluations made over a period of time. The projection
of new cost basis years using current economic factors is the major change
from the previous premises, which were used since April 1980. The other
changes are relatively minor revisions to the design premises: emission of
95% instead of 92$ of the sulfur in eastern bituminous coals, updated spray
dryer FGD designs, and a slightly modified landfill design.
B-3
-------
B-4
-------
DESIGN PREMISES
The design premises specify the coal properties; power unit conditions;
emission control requirements; design features of NOX, S02, and fly ash
control processes; and waste-handling and disposal methodology.
COAL PREMISES
The premise coals consist of four eastern bituminous coals containing
5.0$, 3-5$, 2.0$, and 0.7$ sulfur; a 0.7$ sulfur western bituminous coal; a
0.7$ sulfur western subbituminous coal; and a 0.9$ sulfur North Dakota
lignite. They are based on analyses of U.S. steam coals representative of the
types in current use (17,18). The analysis data for each of these coals are
summarized in Table B-1 and a fly ash analysis for each coal is shown in
Table B-2.
TABLE B-2. FLY ASH COMPOSITIONS
Bituminous Subbituminous Lignite
fly ash, fly ash, fly ash,
wt $ wt $ wt $
S102 50.8 39.7 23.0
A1203 20.6 21.5 11.5
Ti02 2.5 1.1 0.5
F6203 16.9 7.4 8.6
CaO 2.0 20.0 21.6
MgO 1.0 4.7 6.0
Na20 0.4 1.7 5.9
K20 2.6 0.5 0.5
S03 2.4 2.3 19.2
P205 - 1.0 0.4
Other 0.8 0.1 2.8
Total 100.0 100.0 100.0
B-5
-------
TABLE B-l. COMPOSITION OF PREMISE COALS
w
(As- fired basis)
Sulfur
Coal
Eastern bituminous, 5.0$ S
Eastern bituminous, 3-5$ S
Eastern bituminous, 2.0$ S
Eastern bituminous, 0.7$ S
Western bituminous, 0.7$ S
Western subbi luminous, 0.7$ S
(Powder River Basin)
North Dakota lignite, 0.9$ S
Total ,
$
4.80
3.36
1.92
0.67
0.59
0.48
0.57
Pyritic,
$
3.17
2.21
1.25
0.44
0.20
0.16
0.19
Sulfatlo,
t
0.05
0.05
0.04
0.01
0.01
0.01
0.01
Organic
t
1.58
1.10
0.63
0.22
0.38
0.31
0.37
(Moisture- free
Eastern bituminous, 5.0$ S
Eastern bituminous, 3.5$ S
Eastern bituminous, 2.0$ S
Eastern bituminous, 0.7$ S
Western bituminous, 0.7$ S
Western subbitumlnous, 0.7$ S
(Powder River Basin)
North Dakota lignite, 0.9$ S
5.00
3.50
2.00
0.70
0.70
0.68
0.89
3-30
2.30
1.31
0.46
0.24
0.23
0.30
0.05
0.05
0.04
0.01
0.01
0.01
0.01
1.65
1.15
0.65
0.23
0.45
0.44
0.58
, Ash,
t
15.10
15.14
15.08
15.13
9.71
6.30
7.22
basis)
15.7
15.7
15.7
15.7
11.6
8.9
11.3
Moisture,
i
4.0
4.0
4.0
4.0
16.0
29.3
36.3
Heat
content,
Btu/lb
11,700
11,700
11,700
11,700
9,700
8,200
6,600
Ultimate analvsis
C, H,
{ $
65.2 4.0
66.7 3-8
67.8 3.7
68.8 3.6
57.0 3-9
49.0 3.5
40.1 2.8
67.9 4.2
69.5 4.0
70.6 3-9
71.7 3.8
67.9 1.6
69.3 5.0
63.0 4.4
0,
$
5.5
5.6
6.0
6.3
11.5
10.7
12.4
5.7
5.8
6.3
6.6
13.7
15.1
19.5
N,
$
1.3
1.3
1.4
1.4
1.2
0.7
0.6
1.4
1.4
1.4
1.4
1.4
1.0
0.9
Cl,
$
0.1
0.1
0.1
0.1
0.1
0.02
0.01
0.1
0.1
0.1
0.1
0.1
0.02
0.01
-------
As- fired coal refers to the coal entering the coal-cleaning plant or
power plant. This coal is supplied in a 3-inch top size after large rocks and
trash have been removed from the run-of-mine coal. Broken coal is assumed to
have the particle size distributions represented by the Bennett form of the
Rosin and Rammler equation,
R =
which can be plotted on special graph paper devised by the U.S. Bureau of
Mines (BOM) (19) as shown in Figure B-1 . In the equation,
x = particle diameter or width of screen aperture in millimeters. It is
the abscissa in Figure B-1 .
x = a size constant, in millimeters, that is specific to each distribu-
tion line of particle size. In Figure B-1, it is the value of x when
R = 36.79$; in turn R = 36.79$ when x = x in the Rosin and Rammler
equation.
n = a size distribution constant. In Figure B-1, it is the arithmetical
slope of a distribution line. Parallel distribution lines have the
same value of n.
e = the base of the natural logarithm.
R = the weight percentage of coal retained on a screen whose aperture is
x. R expresses cumulative oversize and is the ordlnate in Figure
B-1.
For all distribution lines in Figure B-1, the value of n is 0.8840.
Values of x for selected size distributions are given below.
Actual aperture size
Nominal (Tyler V~2 series) x
too sizes in. mmmm
3 in. 2.970 75.43 13.40
2 in. 2.100 53.34 9.478
1-1/2 in. 1.485 37.71 6.702
3/4 in. 0.742 18.86 3.351
3/8 in. 0.371 9.429 1.676
3 mesh 0.093 2.357 0.4189
14 mesh 0.046 1.179 0.2094
28 mesh 0.023 0.589 0.1047
B-7
-------
SCREEN OPENING
00 M .« 36 0! I P>
to
[
00
<00 325 270 200 140
I I I
•oo si in
10 60 50 40 30 20 IS 16 14 12 10 B -i6
US. STANDARD SIEVE DESIGNATION .
(• I ! I I I ! I I ; I I I I
100 60 60 48 35 2> 20 16 14 12 10 9 ( «
TYLER SIEVE DESIGNATION
100 14
5 I |= 1
SCREEN OPENING. INCHES
3/4
Figure B-l. Rosin-Rammler plots of premise coal sizes.
-------
POWER PLANT
The power plant site is assumed to be in the north-central region
(Illinois, Indiana, Ohio, Michigan, Kentucky, and Wisconsin). The location
represents an area in which coal-fired power plants burning coals of diverse
type and source are situated (20). The design is based on standard design
practices (21,22) and current trends in utility boiler construction (23). The
base case power unit is a new, single 500-MW, balanced-draft, dry-bottom
boiler fired with pulverized coal. The steam pressure is 2,100 psi. The
superheat and reheat temperatures are 1,000°F.
Power unit size case variations consist of similar 200-MW and 1,000-MW
units. For new units, the systems being evaluated are assumed to be installed
during construction of the power plant. New units are assumed to have a 30-
year life and to operate at full load for 5,500 hours/yr. For case varia-
tions, identical existing units with 20 years of remaining life at 5,500
hours/yr of full-load operation are used. The heat rates are shown in
Table B-3. They are based on coal type, unit size, and unit age. To provide
for equitable comparisons, the power units are not derated for energy consump-
tion by the systems evaluated. Instead, the energy requirements are charged
as independently purchased commodities. Normally, cost estimates are based on
a single power unit independent of other units at the site. In cases in which
a plant-wide process or system is evaluated, a plant capacity of 1,000 MW is
normally used.
TABLE B-3- POWER UNIT HEAT RATE
Power unit sizer MW:
Remaining life, years
Full load, hr/yr
Heat rate, Btu/kWh
Bituminous coal
Subbituminous coal
Lignite
200
30
5,500
9,700
10,700
11,200
New
500
30
5,500
9,500
10,500
11,000
Existing
1.000
30
5,500
9,200
10,200
10,700
200
20
5,500
9,900
11,000
11,400
500
20
5,500
9,700
10,700
11,200
1,000
20
5,500
9,500
10,500
11,000
FLDE GAS COMPOSITIONS
Flue gas compositions are based on combustion of pulverized coal assuming
a total air rate equivalent to 139$ of the stoichiometric requirement (defined
as air for combustion of carbon, hydrogen, and sulfur). This includes 20$
excess air to the boiler and 19$ additional air leakage to the flue gas in the
air heater. It is assumed that 80$ of the ash present in all coals is emitted
B-9
-------
as fly ash. Sulfur emitted is dependent on the coal type; 95% of the sulfur
in all eastern coals and 85$ of the sulfur in all western coals and lignite
are emitted as gaseous sulfur oxides (SOX). The remaining sulfur is removed
in the bottom ash and fly ash. No loss of sulfur in the pulverizers is
assumed. Three percent of the sulfur emitted as SOX is SQ^ and the
remainder is 862.
A flow diagram around the boiler is shown in Figure B-2 and detailed
boiler material balances and flue gas composition summaries for stream 8, for
each premise coal, are shown in Tables B-4 through B-17. The streams shown in
the material balances have excess significant digits for cases in which higher
accuracy is needed. These numbers are not to be published without rounding to
four significant digits, no more - no less.
ENVIRONMENTAL REGULATIONS
Emissions from new coal-fired utility plants are regulated by the new
source performance standards (NSPS), which are promulgated by the U.S.
Environmental Protection Agency (EPA) under authority of the Clean Air Act as
amended in 1970 and 1977 (2*0. This section requires EPA to set Federal emis-
sion limitations that reflect the degree of control that can be achieved by
using the best available control technology (BACT). In 1971> EPA issued NSPS
to limit emissions of S02, NOx, and particulate matter from utility power
plants (25). The 1971 NSPS specify a maximum emission based on heat input of
0.10 Ib/MBtu for particulate matter and 1.2 Ib/MBtu for S02. They apply to
power units, for which construction began between August 1971 and September
1978. In 1979, EPA revised the NSPS (26) as shown in Table B-18. The con-
trolled outlet S02 emission and S02 removal efficiencies for the premise
coals are shown in Figure B-3 and tabulated in Table B-19.
Equation to determine equivalent S02 content of coal;
E = (S/H)(2 x 101*)
where: S = % sulfur>in coal, as fired
H = heat content of coal, as fired
E = equivalent S02 content of coal as fired, Ib equivalent
S02/MBtu
Equations to deterpijn? overall J sulfur removal required
E < 2.Q
70$ equivalent S02 removal required
2.Q < E < 6.0
% equivalent S02 removal required = ((E - 0.6)/E)(100)
B-10
-------
COAL-
BOILER
BOTTOM
ASH
ECONOMIZER
NOx
PROCESS
TOTAL
AIR
Figure B-2. Boiler flow diagram.
HOT-SIDE
ESP
IF USED
U-7-*| AIR ;
'^T
fl O
«—-—»•
AIR HEATER
FLUE
GAS
B-ll
-------
TABLE B-4. BOILER MATERIAL BALANCE FOR
5% SULFUR EASTERN BITUMINOUS COAL
Stream No.
Description
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
405,983
(264,701)
(16,239)
(22,329)
(5,278)
(406)
(19,487)
16,239
61,303
2
Total air
to air heater
5,047,807
1,115,166
BO
3,829,456
1,153,571
64,799
3
Combustion air
to boiler
4,357,819
962,733
3,306,006
995,888
55.925
4
Bottom ash
12.455
12,455
Stream No.
Description
Total stream, Ib/hr
Flow rate, sft-Vmin @ 60°F
Temperature, °F
N2 Ib/hr
02 Ib/hr
C02 Ib/hr
S02 Ib/hr
503 Ib/hr
NO Ib/hr
N07 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash
5
Gas to
4.751.973
999.502
3,310,415
164,941
969. 9ft?
35,915
1,388
1,766
142
418
217.184
49,822
6
Gas to air
heater
4,751,973
999,502
3,310,415
164,941
969,982
35,915
1,388
1,766
142
418
217,184
49,822
7
Air
inleakage
689,988
152,433
523,451
157,682
8.855
8
Gas to
electrostatic
precipitator
5,441,961
1,151,935
3,833,866
322,623
969,982
35.915
1,388
1,766
142
418
226.039
49,822
B-12
-------
TABLE B-5. FLUE GAS COMPOSITION
FOR 551 SULFUR EASTERN BITUMINOUS COAL
(Stream 8; gas to electrostatic precipitator)
Comoonent
N2
02
C02
S02
S03
NO
N02
HC1
H20
Fly asha
Total
' Volume. «
75.12
5.53
12.10
0.31 (3,076 ppm)
0.01 (96 ppm)
0.03 (324 ppm)
0.00 (16 ppm)
0.01 (66 ppm)
6.8Q
100.00
Lb— mol/hr
136,900
10,080
22,040
561
17
59
3
12
12r"550
182,200
Lb/hr
3,834,000
322,600
970,000
35,920
1,388
1,766
142
418
226.000
5,392,000
4Q.820
5,442,000
Sft3/min (6QOF) = 1,152,000
Aft3/min (30QOF) = 1,684,000
Fly Ash Loading
Gr/sft3
Wet 5.04
Dry 5.42
Sulfuric acid dewpoint temperature: 316°F
a. See Table B-2 for fly ash composition.
B-13
-------
TABLE B-6. BOILER MATERIAL BALANCE FOR
3.5% SULFUR EASTERN BITUMINOUS COAL
Stream No.
Description
Tital stream. Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
0? (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
503 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
405.983
(270.791)
(15,427)
(22,735)
(5,278)
(406)
(13,641)
16,239
61,466
2
Total air
to air heater
51071.690
1.120.442
80
3.847.575
1,159,029
65.086
3
Combustion air
to boiler
4.378.438
967,288
1.321.648
1,000,601
56.189
4
Bottom ash
12,430
12.430
Stream No.
Description
Total stream. Ib/hr
Flow ratej sft3/min @ 60°F
Temperature, °F
Nj Ib/hr
02 Ib/hr
C02 Ib/hr
SO? Ib/hr
S03 Ib/hr
NO Ib/hr
NO? Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
5
Gas to
economizer
4.772.430
1,002,880
3,326,058
165,726
992,298
25,140
972
1,766
142
418
210,192
49.718
6
Gas to air
heater
4.772.4^0
1,002,880
3,326,058
165,726
992,298
25,140
972
1,766
142
418
210,192
49.718
7
Air
inleakage
693,252
153,154
525,927
158,428
8.879
8
Gas to
electrostatic
precipitator
5.465.682
1,156,034
3,851,985
324,154
992,298
25,140
972
1,766
142
418
219,089
49,718
B-14
-------
TABLE B-7. FLUE GAS COMPOSITION
FOR 3-5% SULFUR EASTERN BITUMINOUS COAL
(Stream 8; gas to electrostatic precipitator)
Comoonent
N2
02
C02
S02
S03
NO
N02
HC1
H20
Fly asha
Total
Volume, 1
75.21
5.54
12.33
0.22 (2,149 ppm)
0.01 (68 ppm)
0.03 (323 ppm)
0.00 (16 ppm)
0,01 (66 ppm)
6.6«5
100.00
Lb-mol/hr
137,500
10,130
22,550
393
12
59
3
12
12.160
182,800
Lb/hr
3,852,000
324,200
992,300
25,140
972
1,766
142
418
21Q.100
5,416,000
49.720
5,466,000
Sft3/mln (600F) = 1,156,000
Aft3/min (30QOF) = 1,690,000
Fly Ash Loading
Wet
Dry
Sulfuric acid dewpoint temperature: 308°F
Gr/sft3
5.02
5.38
a. See Table B-2 for fly ash composition.
B-15
-------
TABLE B-8. BOILER MATERIAL BALANCE FOR
2% SULFUR EASTERN BITUMINOUS COAL
Stream No.
Description
Total stream. Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
Of (H) Ib/hr
C02 (0) Ib/hr
SO 2 (N) Ib/hr
SOI (Cl) Ib/hr
NO (S) Ib/hr
NO 2 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
405.983
406,000
075.2561
(15,021)
(24,359)
(5,684)
(406)
(7,795)
16,239
61,223
2
Total air
to air heater
5,081,446
1,122,597
80
3,854,977
1,161,258
65,211
3
Air to
furnace
4,386,860
969,149
3,328,038
1,002,525
56.297
4
Bottom ash
12,322
12,322
Stream No.
Description
Total stream, Ib/hr
Flow rate, sft^/min
-------
TABLE B-9. FLUE GAS COMPOSITION
FOR 2% SULFUR EASTERN BITUMINOUS COAL
(Stream 8; gas to electrostatic precipitator)
Component
N2
02
C02
S02
S03
NO
N02
HC1
H20
Fly asha
Total
Volume. 1
75. 24
5.54
12.52
0.12 (1,225 ppm)
0.00 (39 ppm)
0.03 (322 ppm)
0.00 (16 ppm)
0.01 (66 ppm)
6.54
100.00
Lb— mol/hr
137,800
10,100
22,920
224
7
59
3
12
11.Q70
1 83 , 1 00
Lb/hr
3,860,000
324,800
1,009,000
14,400
555
1,766
142
418
215.600
5,427,000
4Q.240
5,475,000
Sft3/mln (600F) = 1,158,000
Aft3/mln (30QOF) = 1,692,000
Flv Ash Loading
Wet
Dry
Sulfuric acid dewpoint temperature: 297°F
Gr/sft3
4.96
5.30
a. See Table B-2 for fly ash composition.
B-17
-------
TABLE B-10. BOILER MATERIAL BALANCE FOR
0.7% SULFUR EASTERN BITUMINOUS COAL
Stream -No.
Description
Total stream, Ib/hr
Flow rate, sft3/min 0 60°F
Temperature, op
N2 . (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
NO? Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
405,983
(279,316)
(14,616)
(25,577)
(5,684)
(406)
(2,720)
16,239
61,425
2
Total air
to air heater
5.091,465
1,124,811
80
3,862,577
1,163,548
65,340
3
Combustion air
to boiler
4,395,510
971,060
3.334.599
1,004,502
56.409
4
Bottom ash
12,312
12,312
Stream No.
Description
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 Ib/hr
02 Ib/hr
C02 Ib/hr
S02 Ib/hr
803 Ib/hr
NO Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash
5
Gas to
economizer
4,789,268
1,006,060
800
3,339,415
166,376
1,023,540
5,013
194
1,766
142
418
203,155
49,249
6
Gas to
air heater
4,789,268
1,006,060
705
3,339.415
166,376
1,023,540
5,013
194
1.766
142
418
203,155
49,249
7
Air
inleakage
695,955
153.751
535
527,978
159,046
8,931
8
Gas to
electrostatic
precipitator
5,485,223
1,159,811
300
3,867,393
325,422
1,023,540
5,013
194
1,766
142
418
212.086
49,249
B-18
-------
TABLE B-11. FLUE GAS COMPOSITION
FOR 0.7* SULFUR EASTERN BITUMINOUS COAL
(Stream 8; gas to electrostatic precipitator)
Component
N2
02
C02
S02
803
NO
N02
HC1
H20
Fly asha
Total
Volume , 1
75.27
5.55
12.68
0.04 (428 ppm)
0.00 (11 ppm)
0.03 (322 ppm)
0.00 (16 ppm)
0.01 (65 ppm)
6.42
100.00
Lb— mol/hr
138,100
10,170
23,260
78
2
59
3
12
11,770
183,400
Lb/hr
3,867,000
325,400
1,024,000
5,013
194
1,766
142
418
212.100
5,436,000
4Qr2"50
5,485,000
Sft3/min (6QOF) = 1,160,000
Aft3/min (300°F) = 1,695,000
Flv Ash Loading
Wet
Dry
Sulfuric acid dewpoint temperature: 273°F
Gr/sft3
4.95
5.29
a. See Table B-2 for fly ash composition.
B-19
-------
TABLE B-12. BOILER MATERIAL BALANCE FOR
0.7% SULFUR WESTERN BITUMINOUS COAL
Description
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N9 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
SOl (CD Ib/hr
NO (S) Ib/hr
NO? Ib/hr
HC1 ^/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
489,691
(279.124)
(19,098)
(56^314)
(5,876)
(490)
(2,889)
78.351
47,549
2
Total air
to air heater
5,117,371
1,130,534
80
3.882.231
1,169,468
65.672
3
Combustion air
to boiler
976,000
3,351,566
1,009,613
56,695
4
Bottom ash
9,596
9.596
Stream No.
Description
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
TemDerature. °F
N? Ib/hr
Oj Ib/hr
C02 Ib/hr
SO? Ib/hr
S03 Ib/hr
NO Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash
5
Gas to
economizer
4,897,968
1,045,965
3,356,574
167,228
1,022,834
4,760
184
1,766
142
504
305,590
38,386
6
Gas to
air heater
4,897,968
1,045,965
3,356,574
167,228
1,022,834
4,760
184
1,766
142
504
305,590
38,386
7
Air
inleakage
699,498
154,534
530,666
159,855
8,977
8
Gas to
electrostatic
precipitator
5,597,466
1,200,499
3,887 ,Z4U
327,083
1,022,834
4,760
184
1,766
14Z
564
314,567
38,386
B-20
-------
TABLE B-13. FLUE GAS COMPOSITION
FOR 0.7$ SULFUR WESTERN BITUMINOUS COAL
(Stream 8; gas to electrostatic precipitator)
Comoonent
N2
02
C02
S02
S03
NO
N02
HC1
H20
Volume , 1
73.10
5.38
12.24
0.04 (390 ppm)
0.00 (10 ppm)
0.03 (311 ppm)
0.00 (16 ppm)
0.01 (74 ppm)
9.20
138,800
10,220
23,240
74
2
59
3
14
17.460
Lb/hr
3,887,000
327,100
1,023,000
4,760
184
1,766
142
504
314.600
100.00 189,800 5,559,000
Fly asha 38.3QO
Total 5,597,000
Sft3/mln (600F) = 1,200,000
AftS/min (30QOF) = 1,755,000
Fly Ash Loading
Gr/sft3
Wet 3-73
Dry 4.11
Sulfuric acid dewpoint temperature: 278°F
a. See Table B-2 for fly ash composition.
B-21
-------
TABLE B-14. BOILER MATERIAL BALANCE FOR
0.7% SULFUR WESTERN SUBBITUMINOUS COAL
Stream No.
Description
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
1
Coal to
boiler
640,244
(313,720)
(22,409)
(68.506)
(4,482)
(128)
(3,073)
187.591
40,335
2
Total air
to air heater
5,765,154
1,273,643
80
4,373,663
1,317,506
73.985
3
Combustion air
to boiler
4,977,111
1,099,548
3,775,824
1,137,415
63,872
4
Bottom ash
8,159
8,159
Stream No.
Description
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 Ib/hr
02 Ib/hr
C02 Ib/hr
S02 Ib/hr
SQi Ib/hr
NO Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
5
Gas to
economizer
5,609,196
1,215,098
3,779,506
188,611
1,149,608
5.063
196
1,627
131
132
451,685
32,637
6
Gas to
air heater
5,609,196
1,215,098
3,779,506
188,611
1,149,608
5,063
196
1,627
131
132
451,685
32,637
7
Air
inlealcage
788,043
174,095
597,839
180,091
10,113
8
Gas to
electrostatic
precipitator
6,397,239
1,389,193
4,377,345
368,702
1,149,608
5,063
196
1.627
131
132
461,798
32,637
B-22
-------
TABLE B-15. FLUE GAS COMPOSITION
FOR 0.7$ SULFUR WESTERN SUBBITUMINOUS COAL
(Stream 8; gas to electrostatic precipitator)
Comoonent
N2
02
C02
S02
S03
NO
N02
HC1
H20
Fly asha
Total
Volume. I
71.13
5.25
11.89
0.04 (360 ppm)
0.00 (9 ppm)
0.02 (246 ppm)
0.00 (14 ppm)
0.00 (18 ppm)
11.67
100.00
Lb-mol/hr
156,300
11,520
26 , 1 20
79
2
54
3
4
25 f 630
219,700
Lb/hr
4,377,000
368,700
1,150,000
5,063
196
1,627
131
132
461.800
6,365,000
32.640
6,397,000
Sft3/min (6QOF) = 1,389,000
Aft3/mln (3000F) = 2,030,000
Flv Ash Loading
Gr/sft3
Wet 2.74
Dry 3.10
Sulfuric acid dewpoint temperature: 280°F
a. See Table B-2 for fly ash composition.
B-23
-------
TABLE B-16. BOILER MATERIAL BALANCE FOR
0.9% SULFUR NORTH DAKOTA LIGNITE
Stream No.
Description
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N2 (C) Ib/hr
02 (H) Ib/hr
C02 (0) Ib/hr
S02 (N) Ib/hr
S03 (Cl) Ib/hr
NO (S) Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash
1
Coal to
boiler
833,333
(334,167)
(23,333)
(103,333)
(5,000)
(83)
(4,750)
302,500
60,167
2
Total air
to air heater
5.938,178
1,311,867
80
4.504.926
1,357,047
76,205
3
Combustion air
to boiler
5.126.485
1,132,547
3.889,145
1,171,551
65,789
It
Bottom ash
12,176
12,176
Stream No.
Description
Total stream, Ib/hr
Flow rate, sft3/min @ 60°F
Temperature, °F
N7 Ib/hr
02 Ib/hr
C02 Ib/hr
S02 Ib/hr
SOi Ib/hr
NO Ib/hr
N02 Ib/hr
HC1 Ib/hr
H20 Ib/hr
Ash Ib/hr
5
Gas to
economizer
5,947,642
1,296,872
800
3,893,140
194,053
1.224,537
7,825
302
2,045
165
86
S7fi,7Rfi
48,703
6
Gas to
air heater
5.947,642
1,296,872
3.893.140
194,053
1,224,537
7,825
302
2,045
165
86
576,786
48,703
7
Air
inleakage
811,693
179,320
615,780
185,496
10,417
8
Gas to
electrostatic
precipitator
6,759,335
1,476,192
4,508,920
379,549
1,224,537
7,825
302
2,045
165
86
587.203
48,703
B-24
-------
TABLE B-17. FLUE GAS COMPOSITION
FOR 0.9$ SULFUR NORTH DAKOTA LIGNITE
(Stream 8; gas to electrostatic precipitator)
Component
N2
02
C02
S02
S03
NO
N02
HC1
H20
Fly asha
Total
Volume . I
68.95
5.08
11.92
0.05 (524 ppm)
0.00 (17 ppm)
0.03 (291 ppm)
0.00 (17 ppm)
0.00 (9 ppm)
13. Q7
100.00
Lb— mol/hr
161,000
11,860
27,820
122
4
68
4
2
32.600
233,400
Lb/hr
4,509,000
379,500
1,225,000
7,825
302
2,045
165
86
587.200
6,711,000
48.700
6,759,000
Sft3/min (6QOF) = 1,476,000
Aft3/min (30QOF) = 2,158,000
Flv Ash Loading
Wet
Dry
Sulfuric acid dewpoint temperature: 295°F
a. See Table B-2 for fly ash composition.
Gr/sft3
3.85
4.47
B-25
-------
w
1.2-
Ox)
O
CO
CO
w
0.8-
0.6,
w
H
! 0.4.
W
O
Pi
H
I 0.2.
% S02 Removal Required
70 80 85 88 90
^O
5.0% S, 11,700 Btu/lb bit, coal
80
I
85
I
I
[3.5% S, 11,700 Btu/lb bit, coal
2.0% S, 11.700 Btu/lb bit, coal
0.9% S, 6,600 Btu/lb lignite
0.7% S, 9,700 Btu/lb bit, coal
0.7% S, 9,700 Btu/lb subbit. coal
0.7% S, 8,200 Btu/lb subbit. coal
I I I I I I I I
4 6 8 10
EQUIVALENT S02 CONTENT OF RAW COAL, Ib S02/MBtu
r
12
Figure B-3. Controlled S02 emission requirements for 1979 NSPS. Premise coals, shown
underlined, are based on premise boiler conditions.
-------
6.0 < E < 1£.Q
90? equivalent S02 removal required
E > 12.0
% equivalent S02 removal required = ((E - 1.2)/E)(100)
Equation to determine equivalent S02 removal required
% equivalent S02 removal required = ((A - B)/(1.0 - B))(100)
where: A = overall removal efficiency, decimal fraction
B = decimal fraction of S removed with ash: (1.0 - decimal
fraction of sulfur emitted as SOx)
TABLE B-18. 1979 NSPS EMISSION STANDARDS
SO;
70$ S02 removal (minimum) to a maximum S02
emission of 0.6 Ib S02/MBtu
0.6 lb.S02/MBtu maximum emission up to 90$ S02
removal
90$ S02 removal (minimum) to a maximum S02 emission
of 1.2 Ib S02/MBtu
1.2 Ib S02/MBtu maximum emission
NOx
Bituminous coal - 0.6 equivalent Ib N02/MBtu
Subbituminous coal - 0.5 equivalent Ib N02/MBtu
Lignite - 0.6 equivalent Ib N02/MBtu
Partioulate
0.03 Ib/MBtu
Reference 26
EMISSION CONTROL PROCESS DESIGN
With the exception of some standard designs and frequently used reference
processes—most notably the limestone FGD process—detailed design features
B-27
-------
that will be applicable to all evaluations cannot be specified. The diversi-
ties of processes and evaluation objectives and continuing technological
advances make such an approach impractical. Most designs must be based on a
thorough assessment of the objectives of the study, its relationship to past
and possible future studies, and on aspects that enhance the scope and detail
of the evaluation.
TABLE B-19. PREMISE COAL EMISSION STANDARDS FOR 1979 NSPS
Coal
Eastern bit. , 5.0$ S
Eastern bit. , 3-5? S
Eastern bit., 2.0$ S
Eastern bit. , 0.7$ S
Western bit. , 0.7$ S
Western subbit., 0.7$ S
N.D. lignite, 0.9$ S
Equivalent
S02 content
of coal,
Ib S02/MBtu
8.21
5.7^
3.28
1.15
1.22
1.17
1.73
Overall
equivalent S02
removal
efficiency, $
90.0
89.6
81.7
70.0
70.0
70.0
70.0
Equivalent
S02 removal
required
in FGD
system, $a
89.5
89.1
80.7
68.4
64.7
64.7
64.7
Controlled
outlet
emission,
Ib S02/MBtu
0.82
0.60
0.60
0.34
0.36
0.35
0.52
a. Based on FGD system as the only S02 control device and the previously
defined sulfur retention in the ash.
The standardized design features and procedures outlined in the following
sections are followed to the maximum extent compatible with the objectives of
the evaluation since this facilitates more detailed evaluations of significant
design and operating features and more meaningful identification of cost
elements. In all cases, the design and costing procedures are based on
division of costs into definable functional areas so that the role of
particular functions in determining costs can be identified.
Generic designs based on current practices and technology are usually
preferable for evaluating technologies in which several vendors offer proprie-
tary processes (limestone FGD, spray dryer FGD, and fabric filter baghouses
are examples of the early 1980s). This approach allows a general assessment
of the technology and of design trends and practices, less effected by the
specific concepts and preferences of individual vendors.
Evaluations of proprietary designs depend on the nature and objectives of
the evaluation. Standard design features are used as much as is consistent
with the objectives of the evaluation. The vendor's specifications and sug-
gestions are used for all features that represent and define the process while
B-28
-------
preferences that have no effect on the function of the process are—to dif-
ferent degrees, depending on the nature of the features and the objectives of
the evaluation—avoided if they reduce the comparability of the process
economics.
Particulate Matter
Fly ash and bottom ash collection, handling, and disposal or utilization
are included in the evaluation of other emission control processes when the
inclusion is pertinent to the evaluation or is expected to be in related
future evaluations. (However, these costs are not included in the FGD costs
from the Shawnee FGD computer model.) The standard bottom ash system consists
of conventional vee-bottom water-filled hoppers with clinker grinders, a
hydraulic conveying system with a combined ejector pump and centrifugal pump
system, and a dewatering system one-fourth mile from the boiler.
Normal fly ash control consists of rigid-frame cold-side (after the air
heater) electrostatic precipitators (ESPs) for coals with 2% or more sulfur
and rigid-frame hot-side ESPs for coals with less than 2% sulfur. Fabric
filter baghouses may be used in place of ESPs, particularly hot-side ESPs in
low-sulfur coal cases, if this favors the evaluation. Baghouses are used with
spray dryer FGD for particulate collection. Normally, economizer and air
heater (and reactor for NOg control, if used) and ash hoppers are included
in fly ash costs.
Vacuum conveying systems are used for conveying distances less than 300
feet. Vacuum-pressure systems are used when longer conveying distances are
necessary. In this case, the vacuum system is used to convey the solids from
the collection hoppers to one or more collection points, from which they are
conveyed to storage silos in the pressure system. Normally, the vacuum-
pressure system is used when more than 24 collection hoppers are involved.
The design of the waste conveying system is based on standard industry
practices.
The bottom ash dewatering bins, fly ash silos, and spray dryer waste
silos are sized for a 64-hour capacity to allow a 5-day, 2-shift disposal
operation. The bins and silos are elevated for direct discharge to trucks.
Silos for eastern coal fly ash are provided with moisturizer-mixers to add
water to the ash as it is discharged.
Flue Gas Desulfurization
The FGD system consists of two or more trains of absorbers supplied by a
common inlet plenum into which the flue gas from the power unit duct system
discharges. The plenum allows optimization of the FGD system design by making
it independent of the power plant duct configuration. The plenum and all
equipment between it and the stack plenum are included in the FGD costs. This
is based on the premise that in the absence of the FGD system, the flue gas
discharged to the inlet plenum would be discharged directly to the stack
plenum.
B-29
-------
Unless process requirements dictate otherwise, the absorber trains have a
maximum size of 125 MW or 513fOOO sft3/min (60°F), whichever is larger.
All systems with capacities of 200 MW or more, or processing 340,000 aft3/
min of flue gas, have two or more absorber trains. Each train is assumed to
have an annual availability of 85$. Spare trains are included to provide an
excess capacity of at least 25$. (This allows the use of an emergency bypass,
as discussed below.) All trains, including the spares, are identical although
this results in a spare capacity over 25$ in some cases: a 200-MW system
would have three 100-MW trains, for example. The 500-MW systems with full
scrubbing have four operating trains and one spare train and the 1,000-MW
systems have eight operating and two spare trains.
All wet-scrubbing systems that do not include prescrubbers such as
Venturis are equipped with presaturators to cool the flue gas to the satura-
tion temperature (approximately 127°F). Usually these are modified sections
of inlet duct equipped with spray headers to spray the flue gas with absorbent
liquid. The absorbers are also equipped with mist eliminators and reheaters
as required to produce a stack temperature of 175°F. Booster fans are
provided to compensate for the pressure drop in the system. Normally, these
are induced draft (ID) fans in each train downstream from the reheater.
Emergency Bypass—
Because the 1979 NSPS allow emergency bypass around the FGD system under
some conditions if spare scrubbing capacity is provided, spare scrubbing
trains and bypass of 50$ of the gas that would normally be scrubbed are
included. An emergency bypass of 50$ of the scrubbed gas is assumed to be an
economic balance between the higher cost of providing additional bypass and
the small likelihood of multiple scrubbing train failures, which would make
higher bypass rates necessary. The bypass is installed as two identical ducts
from each end of the inlet plenum to the stack plenum downstream from the
scrubbing trains. Particulate collection equipment is not bypassed.
Partial Scrubbing—
In some cases, depending on the sulfur content of the coal and SC>2
removal requirements, scrubbing a portion of the flue gas at a high removal
efficiency and combining it with the remaining flue gas may be more economical
than scrubbing all of the flue gas at a lower removal efficiency. In such
cases, the bypassed gas duct requirements and the emergency bypass capability
are combined in the same duct. The ducts are sized to handle both the flue
gas normally bypassed and emergency bypass of 50$ of the flue gas scrubbed.
Depending on sulfur content of the coal, for the 500-MW power unit, partial
scrubbing could involve scrubbing as little as 375 MW of flue gas. Three
operating scrubbing trains and one spare scrubbing train are provided for this
case.
Ductwork—
Square ductwork with 2-inch insulation (in standard cases) is used for
the inlet plenum and absorber trains. To prevent ash settling, a gas velocity
of 50 ft/sec is used for the inlet plenum, all ductwork, and the emergency
bypass. A gas velocity of 25 ft/sec is used for the reheater section. Duct
B-30
-------
material is usually 3/16-inch Cor-Ten steel when the gas temperature is higher
than 150°F and 3/16-inch stainless steel when the gas temperature is lower
than 150°F.
Removal Efficiencies—
It is assumed that 50% of the SOo, 95$ of the HC1, none of the NOX,
and 50$ of the remaining fly ash in the flue gas are removed in the FGD
system. For systems requiring a presaturator or humidifier, it is assumed
that 5$ of the S02 is removed in the presaturator and that the remaining
SC>2 removal takes place in the FGD absorber.
Mist Eliminator—
The mist eliminator is a fiberglass-chevron-baffle type. The mist
eliminator reduces entrained moisture to a maximum level of 0.1$ (by weight)
of the flue gas. This maximum level is used for calculation of the amount of
flue gas reheat required.
Flue Gas Reheat—
A reheater consisting of a steam-heated tube bank is provided in each
train to provide a stack temperature of 175°F. This is considered necessary
to evaporate corrosive liquid not removed by the mist eliminator and to
provide adequate plume buoyancy. The size of the reheater is determined by
the temperature of the scrubbed flue gas (which is assumed to be 125°F for
wet-scrubbing systems), the quantity of flue gas bypassed, and the heat of
compression through the ID booster fans—which is assumed to be equivalent to
an adiabatic compression equal to the pressure drop in the FGD system.
Necessary Information for calculation of the steam requirements and reheater
surface area is shown in Table B-20 and a sample calculation is shown in
Table B-21.
For full-scrubbing processes, the reheater tubes are Inconel 625 for
corrosion resistance below 150°F and the remainder are Cor-Ten steel. In
cases in which the scrubbed flue gas is not heated to 175°F (as in the case
of partial bypass), the quantity of Inconel tubes remains the same and the
quantity of Cor-Ten tubes is reduced.
Piping-
Carbon steel piping is used for water and other noncorrosive and non-
abrasive liquids. Stainless steel is used for slurry and other corrosive or
abrasive liquid lines 3 inches in diameter or less; neoprene-lined carbon
steel is used for larger lines carrying these liquids. For slurry lines, plug
valves are used for lines up to 3 inches in diameter; eccentric plug valves
are used for 3- to 20-inch lines; and knife gate valves are used for lines
larger than 20 inches in diameter. Pneumatic actuators are provided for
valves 12 inches in diameter or larger.
Buildings--
Metal buildings are provided when it is necessary to provide weather
protection. The buildings have 6-inch concrete floors, insulation, electrical
heating, overhead doors, and other features required for their function.
Normally, buildings are provided for feed preparation, waste dewatering,
B-31
-------
TABLE B-21. SAMPLE REHEATER CALCULATIONS
Gas to Reheater
CC-2
HC1
S02
02
N2
H20 (vapor)
Total gas
H20 (liquid entrainment)
Total
Reheater Heat Duty
C02
HC1
S02
02
N2
H20 (vapor)
Ib/hr
1,008,000
21
2,850
319,800
3,852,000
444.873
5,627,544
5.627
5,633,171
Ib/hr x Cpm(Btu/lb)b = Btu/hr
1,008,000 x 10.8
21 x 9.5
2,850 x 7-9
319,800 x 11.2
3,852,000 x 12.5
444,873 x 22.6
10,886,400
200
22,515
3,581,760
48,150,000
5,627 x 1,043.2b
Total
H20 (liquid entrainment)
Total
Steam Requirement
78,565,095 Btu/hr T 751.9 Btu/lb = 104,489 Ib/hr
Reheater Area
78,565,095 Btu/hr v 4 operating reheaters T 20.8 Btu/ft2-hr-op 7
3190pa,b = 2,960 ft2
72,695,005
5.870.QQQ
78,565,095 Btu/hr
a. Log mean temperature difference (ATL) = (T1- T2)/(ln(Ti/T2))
TI = Tsteam - Tgas in = 470 - 125 = 345
T2 = Tsteam - Tgas out = 470 - 175 = 295
ATL = (345 - 295)/(ln(345/295))
b. For a temperature change from 125°F to 175°F only.
B-32-
-------
storage, offices, laboratories, and for spray dryer FGD reactors (for
temperature control).
TABLE B-20. REHEATER DATA
Compound CP°> (Btu/lb)a
C02 10.8
HC1 9.5
S02 7.9
80s 8.2
02 11.2
N2 12.5
NO 12.0
N02 10.2
H20 (vapor) 22.6
Steam:
saturated at 470°F (500 psig), heat of
vaporization 751.9 Btu/lb
Reheater overall heat transfer coefficient:
20.8 Btu/ft2-hr-OF
Entrained water enthalpy:
liquid at T = 125°F: 92.9 Btu/lb
vapor at T = 175°F: 1136.1 Btu/lb
AHa = 1043.2 Btu/lb
a. For temperatures between 125°F and 175°F
only.
Spare Equipment—
Spare equipment is provided in accordance with general practice. For
most processes, the following spares are provided:
• A spare train of crushing and grinding equipment
• Slakers
• Waste filters
• Pumps
• A spare scrubbing train or trains
B-33
-------
NOx Control
Reduction of NOX emissions to meet the 1979 NSPS is assumed to be met
by modifications to the boiler combustion system. Evaluations of NOX
control processes are normally based on an 80$ reduction of these emissions.
With the exception of selective catalytic reduction (SCR) processes,
NOX control processes are usually based on proprietary designs. These vary
considerably, from various forms of combustion modification and furnace injec-
tion to—conceivably—wet scrubbing. The designs in these cases are dealt
with on an individual basis, usually following the vendor's specification.
For processes that control both NOX and SC-2, "the comparative processes are
the standard limestone FGD process and a generic SCR process.
A generic SCR process design is based on the designs of U.S. vendors of
the process. For the base case conditions, parallel vertical reactors up to
250 MW in size (two reactors for the 500-MW base case) are used. Flue gas is
ducted from the outlet of the boiler economizer to the reactors and from the
reactors to the boiler air heater. The air heater is modified to accommodate
the buildup of ammonia salts and the incremental costs are included in the
NOX control costs. An economizer bypass to maintain the flue gas tempera-
ture during low-load operation and an emergency bypass for the reactors are
also included. No spare reactor trains are provided. The assumed catalyst
life is equivalent to the catalyst life generated by process vendors and the
catalyst volume is based on maintenance of the design NOX reduction over the
catalyst life. Boiler operation is assumed to be unaffected by the process
(catalyst changes and other maintenance occur during boiler outages).
WASTE PROCESSING AND DISPOSAL
For processes producing a waste, either landfill or pond disposal is
provided. Normally, an onsite disposal facility one mile from the process
facility is used. The size of the disposal facility is based on the lifetime
volume of waste. Both the landfill and pond designs and costs are determined
using the landfill and pond models in the Shawnee computer model.
Normally, landfill disposal is used for ash and insoluble FGD waste.
Ponds are used for wastes such as coal-cleaning fines that are not normally
dewatered. Ponds, which serve as solid impoundments, are also used for
soluble wastes such as sodium-based FGD waste.
Waste storage facilities are normally based on truck transport and land-
fill disposal on a 2-shift, 5-day-week schedule. A 64-hour silo and stockpile
storage capacity is provided to allow the landfill operating schedule. For
pond disposal—which may be used in special studies or for waste that is
normally ponded—an 8-hour storage tank is provided. The waste is pumped
directly to the pond and the supernate is returned for reuse.
B-34
-------
Waste Properties
The densities upon which equipment sizes and storage volumes are based
are shown in Table B-22. Settled and compacted moisture contents and bulk
densities are also shown for use in disposal site designs, which are discussed
below. These are used in conceptual design evaluations in which uniform
representative values are more useful than specific values or in which spe-
cific data are unavailable. The values in Table B-22 are based on published
data and are representative of the rather large range over which the moisture
contents and bulk densities of most wastes vary, depending on the conditions
under which they were produced. In evaluations based on specific wastes,
measured values or more specific estimates should be used.
TABLE B-22. WASTE BULK DENSITIES
Model defaults bulk density, Ib/ft3
In-process waste Compacted
Waste Sludge
Sulfite (filtered) 70 85
Gypsum (filtered) 75 95
Fixed sulfite (filtered) 90 106
Fixed sulfate (filtered) 85 100
Dry FGD waste 70 85
FGD Waste Processing and Handling
High-sulfite slurry (70$ CaS03-1/2H20 and 30$ CaSOij'2H20) is
normally dewatered and mixed with dry fly ash and lime (100$ fly ash and 3.5$
lime, both based on the dry weight of FGD solids) for landfill disposal. The
slurry from the absorbers is first dewatered to 30$ solids in a thickener,
then filtered to 55$ solids in rotary vacuum filters. The filter cake is
mixed with the fly ash and lime in .a pug mill and conveyed to a radial-arm
stacker that stacks it in a 64-hour capacity stockpile for removal to a
landfill.
Gypsum waste (95$ CaSO^-I^O or more) is thickened to 30$ solids and
filtered to 85$ solids in rotary vacuum filters. The filter cake is stacked
in a 64-hour capacity stockpile by a radial-arm stacker from which it is
removed to a landfill.
B-35
-------
Waste Transportation
Trucks are used for transportation of solid wastes. Bottom ash and fly
ash are discharged directly from the elevated dewatering bins and silos into
the trucks. A moisturizer-mixer mounted on the storage silo is used to add
water to fly ash from eastern bituminous coal (the quantity of water is based
on the optimum compaction moisture) to control dusting. Other fly ash and
spray dryer FGD waste, which is likely to have cementitious properties, is
moisturized with similar truck-mounted moisturizers at the disposal site.
Wastes in slurry form are sluiced to the disposal site and the supernate
is returned for reuse. If the slurry is abrasive (ash and coal-cleaning
waste), an abrasion-resistant ash-sluicing pipe is used. Equipment for
control of the return water pH and scaling potential is included in all wet
sluicing systems.
Disposal Site
Both the pond and landfill design and costs are determined using the
Shawnee flue gas desulfurization computer model, which allows numerous design
variations. The standard conditions are described below. The disposal site
is normally situated one mile from the process facility. Sufficient land is
provided for disposal during the remaining life of the facility. The disposal
site is assumed to be an area of low relief with sufficient soil for dike
construction or landfill requirements.
Pond—
Disposal ponds are square, earthen-diked enclosures with a medium
diverter dike. Dikes are constructed from material removed from the impound-
ment area as shown in Figure B-4. The entire impoundment area is lined with
12 inches of clay (assumed available onsite). Pond size and depth are
normally adjusted to minimize the sum of land and construction costs. Pond
costs include a 6-foot security fence around the perimeter dike, security
lighting, a topsoil storage area, and one upstream and three downstream
groundwater monitoring wells.
Landfill—
The landfill, one mile from the fixation area, has a square configuration
with a 20-foot rise and a 6-degree cap, as shown in Figure B-5. After topsoil
removal, the landfill area is lined with 12 inches of clay (assumed available
onsite) with a drain system to a sump and 24 inches of bottom ash is placed on
the liner. Surface runoff drains into a catchment ditch around the perimeter-
The ditch drains into a catchment basin for pH adjustment. Land requirements
include the landfill, the catchment basin, an office, equipment storage area,
topsoil storage area, and a 50-foot perimeter of undisturbed land. Costs for
access roads; a 6-foot security fence around the total landfill area; security
lighting; and topsoil stripping, replacement, and revegetation are included.
One upstream and three downstream groundwater monitoring wells are also
included.
B-36
-------
F~ "*
;
t
;
i
t
<
*
w
1 '
W A «
li
i-t
WASTE DISPOSAL
POND
A B
_t t-
B
Jf
4
SUPERNATE SLURRY
IN
OUTER BOUNDRY —_._
X OF POND AREA TOPSOIL-
10% FREE BOARD
U^
GROUND LEVEL -1 1
TOPSOIL
EXCAVATION
(1.5 FT.I\
_t_ TOTAL
EXCAVATION DEPTH
TOPSOIL '
EXCAVATION
(1.5 FT.)
SECTION AA
POND PERIMETER DIKE
SECTION BB
POND DIVERTER DIKE
10% FREE BOARD
DEPTH OF SLUDGE
1 TOTAL
EXCAVATION DEPTH
Figure B-4. Pond design.
-------
Equipment.
., Storage
Topsoil u ,
Storage \ \
—-X--4--X x *
OJ
00
Access Road
Office
Drain Sump
Catchment Basin
v~Ca
x-rf-T-yx- — r-x — i
Landfill
Area
L—x x x—
6' Fence
Ditch
6' Fence
l'-6" Topsoil
6IT Clay
1
2' Bottom Ash
With Drains
1' Clay
Figure B-5. Landfill design.
-------
ECONOMIC PREMISES
Schedule and Cost Factors
The construction schedule used as a cost basis is shown in Figure B-6. A
3-year construction period, from early 1984 to late 1986, is used. Mid-1985
costs are used for capital investment. Mid-198? costs are used for annual
revenue requirements. These costs represent the midpoint of construction
expenditures and the midpoint of the first year of operation. Costs are
projected from Chemical Engineering cost indexes (27), as shown in
Table B-23. Frequently used costs are shown in Table B-24.
Capital Cost Estimates
Four grades of capital cost estimates are prepared depending upon the
intended use and the amount of information available. The grades, in
increasing order of accuracy, are (1) order of magnitude, (2) study, (3)
preliminary, and (4) definitive. The two grades normally used are the study
and preliminary grades. The purpose, information required, and predicted
accuracy are listed in Table B-25.
A typical capital investment sheet is shown in Table B-26. The capital
investment sheet is divided into three major sections: direct investment,
indirect investment, and other capital investment.
Direct Investment—
Direct investment consists of total process capital; services, utilities,
and miscellaneous; and waste disposal investment. Total process capital is
determined from the equipment list. Using standard estimating techniques
(28,29,30) and the Chemical Engineering cost indexes and projections shown
in Table B-23, the equipment cost and installation costs of each area are
estimated. The installation costs include charges for all piping, founda-
tions, excavations, structural steel, electrical equipment, instruments,
ductwork (all ductwork is included in the gas-handling area), paint, build-
ings, taxes, freight, and a premium for 1% overtime construction labor as
shown in Figure B-7. The total process area costs are summed on the area
summary sheet shown in Figure B-8 to give the total process capital.
Service facilities such as maintenance shops, stores, communications,
security, offices, and road and railroad facilities are estimated or allocated
on the basis of process requirements. Included in the utilities investment
are necessary electrical substations, conduit, steam, process water, fire and
service water, instrument air, chilled water, inert gas, and compressed air
distribution facilities. Services, utilities, and miscellaneous are in the
range of 4$ to 8% of the total process capital. For most cases, 6$ is to be
used, higher for processes and lower for waste disposal facilities. The base
case limestone-scrubbing process is charged 6% for services, utilities, and
miscellaneous.
All equipment and direct construction costs associated with waste
disposal are included in waste disposal costs. For ponds, this includes pond
B-39
-------
-3
-2
-1 0
I Operating year
•Construction-
Period
•Operation-
i
.p-
o
1934
Begin
construction
1985
1986
Midpoint of
construction
expenditure
1987
End of
construction
and beginning
of operation
Figure B-6. Construction schedule.
-------
w
I
-C-
TABLE B-23. COST INDEXES AND PROJECTIONS
Year: 1972 1973 1Q714 1975 1976 1977
Plant 137.2 144.1 165.1 182.1 192.1 201.1
Materialb 135.1) 141.9 171.2 194.7 205.8 220.9
Laborc 152.2 157.9 163-3 168.6 171.2 178.2
1978
218.8
240.6
185.9
1979
238.7
264.4
194.9
a. TVA projections.
b. Same as "equipment, machinery, supports," Chemical Engineering
c. Same as "construction labor," Chemical Engineering index.
1980
261.1
292.6
204.3
index
1981
297.0
323.0
242.4
•
1982
314.0
336.2
263-9
1983
316.9
336.0
267.6
1984a
326.4
346.1
275.6
1985a
346.0
366.8
292.2
1986a
366.8
388.9
309.7
1987a
388.8
412.2
328.3
1988a
412.1
436.9
348.0
-------
TABLE B-24. COST FACTORS
1Q87 Utility Costs
Electricity
Steam
Eastern bit. coal «1$ S)
Eastern bit. coal (2% S)
Eastern bit. coal (3% S)
Eastern bit. coal (4$ S)
Western bit. coal (0.7$ S)
Western subbit. coal (0.7% S)
N.D. lignite (0.9* S)
Fuel oil No. 6
Diesel fuel
Natural gas
Filtered river water
1987 Labor Costs
FGD
Waste disposal
Analysis
1987 Raw Material Costs
Limestone
Lime
Ammonia
Soda ash
Adipic acid
MgO
1985 Land Cost
$0,
$4,
$63.
$53
$43.
$38,
$65,
$35,
$18,
$10,
$1,
$6,
$0,
$0,
$0,
055/kWh
00/klb;
00/ton;
00/ton;
00/ton;
00/ton;
00/ton;
00/ton;
00/ton;
50/MBtu
60/gal
00/MBtu
16/kgal
14/kgal
12/kgal
$0.10/kgal
$5.30/MBtu
$2.30/MBtu
$2.03/MBtu
$1.8l/MBtu
$1.71/MBtu
$3.40/MBtu
$2.10/MBtu
$1.35/MBtu
(up to 0.6 Ggal)
(0.6-2 Ggal)
(2-5 Ggal)
(over 5 Ggal)
$19.00/man-hr
$24.00/man-hr
$26.00/man-hr
$15.00/ton (95$ CaC03, dry basis)
$90.00/ton (pebble, 95$ CaO, dry basis)
$230.00/ton
$190.00/ton (99.8$
$1,500.00/ton
$510.00/ton
$6,000.00/acre
These cost factors are based on a north-central plant location.
B-42
-------
TABLE B-25. CAPITAL COST ESTIMATE CLASSIFICATION
Grade
Purpose
Minimum Information required
Predicted
accuracy,
_±l =1
Order of magnitude
(ratio estimate)
Study (factored
estimate)
Preliminary (initial
budget or scope
estimate)
Definitive (project
control estimate)
Preliminary feasibility study to deter-
mine whether continued investigation is
merited. Rough comparison of
alternatives.
Comparison of alternatives. Prelimi-
nary screening. Preliminary budget
preparation. Authorization for funding
for an engineering study or for develop-
ment of additional information.
Preliminary budget approval. More
accurate comparison of alternatives.
Follow up of an order-of-magnitude or
study estimate.
Final capital authorization. Project
cost control. Follow up on order-of-
magnitude, study, or preliminary
estimates for more accurate Informa-
tion. Generally reserved for a real
construction project with a known
site.
General design basis,a flowsheet and >50 >50
material balance, heat and energy
balance. For the order-of-magnitude
estimates, this information Is of a
tentative nature, developed from a
preliminary process concept.
All of the above on a firm, rather 40
tentative basis plus overall layout
of manufacturing and nonmanufacturlng
facilities, sized equipment and instru-
ment lists, and performance data
sheets.
All of the study estimate requirements 30
plus process control diagrams, process
piping sketches with sizes, plan and
elevation drawings, offsite descrip-
tions, including sizes and capacities.
20
All of the preliminaj-y estimate .
requirements plus piping plan and
elevation drawings integrated with the
equipment plan and elevation drawings,
electrical layout single line
drawings, detailed piping and Instru-
mentation flowsheets, layout of non-
manufacturing facilities, design
sketches for unusual equipment items,
and specific site data, including
utilities and transportation availa-
bility, soil bearing, wind and snow
loads.
20
15
10
General design basis includes product, product specifications, plant capacity, storage requirements,
operating stream time, provisions for expansion, and raw materials and their storage requirements.
-------
TABLE B-26. CAPITAL INVESTMENT SHEET
TABLE LIMESTONE PROCESS CAPITAL INVESTMENT
(500-MW new coal-fired power unit; 3.5? S in coal;
89$ S02 removal; onsite solids disposal)
Direct Investment Investment, kt
Materials handling
Feed preparation
Gas handling
S02 absorption
Stack gas reheat
Oxidation
Solids separation
Total process capital
Services, utilities, and miscellaneous
Total direct investment excluding landfill
Solids disposal equipment
Landfill construction
Total direct investment
Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Contingency
Disposal area indirects
Total fixed investment
Other Capital Investment
Allowance for startup and modifications
Interest during construction
Royalties
Land
Working capital
Total capital investment
Dollars of total capital per kW of generating capacity
Basis: North-central plant location represents project beginning early
1981, ending late 1986; average cost basis for scaling, mid-1985.
One spare scrubber train, 50$ emergency bypass, spare pumps.
Landfill located one mile from power plant.
FGD process costs begin with feed plenum. Stack plenum and stack
excluded.
B-44
-------
Area
Process equipment
Piping & insulation
Concrete foundations
Excavations, site prep-
aration, roads, etc.
Structural
Electrical
Instrumentation
Ducts , chutes , expan-
sion joints, etc.
Paint & miscellaneous
Buildings
Trucks & earthmoving
equipment
Subtotal
Freight (3.5% of pro-
cess material)
Tax (4% of material
subtotal)
Total process
area cost
% of
process
equipment
x^
Material
Labor
X
X
1
Total
a. Includes premium for 7% overtime, i.e., labor is 0.93 (straight
time labor) + (0.07) (1.5) (straight time labor) or 1.035 (straight
time labor) .
Figure B-7. Process area cost summary sheet.
B-45
-------
Area
1
2
3
4
5
6
7
Description
Materials handling
Feed preparation
Gas handling
SO absorption
Stack gas reheat
Oxidation
Solids separation & disposal
Total process
area cost, $
Total process
capital, $
Figure B-8. Area summary sheet.
B-46
-------
construction costs from the computer pond model. For landfills, mobile equip-
ment and construction costs are included. All mobile equipment involved in
loading and transporting the waste from the in-process storage area, as well
as working the landfill, is included in solids disposal equipment. The land-
fill construction cost, as calculated from the landfill computer model, is
listed separately from the solids disposal equipment. The sum of total
process capital; services, utilities, and miscellaneous; and the waste
disposal cost is the total direct investment.
Indirect Investment—
Indirect capital investment covers fees for engineering design and super-
vision, architect and engineering contractor, construction expense, contractor
fees, and contingency. Listed in Table B-27 are the ranges to be used to
calculate the process and waste disposal indirect investments. The base per-
centages are normally used. The low and high ranges are used if the process
being studied is either much more complex than the typical system (the higher
percentage factors are used) or much less complex (the lower percentage
factors are used). The limestone- and lime-scrubbing processes use the low
percentages for a 1,000-MW unit, base percentages for a 500-MW unit, and the
high percentages for a 200-MW unit. Contingency is included to compensate for
unforeseen expenses. The contingency varies depending on the process and the
waste disposal method, as shown in Table B-28. The limestone- and lime-
scrubbing processes are assessed a contingency of 10$ for the process and 20$
for the landfill.
Other Capital Investment—
The allowance for startup and modifications is applied as a percentage of
the total fixed investment. Since the startup and modification costs for the
waste disposal area are assumed to be negligible, this allowance is calculated
as a percentage of the total process fixed investment only. The values used
are shown in Table B-29. The limestone- and lime-scrubbing processes are
assessed at a rate of 8$ for this charge.
The cost of borrowed funds (interest) during construction is 15.6$ of the
total fixed investment (both process and waste disposal). This factor is
based on an assumed 3-year construction schedule and is calculated with a 10$
weighted cost of capital with 25$ of the construction expenditures in the
first year, 50$ in the second year, and 25$ in the third year of the project
construction schedule. Expenditures in a given year are assumed uniform over
that year. Startup costs are assumed to occur late enough in the project
schedule that there are no charges for the use of money to pay startup costs.
Table B-30 illustrates the calculation of the interest during construction for
3- through 6-year construction schedules.
Most processes will include a one-time royalty charge using either an
actual royalty obtained from the vendor or 1$ of the total process capital
involved. Processes exempt from royalties due to their generic design are
limestone and lime processes, including those with forced oxidation or adipic
acid or both, and the magnesia process.
B-47
-------
TABLE B-27. RANGE OF INDIRECT INVESTMENTS
Indirect Investment. Process
% of total direct investment
excluding waste disposal investment
Low Base High
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total
Waste Disposal Indirects FGD Pond.
FGD Landfill, or Ash Pond
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total
Ash Landfill
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total
6
1
14
JL
25
7
2
16
30
8
3
18
JL
35
5 of total direct waste
disposal investments
Low Base High
2
1
7
JL
14
2
1
8
16
2
1
9
18
% of total direct waste
disposal investment^
Base
6
3
10
JL
25
a. Pond (or landfill) construction only.
B-48
-------
TABLE B-28. CONTINGENCY
Process Contingency
Limestone and lime slurry
Limestone and lime - forced oxidation
Limestone and lime - forced oxidation
with adipic acid
All others
Waste Disposal Contingency
FGD pond
Ash pond
FGD landfill
Ash landfill
% of total direct investment
excluding waste disposal plus
process indirect investment
10
10
10
20
% of total waste disposal direct
investment plus waste
disposal indirect investment
10
10
20
10
TABLE B-29. ALLOWANCE FOR STARTUP AND MODIFICATIONS
Process
% of total fixed investment
for process only
Limestone and lime
(generic )
All other processes
Waste Disposal
8
10
% of total fixed investment
for waste disposal only
Ponds and landfills
B-49
-------
TABLE B-30.. INTEREST DURING CONSTRUCTION ILLUSTRATION
Three-Year Construction Schedule
Years from Compound amount
startuo factor^
3-2 1.2686 x
2-1 1.1533 x
1-0 1.0484 x
Total fixed investment plus interest
Interest during construction = 1 . 1 56
Four-Year Construction Schedule
Years from Compound amount
startuo factor^
4-3 1.3955 x
3-2 1.2686 x
2-1 1.1533 x
1-0 1.0484 x
Total fixed investment plus interest
Interest during construction = 1.204
Five-Year Construction Schedule
Years from Compound amount
startup factors
5-4 1.5349 x
4-3 1.3955 x
3-2 1 .2686 x
2-1 1.1533 x
1-0 1.0484 x
Fraction of total
olant investment
0.250
0.500
0.250"
during construction:
- 1.000 = 0.156 or 15.6$
Fraction of total
olant investment
0.150
0.300
0.350
0.200 =
during construction:
- 1.000 = 0.204 or 20.4$
Fraction of total
Dlant investment
0.10
0.20
0.30
0.25 =
0.15
0.317
0.577
SL2&2
1.156
0.209
0.381
0.404
Q.210
1.204
0.154
0.279
0.381
0.288
0.157
Total fixed investment plus interest during construction: 1.259
Interest during construction = 1.259 - 1.000 = 0.259 or 25.9$
(Continued)
B-50
-------
TABLE B-30. (Continued)
Six-Year Construction Schedule
Years from Compound amount Fraction of total
startup factors plant investment
6-5 1.6886 x 0.10 = 0.169
5-4 1.5349 x 0.15 = 0.230
4-3 1.3955 x 0.25 = 0.349
3-2 1.2686 x 0.25 = 0.317
2-1 1.1533 x 0.15 = 0.173
1-0 1.0484 x 0.10 = 0.105
Total fixed investment plus interest during construction: 1.343
Interest during construction = 1.343 - 1.000 = 0.343 or 34.3$
a. Present worth and compound amount factor using the 10$ cost of capital
with continuous compounding (28).
Years from Uniform expenditure Compound amount
startup present worth (28) factor (28)
7-6 0.5384 1.8574
6-5 0.5922 1.6886
5-4 0.6515 1.5349
4-3 0.7166 1.3955
3-2 0.7883 1.2686
2-1 0.8671 1.1533
1-0 0.9538 1.0484
B-51
-------
Land—
All land associated with the process and waste disposal area is charged
to the process. The cost of land is $6,000 per acre.
Working Capital—
Working capital is the total amount of money invested in raw materials,
supplies, finished products, accounts receivable, and money on deposit for
payment of operating expenses. For these premises, working capital is defined
as the equivalent cost of 1 month's raw material cost, 1.5 months' conversion
cost, *1.5 months' plant and administrative overhead costs (all of the above
are found on the annual revenue requirements sheet), and 3% of the total
direct capital investment (from the capital investment sheet). One month is
defined as 1/12 of annual costs. The equation is shown below:
Working capital = 1/12 (total raw materials cost) +
(1.5) (1/12) (total conversion cost) +
(1.5) (1/12) (plant and administrative overhead) +
0.03 (total direct investment)
Battery Limits—
Since battery limits costs typically include most of the associated
indirect investments, battery limits costs have their own indirect investment
factors as shown below:
% of battery
limits cost
Engineering design and supervision 6
Architect and engineering contractor 1
Construction expense 14
Contractor fees 0
Contingency 10
Retrofit Factor—
For existing plant cases, a retrofit factor is assigned to cover the
additional investment required. Each of the area investments (i.e., material
handling, etc.) is multiplied by the retrofit factor. Retrofit factors vary
widely depending on the process and the site involved (31). For emission
control processes which are coupled to the boiler, the following retrofit
factors are used:
B-52
-------
Process
Retrofit
factor
Reason
Limestone scrubbing
Spray dryer
NOx FGT (SCR)
1.3 These scrubbing systems are add-on in that
they require no boiler modifications. This
factor for the retrofit cases is due to the
need to fit the equipment into available
space.
1.5 These scrubbing systems require relatively
minor modifications to the boiler and duct-
work. This factor also includes the
expense of fitting the equipment into the
available space.
1.7 These control systems require extensive
modifications to the boiler economizers and
air heaters and the associated ductwork.
This factor also includes the expense of
locating the equipment in the available
space.
It is assumed that most FGD systems will be of the add-on type and, therefore,
use the 1.3 retrofit factor.
Annual Revenue Requirements
Annual revenue requirements consist of various direct and indirect
operating and maintenance costs and capital charges. Annual revenue require-
ments normally vary from year to year as operating and maintenance costs
change and capital charges decline. Thus, no single year is necessarily
representative of the lifetime costs, nor can single-year undistorted compari-
sons be made among processes with different ratios of operating costs to
capital charges. In addition, it is necessary to take into account the effect
of time on the value of money (for inflation, the future earning power of
money spent, and other factors).
Frequently these factors are accounted for by levelizing (32). Leveliza-
tion converts all the varying annual revenue requirements to a constant annual
value, such that the sum of the present worths of the levelized annual revenue
requirements equals the sum of the present worths of the actual annual revenue
requirements. The levelized value is calculated by multiplying the revenue
requirements for each year by the appropriate present worth factor and summing
the present worth values. Then the single present worth value is converted to
equal annual values by multiplying the result by the capital recovery factor.
In these premises, the operating and maintenance costs are levelized by
multiplying the first-year operating and maintenance cost by a levelizing
factor. The levelized capital charges are determined by levelizing the per-
centage of capital investment applied yearly as capital charges. The
B-53
-------
levelizing factor includes a discount factor reflecting the time value of
money and an inflation factor reflecting the effects of inflation during the
operating life of the system. The discount rate used is 10? and the inflation
rate used is 6%. The levelizing factor produced varies with the remaining
life of the system. Calculation of the levelizing factor for operating and
maintenance costs and of levelized capital charges is discussed below.
A typical annual revenue requirement tabulation is shown in Table B-31.
Direct costs consist of raw material and conversion costs. These, combined
with overheads, are the operating and maintenance costs. For processes that
produce a salable byproduct, byproduct sales are applied as a credit to the
operating and maintenance costs. Levelized capital charges are calculated as
a percentage of the capital investment and added to the operating and mainte-
nance costs to provide the first-year annual revenue requirements. The
levelized annual revenue requirements are determined by multiplying the
operating and maintenance costs by the levelizing factor and adding the
product to the same levelized capital charges used in the first-year annual
revenue requirements.
Operating and Maintenance Costs—
Frequently used raw material costs and standard conversion costs are
shown previously in Table B-24. Other costs are obtained from vendors or
published information. These costs are converted to 1987 costs using the cost
indexes in Table B-23 or industry projections.
Raw materials—Consumables required for their chemical or physical
properties, other than fuel for the production of heat, are classified as raw
materials. Raw material costs are determined as necessary from vendor quota-
tions or published sources and escalated to 198? costs. All costs are
delivered costs.
Operating labor and supervision—Unit labor costs for 198? were shown
in Table B-24. The allocation of operating labor and supervision depends on
the process complexity, number of process areas, labor intensity of the
process, and operating experience.
Utilities—Services used, such as steam, electricity, process water,
fuel oil, and heat credits, are charged under the utilities heading. Unit
1987 costs are shown in Table B-24. Costs for steam and electricity are based
on the assumption that the required energy is purchased from another source.
This simplifying assumption eliminates the need to derate the utility plant.
Process water requirements are defined as any water used by the process being
evaluated and are usually determined by the material balance. Steam require-
ments are for flue gas reheat and process requirements. Electrical power
requirements are determined from the installed horsepower of operating
electrical equipment (excluding the horsepower of spare equipment). Each
motor in operation is assumed to be operating at rated capacity, although this
results in higher power consumptions than would actually occur- Electrical
requirements are obtained from the equipment list, where the motor horsepower
is identified, plus an additional amount for functions such as lighting. A
sample calculation is shown in Table B-32.
B-54
-------
TABLE B-31. ANNUAL REVENUE REQUIREMENTS SHEET
TABLE LIMESTONE PROCESS ANNUAL REVENUE REQUIREMENTS
(500-MW new coal-fired power unit, 3.5? S in coal;
89$ S02 removal; onsite solids disposal)
Annual
quantity
Unit
cost, t
Total annual
cost, kt
Direct Costs - First Year
Raw materials
Limestone
Total raw material cost
Conversion costs
Operating labor and supervision
FOD
Solids disposal
Utilities
Process water
Electricity
Steam
Maintenance
Labor and material
Analysis
Total conversion costs
Total direct costs
Indirect Costs - First Year
Overheads
Plant and administrative
Marketing (10J of byproduct sales)
Byproduct credit
tons
man-hr
man-hr
kgal
kWh
klb
man-hr
/ton
/man-hr
/man-hr
/kgal
/kWh
/klb
/man-hr
tons
$/ton
Total first-year operating and maintenance costs
Levellzed capital charges ( % of
total capital Investment)
Total first-year annual revenue requirements
Levellzed first-year operating and maintenance
costs ( first-year 0 and M)
Levellzed capital charges (
Investment)
J of total capital
Levellzed annual revenue requirements
Hilla/kWh
First-year annual revenue requirements
Levellzed annual revenue requirements
Basis: One-year, 5,500-hour operation of the system described in the capital
Investment sheet; 1987 cost basis.
B-55
-------
TABLE B-32. SAMPLE ELECTRICAL REQUIREMENT CALCULATION
Electricity requirements are determined by summing the horsepower of all
operating electrical equipment and multiplying by a factor of 0.7457 kW/hp.
It is assumed that the instantaneous load factor and the power load factor
are equal and thus cancel. Additional electricity is added for functions
such as lighting. For the limestone and lime processes, 100 kW is added.
For other processes, more or less electricity, depending on the process
type, size, and complexity, may be necessary.
Sample Calculation
Area Total operating ho
Materials handling 70.5
Feed preparation 797.5
Gas handling 3*580.0
S02 absorption 6,189.0
Stack gas reheat 0.0
Oxidation 4,903-0
Solids disposal 71 .0
Total 15,611.0 hp
15,611 hp x 0.7457 kW/hP = 11,641 kW
+ 100 kW
11,741 kW
11,741 kW x 5,500 hr - 64,575,500 kWh
Maintenance—Process maintenance costs are 3% to 10$ of the total
direct process capital investment depending on process complexity, process
equipment, materials handled, process areas, and unit size. The percentages
shown in Table B-33 are used under most circumstances. For specific FGD
processes, the maintenance percentages shown in Table B-34 are used. For
example, a 500-MW limestone-scrubbing process normally has a maintenance
factor of 8$.
Waste disposal maintenance costs are estimated from the appropriate model
and are typically 3% of the waste disposal site construction costs. Mainte-
nance costs for waste disposal are not shown separately. If no other informa-
tion is available, the maintenance material-to-labor ratio can be assumed to
be 60:40.
B-56
-------
TABLE B-33. MAINTENANCE FACTORS
Process conditions
$ of total direct investment
excluding waste disposal
Low Base High
Corrosive or abrasive slurry
Solids, high pressure, or high
temperature
Liquids and gases
6
4
3
8
5
4
10
6
5
TABLE B-34. MAINTENANCE FACTORS FOR SPECIFIC FGD PROCESSES
Maintenance, % of total
direct investment
FGD svstem
Limestone and lime (generic)
Double alkali
Wei Iman- Lord
Magnesia
Lime spray dryer (including baghouse)
200
MW
9
7
7
8
7
500
MW
8
6
6
7
6
1,000
MW
7
5
5
6
5
Waste
disoosal
3
3
-
-
3
Analysis—Analysis costs are based on process complexity and are listed
as a single entry.
Plant and Administrative Overheads—Plant and administrative overheads
include plant services such as safety, cafeteria, and medical facilities;
plant protection and personnel; general engineering (excluding maintenance),
interplant communications and transportation; and the expenses connected with
management activities. Plant and administrative overheads for the FGD process
are 60$ of the total conversion costs less utilities.
Marketing Overhead—This is calculated as 10$ of byproduct sales
income.
B-57
-------
Byproduct Credit—-Total revenue from the sale of byproducts is applied
as a credit to processes in which a byproduct is salable.
Capital Charges—
Capital charges are those costs incurred by construction of the facility
that must be recovered during its life. They consist of returns on equity and
debt (discount rate), depreciation, income taxes, and other costs such as
insurance and local taxes. In keeping with common practice for investor-owned
utilities, the weighted cost of capital is used as the discount rate. Depre-
ciation is stated as a sinking fund factor to simplify calculations. An
allowance for interim replacement is included to compensate for possible early
retirement of the facility. Credits are also included for tax preference
allowances. The capital charges are shown in Table B-35. In keeping with
standard practice, book, tax, and economic lives are used in the following
calculations. In these premises, however, all three are assumed to be equal.
TABLE B-35. LEVELIZED ANNUAL CAPITAL CHARGES
Levelized annual capital charge as
1 of total capital investment
Remaininc life, vears
Weighted cost of capital
Depreciation (sinking fund factor)
Annual interim replacement
Levelized accelerated tax depreciation
Levelized investment tax credit
Levelized income tax
Insurance and property taxes
Levelized annual capital charge
15
10.00
3-15
0.72
(1.44)
(2.39)
3-96
2. 50
16.53
20
10.00
1.75
0.67
(1.43)
(2.14)
4.08
2.50
15. 4a
25
10.00
1.02
0.62
(1.40)
(2.00)
4.20
2.50
14.93
™
10.00
0.61
0.56
(1.36)
(1.93)
4.31
2. 50
14.73
a. Rounded to three significant figures.
The capital structure is assumed to be 35$ common stock, 15% preferred
stock, and 50? long-term debt. The cost of capital is assumed to be 11.4$ for
common stock, 10.0$ for preferred stock, and 9.0$ for long-term debt. The
weighted cost of capital (WCC) is 10.0$. The discount rate (r) is equal to
the weighted cost of capital.
Other economic factors used in financial calculations are a 10$ invest-
ment tax credit rate, 50$ State plus Federal income taxes, 2.5$ property tax
and insurance, and an annual inflation rate of 6$. Salvage value is assumed
to be less than 10$ and equal to removal cost.
B-58
-------
Weighted cost of capital is calculated as follows:
WCC = (fraction long-term debt) (long-term debt cost, %) +
(fraction preferred stock) (preferred stock cost, %) +
(fraction common stock) (common stock cost, %}
The sinking fund factor method of depreciation is used since it is
equivalent to straight-line depreciation levelized for the economic life of
the facility using the weighted cost of capital. The use of the sinking fund
factor does not suggest that regulated utilities commonly use sinking fund
depreciation. All factors and rates are expressed as decimals. The equation
is:
SFF = (WCC)/((1 + WCC)Ne -1)
where: SFF = sinking fund factor
WCC = weighted cost of capital
Ne = economic life in years
An annual interim replacement (retirement dispersion) allowance of 0.56?
for new plants and 0.67$ for existing plants is also included as an adjustment
to the depreciation account to ensure that the initial investment will be
recovered within the actual rather than the forecasted life of the facility.
Since power plant retirements occur at different ages, an average service life
is estimated. The type S-1 Iowa State (33) retirement dispersion pattern is
used. The S-1 pattern is symmetrical with respect to the average life axis
and the retirements are represented to occur at a low rate over many years.
The interim replacement allowance covers replacement of individual items of
equipment with typical lifespans less than the life of the power plant.
Repair of other equipment is covered by the maintenance charge.
Tax preference allowances are incentives designed to encourage investment
as a stimulus to the overall economy. The basic accounting method used is the
flow-through method which passes the tax advantage to revenue requirements as
soon as they occur.
Using the sum of the years digits method, which allocates costs early in
the life of the facility, the accelerated tax depreciation (ATD) is calculated
as follows:
ATD = (2)(CRFe)(Nt- (1/CHFt))/(Nt)(Nt + 1)(WCC)
where: CRFe = capital recovery factor (WCC + SFF) for the economic life
CRFt = capital recovery factor (WCC + SFF) for the tax life
Nt = tax life in years
B-59
-------
Levelized accelerated tax depreciation is calculated as follows:
LATD = (AID - SLD)(ITR)/(1 - ITR)
where: SLD = straight-line depreciation
= 1/Nb
Nb = book life in years
ITR = income tax rate
The levelized investment tax credit is calculated as follows:
LITC = (CRFe)(investment tax credit rate)/(1 + WCC)(1 - ITR)
The levelized income tax is calculated as follows:
LIT = (CRFb + AIR - SLD)(1 - ((debt ratio x debt cost)/WCC))
(ITR)/(1 - ITR)
where: LIT = levelized income tax
CRFb = capital recovery factor (WCC + SFF) for the book life
AIR = annual interim replacement
The capital charges are applied as a percentage of the total capital
investment, including land and working capital. Although land and most of
working capital cannot be depreciated and are not subject to investment tax
credit, their inclusion has an insignificant effect on capital charges.
Levelized Operating and Maintenance Costs—
Assuming a constant inflation rate, the levelized operating and mainte-
nance costs are determined by multiplying the first-year operating and mainte-
nance costs by an appropriate levelizing factor, Lf. The levelizing factor
is calculated as follows:
Lf = CRFe (K + K2 + K3 + +
= CRFe (K(1 - KN))/(1 _ K)
where: CRFe = capital recovery factor (WCC + SFF) for the economic
life (see the discussion of capital charges)
K = (1 + i)/(1 + r); present worth of an inflationary value
i = inflation rate
r = discount rate
Nb = book life in years
An inflation rate of 6% (i = 0.06) and a discount rate of 10$ (r = 0.10) are
used for new units. Values of Lf for power units with a remaining life of
B-60
-------
15, 20, 25, and 30 (new unit) years are shown In Table B-36. The first-year
operating and maintenance costs are multiplied by the appropriate Lf to
obtain the levelized operating and maintenance costs.
TABLE 36. LEVELIZING FACTORS
Booka
life, Nb
15
20
25
300
K = 1 + i
1 + r
0.96364
0.96364
0.96364
0.96364
KM- KNb)
1 - K
11.2965
13-8669
16.0028
17.7775
CRFb*>
(r, Nb)b
0.13147
0.11746
0.11017
0.10608
Levelizing
factor, Lf
1.485
1.629
1.763
1.886
a. Same as economic life (Ne) and tax life (Nt)•
b. Discount rate (r) of 10$.
c. New units.
SI SYSTEM NOTATION
The SI system of metric units is not used as the primary numerical system
in these premises because of the widespread use of traditional units in cor-
relative and supportive literature and general practice. Use of the SI system
is not standardized in the utility industry, although steps in this direction
are being made (34). The SI system specifies a number of rules of usage,
form, and style in addition to the numerical standards. These too are part of
the SI system and should be followed when using it. Detailed procedures for
use of SI conventions in the primary data or conversion to SI convention are
readily available in the literature. A detailed general guide to SI conven-
tion is available in ASTM E 380 79 (35). To provide uniformity in the
comparison of data developed from these premises, such a guide should be
consulted in using the SI system.
B-61
-------
B-62
-------
Appendix C
DETAILED DESCRIPTIONS OF MODEL INPUT VARIABLES
C-l
-------
TABLE C-l. MODEL INPUTS - FORTRAN VARIABLE NAMES
Uns_
'
1 XINPUT XBC XALK XSSV XSRHT
2 OUTPUT XHGAS XWGAS XRAIR XRGAS XSRHO XSKGAS XSSO XDIS XSTR XGPM XIT
3 IRPT IWAST IEQPR IWTBAL NOPART
>\ Case identification (up to 72 alphanumeric characters)
5 XESP MW BHR HVC EXSAIR THG XRH KEPASS KPAS02 PSS02X KCLEAN PREC SPASH WPRITE TSK TSTEAH HVS
5B SMRW SMCL ASHCLN HVCLN
6A DJPOPT WPC WPH WPO WPN WPSUL WPCL WPASH WPH20 SULO ASHO IASH ASHUPS ASHSCR
6B INPOPT VC02 VHCL VS02 V02 VN2 VH20 SCFM WASH SULO ASHO IASH ASHUPS ASHSCR
7 XLG VLG VTR V VRH IS02 XS02 TR ISR SRIN XIALK IADD WPHGO XMGOAD AD ADDC WPI WPM ASHCAO
ASHMGO
8 WPS PSD RS PSC IFOX OX SRAIR PSF FILRAT PHLIME IVPD VPD DELTAP PRES IFAN
9 ISCRUB XNS XNG HS RAIN SEEPRT EVAPRT WINDEX HPTONW NSPREP NOTRAN NOREDN PCNTRN
10 ISLUDG IFIXS SDFEE PSAMAX ACRE* PDEPTH PMXEXC DISTPD ILINER XLINA XLINB
11 ENGIN ARCTEC FLDEXP FEES CONT START CONINT XINT PCTMNT PDMNTP XINFLA IECON PCTOVR
XLEVEL/PCTADM CAPCHG/UNDCAP PCTMKT/PCTINS
12 ITAXFR TXRAT FRRAT SERVRT ROYALT IOTIHE OTRATE INDPND PENGIN PARCH PFLDEX PFEES PCONT PSTART
13 UC(1) - UC(11) XINDEX YINDEX INVYR IREVYR
U IOPSCH ONCAP IYROP PNDCAP BAGDLP BAGRAT BGCOST BGLIFE EFFPS ESPDLP RESIST SCARAT ICEPYE CEPNDX
15 IA(1) - IA(10)
16 IA(11) - IA(20)
17 IA(21) - IA(30)
18 END or NEXT
Note: Line 5B is needed only if KCLEAN 11. Lines 15-18 are needed only if IOPSCH = 3. The number of entries
required on lines 15-17 depends on the number of years specified with the IYROP variable on line 11.
Although 30 years is normally used as a maximum plant life, up to 50 years are allowed and up to two
additional lines may be used for IA(31) - IA(50).
-------
TABLE C-2. MODEL INPUT VARIABLE DEFINITIONS
Line No. Variable
Definition
Unit or value
XINPUT Option to control the printing of input 0
data variables. If a value of zero is
selected, no input data variables are 1
printed; the options to individually
control the printing of input variables
are ignored.
XBC Controls the printing of boiler charac- 0 =
teristics input variables. 1 =
XALK Controls the printing of alkali input 0 =
variables. 1 =
XSSV Controls the printing of scrubber 0 =
system input variables. 1 =
XSRHT Controls the printing of steam 0 =
reheater input variables. 1 =
OUTPUT Option to control the printing of 0 =
model output. If a value of zero is
selected, no output listings are
printed and the options to individually 1 =
control the printing of output listings
are ignored.
XHGAS Controls the printing of calculated 0
properties of hot gas to scrubber. 1
XWGAS Controls the printing of calculated 0
properties of wet gas from scrubber. 1
XRAIR Controls the printing of calculated 0
properties of reheater air- 1
XRGAS Controls the printing of calculated 0
properties of reheater gas (oil-fired 1
reheater only).
(Continued)
no input data
printed
print input
variables
according to
individual
input print
options
no print
print
no print
print
no print
print
no print
print
no output
data
printed
print output
listings
according to
individual
output print
options
>
no print
print
no print
print
no print
print
no print
print
C-3
-------
TABLE C-2. (Continued)
Line No. Variable
Definition
Unit or
XSRHO Controls the printing of calculated
properties of inline steam reheater.
XSKGAS Controls the printing of calculated
properties of stack gas.
XSSO Controls the printing of calculated
scrubber system parameters.
XDIS Controls the printing of calculated
properties of system discharge stream.
XSTR Controls the printing of calculated
properties of scrubber system internal
streams (excluding sludge discharge
and makeup water). This option does
not affect the printout of total
stream flow rate.
XGPM Controls the printing of total flow
rates (gpm and Ib/hr) of internal
streams (excluding sludge discharge
and makeup water).
XIT For the iterative calculation of
stoichiometry, this option controls
the printing of the iteration number
and of the current and the preceding
stoichiometry values.
IRPT Option to select either a short-form
printout (totals only) or a long-form
printout.
IWAST Controls the printing of calculated
waste disposal flow rates, physical
properties and resulting costs.
(Continued)
0 = no print
1 = print
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
no print
print
no print
print
no print
print
no print
print
no print
print
no print
print
short print
long print
no print
print
C-4
-------
TABLE C-2. (Continued)
Line No. Variable
Definition.
Unit or_Y.alufl_
IEQPR Controls the printing of equipment
list.
3 IWTBAL Controls the printing of calculated
properties of water balance scrubber.
3 NOPART Controls the printing of input design
conditions and calculated properties
projected by the Argonne particulate
removal model.
4 CASEID Case identification - this field is free
form and may be up to 72 characters in
length.
5 XESP Particulate collection option
No mechanical collector available
Mechanical collector available
Print internal model examples
(costs are not included In FGD
costs).
(Continued)
0 =
1 =
2 =
3 =
4 =
5 =
0
1
0
1
no print
print entire
list
print only
material-
handling and
feed prepa-
ration area
lists
Print only
gas-handling,
S02 scrub-
bing, oxida-
tion, and
reheat area
lists
Print only
solids
separation
area list
Print only
landfill
area list
no print
print
no print
print
0
1
2
C-5
-------
TABLE C-2. (Continued)
Line No.
5
5
5.
5
5
5
5
5
Variable
MW
BHR
HVC
EXSAIR
THG
XRH
KEPASS
KPAS02
Definition
Electric power output
Boiler heat rate
Heating value of coal
Excess air
Temperature of hot gas to scrubber
Reheat option
No reheat
Inline steam reheater (XRH value = 2)
is the only type of reheat available
at this time.
Emergency bypass option
No emergency bypass
Emergency bypass
Partial scrubbing/bypass option
No partial scrubbing/bypass
Partial scrubbing/bypass
Unit or valu?
megawatts
Btu/kWh
Btu/lb
%
op
0
2
0
1
0
1
5
5
PSS02X Percent S02 removal in the scrubber $ removal
when partial scrubbing/bypass is
specified
KCLEAN Coal-cleaning option
No coal cleaning - line 5B must not 0
be input
Coal cleaning - line 5B is required 1
input
PREC Percent weight recovery (Ib clean coal %
per 100 Ib raw coal) when coal cleaning
is specified
SPASH Weight percent of sulfur in cleaned coal wt %
when coal cleaning is specified
WPRITE Weight percent of pyritic sulfur in raw wt %
coal when coal cleaning is specified
(Continued)
C-6
-------
TABLE C-2. (Continued)
Line No.
5
5
5
5B
5B
5B
5B
6A
6A
6A
6A
6A
6A
6A
6A
6A
Variable Definition Unit or value
TSK
TSTEAM
HVS
SMRW
SMCL
ASHCLN
HVCLN
INPOPT
WPC
WPH
WPO
WPN
WPSUL
WPCL
WPASH
WPH20
Temperature of stack gas OF
Temperature of reheater steam °F
Heat of vaporization of reheater steam Btu/lb
Surface moisture of raw coal wt %
Surface moisture of cleaned coal wt %
Ash content of cleaned coal wt %
Heating value of cleaned coal Btu/lb
The composition input specified on
either line 6A or 6B depends on the
composition option, INPOPT. If a coal
composition will be input (INPOPT = 1)
then line 6A is used. If a flue gas
composition will be input (INPOPT = 2)
then line 6B is used.
Composition input option
Coal composition will be input using 1
line 6A
}
}
}
} — Amount of component (C, H, 0, N, S, Cl, wt $
ash, H20) in coal. WPSUL is the total
of both organic sulfur and pyritic
sulfur.
}
}
}
}
(Continued)
C-7
-------
TABLE C-2. (Continued)
Line No. Variable
Definition
Unit or
6A
6A
6A
6A
6A
6B
6B
6B
6B
6B
6B
6B
SULO Sulfur to overhead as S02 gas
(remainder goes to bottom ash).
ASHO Ash to overhead as particulates
(remainder goes to bottom ash).
IASH Unit of measure option for particu-
late removal
Default to model assumptions
Percent removal
Pounds particulates per MBtu
Upstream removal (percent) with
scrubber default
(The actual values for particulate
removal are provided by the ASHUPS and
ASHSCR variables that immediately
follow.)
Value for particulate removal upstream
from scrubber. (Unit of measure is
indicated by the IASH option above.)
Value for particulate removal within
scrubber. (Unit of measure is indicated
by the IASH option above.)
Composition input option
Flue gas composition will be input
using line 6B
ASHUPS
ASHSCR
INPOPT
VC02 }
VHCL }
VS02 } ~ Amount of component (C02, HC1, S02, 02,
N2, and H20) in flue gas
V02 }
VN2 }
VH20 }
(Continued)
wt %
wt %
0
1
2
3
vol %
C-l
-------
TABLE C-2. (Continued)
Line No. Variable
Definition
Unit or value
6B SCFM Standard cubic feet per minute (6QOF),
gas from boiler
6B WASH Pounds of ash per hour in hot gas from
boiler
6B SULO Should be set to 100 when flue gas
composition is input
6B ASHO Should be set to 100 when flue gas
composition is input
6B
6B
6B
7
IASH
ASHUPS
ASHSCR
XLG
See line 6A
See line 6A
See line 6A
L/G ratio i:
(Refer to the ISR option on the
following page.)
7 VLG L/G ratio in venturi
7 VTR Venturi/oxidation hold tank residence
time. This variable is used to specify
residence time in the second effluent
tank when two tanks are specified. Two
tanks may be specified by the forced-
oxidation option (IFOX, line 8), the
scrubber option (ISCRUB, line 9), or
both. VTR should be set to zero when
only one effluent tank is used (see
the TR variable below) -
7 V Scrubber gas velocity (superficial)
7 VRH Superficial gas velocity through
reheater (face velocity)
(Continued)
sft3/min
Ib/hr
gal/kaft3
gal/kaft3
min
ft/sec
ft/sec
C-9
-------
TABLE C-2. (Continued)
Line No. Variable
Definition
Unit or value
IS02 Unit of measure option for S02 removal
S02 to be removed is a percent value
S02 emission concentration is a pounds
S02/MBtu value
S02 emission concentration is a ppm
value
1979 NSPS
(The actual value for S02 removal
is provided by the XS02 variable that
immediately follows.)
XS02 Value for S02 to be removed. Unit of
measure is indicated by the IS02 option
above; refer to the ISR option below for
additional requirements. The value for
XS02 is automatically calculated when
IS02 = 4 and any input value will be
ignored.
TR Recirculation/oxidation hold tank
residence time. This variable is used
to specify residence time in the effluent
tank when only one tank is specified.
If two tanks are specified, TR specifies
residence time in the first tank (see the
VTR variable above).
ISR Stoichiometry, L/G in scrubber, and S02
removal option. This option controls
model processing of the Stoichiometry
value, SRIN, below; the L/G ratio in the
scrubber, XLG, on the preceding page; and
the S02 to be removed, XS02, above (if
XS02 is required then IS02 is also
required).
SRIN, XLG, and XS02 (also IS02) will be
processed as input variables. (No
checks are made for validity or consis-
tency among the specified values.)
(Continued)
1
2
mln
C-10
-------
TABLE C-2. (Continued)
Line No. Variable
Definition
Unit or value
7
7
XLG and XS02 (also IS02) will be
processed as input variables and SRIN
will be calculated by the model.
SRIN and XS02 (also IS02) will be
processed as input variables and XLG
will be calculated by the model.
SRIN and XLG will be processed as input
variables; the value for S02 to be
removed (XS02) will be calculated by
the model; and all three units of
measure (IS02) will be provided in the
calculated results. Any user input
values for IS02 and XS02 will be
ignored.
SRIN Value for stoichiometry (refer to the
ISR option above)
XIALK Alkali addition option
Limestone
Lime
IADD Chemical additive option
No chemical additive
MgO added
Adipic acid added
WPMGO Soluble MgO in limestone or lime
XMGOAD Soluble MgO added to system (applied
only when MgO added, see IADD above)
AD Adipic acid in scrubbing liquid
(applied only when adipic acid added,
see IADD above)
(Continued)
mols CaC03 added
as limestone per
mol S02 + 2HC1
absorbed
1
2
0
1
2
wt % dry basis
Ib soluble
MgO/100 Ib
limestone
ppm (wt)
C-ll
-------
TABLE C-2. (Continued)
Line No.
7
7
7
7
7
8
8
8
8
8
8
8
8
8
8
Variable
ADDC
WPI
WPM
ASHCAO
ASHMGO
WPS
PSD
RS
PSC
IFOX
OX
SRAIR
PSF
FILRAT
PHLIME
Definition
Adipic acid degradation constant
(applied only when adipic acid added,
see IADD above)
Insolubles in limestone-lime additive
Moisture in limestone-lime additive
Soluble CaO in partioulates
Soluble MgO in parti culates
Solids in recycle slurry to scrubber
Solids in sludge discharge
Thickener solids settling rate
Percent solids in thickener underflow
Forced-oxidation option
No forced oxidation
Forced oxidation in a single effluent
tank
Forced oxidation in the first of two
effluent tanks
Forced oxidation in the disposal feed
tank
Oxidation of sulfite in scrubber liquid
Air stoichiometry value
Percent solids in filter cake
Filtration rate
Recirculation liquor pH for lime and
Unit or vj^ly?
wt % dry basis
lb/100 Ib dry
additive
wt %
wt %
wt %
wt %
ft/hr
wt %
0
1
2
3
mol %
g-atoms 0/g-mol
S02 absorbed
wt %
tons/ft2/day
adipic acid enhancement systems (value
is ignored for limestone system)
(Continued)
C-12
-------
TABLE C-2. (Continued)
Line No. Variable
8 IVPD
8 VPD
8 DELTAP
8 PRES
8 IFAN
9 ISCRUB
9 XNS
9 XNG
9 HS
9 RAIN
9 SEEPRT
9 EVAPRT
9 WINDEX
Definition
Venturi AP option
AP is input in in. H20
Throat velocity (ft/sec) is input and
the corresponding VPD is calculated
Value for either AP or throat velocity
indicated by the IVPD option above
Override AP for entire system
Scrubber pressure
Fan option
Forced-draft fans
Induced-draft fans
Scrubbing option
Spray tower
TCA
Venturi-spray tower, two effluent tanks
Venturi-spray tower, one effluent tank
Venturi-TCA, two effluent tanks
Venturi-TCA, one effluent tank
Number of TCA stages
Number of TCA grids
Height of spheres per stage
Annual rainfall
Seepage rate
Annual evaporation
Limestone hardness work index factor
Unit or value
0
1
in. H20 or
(ft/sec)
in. H20
psia
0
1
1
2
3
4
5
6
in.
in./yr
cm/ sec
in./yr
wi
value 5-15. (Example: 10)
HPTONW Fineness of grind index factor (see
Table C-3)
NSPREP Number of spare preparation units
(Continued)
hp/ton
(0-9)
C-13
-------
TABLE C-2. (Continued)
Line No.
9
9
9
10
10
10
10
10
10
10
10
10
10
Variable
NOTRAN
NOREDN
PCNTRN
ISLUDG
IFIXS
SDFEE
PSAMAX
ACRE$
PDEPTH
PDEPTH
PMXEXC
PMXEXC
DISTPD
Definition
Number of operating scrubber trains
Number of spare scrubber trains
Entrainment level as percentage of wet
gas from scrubber (Example: 0.1)
Sludge disposal option
Onsite ponding
Thickener - ponding
Thickener - fixation (fee)
Thickener - filter - fixation (fee)
Thickener - filter - landfill fixation
fee
Sludge fixation option
No fixation specified
Sludge - fly ash - lime fixation
Sludge disposal fee (Either an actual
value or a zero value must be provided;
refer to the ISLUDG option above.)
Total available land for construction
of pond
Land cost
Final depth of sludge in pond (when
ISLUDG = >1-4)
Uncompacted bulk density of waste (when
ISLUDG = 5)
Maximum excavation depth (when
ISLUDG = 1-4)
Compacted bulk density of waste (when
ISLUDG = 5)
Distance from scrubber area to disposal
Unit or value
(1-10)
(0-10)
wt %
1
2
3
4
5
0
1
$/ton dry
sludge
acres
$/acre
ft
Ib/ft3
ft
Ib/ft3
ft
site
(Continued)
C-14
-------
TABLE C-2. (Continued)
Line No.
10
10
10
11
11
11
11
11
11
11
11
11
Variable
ILINER
XLINA
XLINB
ENGIN
ARCTEC
FLDEXP
FEES
CONT
START
CONINT
XINT
PCTMNT
Definition Unit or value
Disposal site lining option
Clay liner 1
Synthetic liner 2
No liner 3
(Refer to the XLINA and XLINB variables
that immediately follow.)
If ILINER = 1, XLINA = clay depth in.
If ILINER = 2, XLINA = material unit $/yd2
cost
If ILINER = 3, XLINA = 0
If ILINER = 1, XLINB = clay cost $/yd3
If ILINER = 2, XLINB = labor unit cost $/yd2
If ILINER = 3, XLINB = 0
Engineering design and supervision %
Architect and engineering contractor %
Construction field expenses %
Contractor fees %
Contingency %
Allowance for startup and modifications %
Interest during construction %
Cost of capital %
Maintenance rate, applied as percent of %
direct investment excluding disposal
site cost
11 PDMNTP Disposal site maintenance rate, applied %
as percent of direct disposal site
investment
11 XINFLA Inflation factor (used only when unlevel- %
ized lifetime revenue requirements are
calculated, see Appendix B)
(Continued)
C-15
-------
TABLE C-2. (Continued)
Line No. Variable
Definition
Unit or valti?
11 IECON Economic premises option
Current premises 1
Premises prior to 12/5/79 0
11 PCTOVR Plant overhead rate, applied as percent %
of conversion costs less utilities
11 XLEVEL/ The use of this variable depends on the %
PCTADM economic premises specified (IECON,
line 11). If new premises are specified
(IECON =1), XLEVEL specifies the level-
izing factor to be applied to first-
year operating and maintenance cost to
obtain levelized lifetime costs. If
XLEVEL is set to zero, there is no
levelizing and a lifetime revenue sheet
is generated. If old premises are
specified (IECON = 0), PCTADM
specifies the administrative research
and service overhead rate, applied
as a percent of operating labor and
supervision.
11 CAPCHG/ If new premises are specified (IECON = %
UNDCAP 1) CAPCHG specifies levelized annual
capital charges applied as a percent of
total capital investment. If old eco-
nomic premises are specified (IECON = 0),
UNDCAP specifies the annual capital
charge basis for undepreciated
Investment.
11 PCTMKT/ If new premises are specified (IECON = %
PCTINS 1), PCTMKT specifies marketing costs
applied as a percent of byproduct credit
(applies only to processes with a salable
byproduct). If old economic premises are
specified (IECON = 0), PCTINS specifies
the rate for insurance and interim replace-
ments applied as a percent of total capital
investment.
(Continued)
C-16
-------
TABLE C-2. (Continued)
Line No. Variable
Definition
Unit or value
12 ITAXFR Sales tax and freight option
No sales tax or freight
Sales tax and freight rates as
specified by TXRAT and FRRAT
below
12 TXRAT Sales tax rate (applied only when ITAXFR
above set to 1)
12 FRRAT Freight rate (applied only when ITAXFR
above set to 1)
12 SERVRT Services, utilities, and miscellaneous,
applied as a percent of total process
capital
12 ROYALT Royalties, applied as a percent of total
process capital
12 IOTIME Overtime construction labor option
No overtime labor
Overtime labor on 7$ of total labor
based on the OTRATE rate below
12 OTRATE Overtime labor rate (applied to 1% of
total labor). (Example: 1.5)
12 INDPND Separate indirect investment factors
option for construction
No separate indirect factors for
disposal waste site construction
(same as process indirects)
Separate Indirects for waste site
construction specified by PENGIN,
PARCH, PFLDEX, PFEES, PCONT, and
PSTART below
12 PENGIN Disposal site construction engineering
design and supervision expenses (applied
only when INDPND above set to 1)
(Continued)
0
1
0
1
C-17
-------
TABLE C-2. (Continued)
Line No. Variable
Definition
Unit or
12 PARCH Disposal site construction architect %
and engineering contractor expenses
(applied only when INDPND above set
to 1)
12 PFLDEX Disposal site construction field expenses %
(applied only when INDPND above set to 1)
12 PFEES Disposal site construction contractor %
fees (applied only when INDPND above
set to 1)
12 PCONT Disposal site construction contingency %
(applied only when INDPND above set to 1)
12 PSTART Allowance for disposal site startup and %
modification (applied only when INDPND
above set to 1)
Limestone unit cost I/ton
Lime unit cost $/ton
MgO unit cost $/ton
Adipic acid unit cost $/ton
Operating labor and supervision unit $/man-hr
cost
Landfill labor and supervision unit $/man-hr
cost
Steam unit cost $/klb
Process water unit cost $/kgal
Electricity unit cost $/kWh
Diesel fuel cost $/gal
UC (11) Analyses unit cost $/hr
(Continued)
13
13
13
13
13
13
13
13
13
13
13
UC (1)
UC (2)
UC (3)
UC (4)
UC (5)
UC (6)
UC (7)
UC (8)
UC (9)
uc (10;
UC (11]
C-18
-------
TABLE C-2. (Continued)
Line No.
13
13
13
13
14
11
11
11
11
11
11
11
Variable
XINDEX
YINDEX
INVYR
IREVYR
IOPSCH
ONCAP
IYROP
PNDCAP
BAGDLP
BAG RAT
BGCOST
BGLIFE
Definition Unit or value
Chemical Engineering material cost
index (see premises)
Chemical Engineering labor oost index
see premises)
Investment year cost basis yr
Revenue requirement year cost basis yr
Operating profile option
TVA profile 1
FERC profile 2
User input profile [Refer to the IYROP 3
and IA(n) options on lines 11-17-]
Levelized operating profile, 5,500 4
hr/yr
Calculated input operating profile 5
Onstream capacity factor (Example .6) decimal
Years remaining life (lines 15 through
17 are needed only if the IOPSCH variable,
line 11, is set to 3)* Although only 30
years is shown, up to 50 years may be
used.
Expected disposal site capacity (controls
site design capacity; if 100$ of sludge is
to be disposed over the life of the unit,
input 1.0; if &Q% of sludge is to be
disposed, input 0.80).
Baghouse pressure drop in. H20
Baghouse ratio (typically = 0.8) open, f.t.2
actual ft2
Bag cost $/ft2
Bag life yr
(Continued)
C-19
-------
TABLE C-2. (Continued)
wo. Variable Definition Unit or value.
14 EFFPS ESP rectification efficiency (Example - decimal
.65)
U ESPDLP ESP pressure drop in. H20
14 RESIST Resistivity option (high or low)a
Assume u> = 20 ft/min 1
Assume co = 30 2
14 SCARAT SCA ratio
Contingency or safety factor (frac-
tional) to apply to calculated
collection area.
14 ICEPYE Chemical Engineering plant index year yr
14 CEPNDX Chemical Engineering plant index (see
premises)
15 IA(1) - Operating hr/yr (input only 10 years
IA(10) per line)
16 IA(11) - Operating hr/yr (input only 10 years
IA(20) per line)
17 IA(21) - Operating hr/yr (input only 10 years
IA(30) per line)
18 END or "END" terminates further execution.
NEXT "NEXT" execution will continue with
the next group of input variables.
(If variable IOPSCH on line 14 is not
equal to 3, line 15 will be the "END"
or "NEXT" line.)
a. Required for sizing hot ESP. Drift velocity (w) is related to percent sulfur
in the cold ESP model, but is an input for the hot ESP model.
C-20
-------
TABLE C-3. LIMESTONE FINENESS OF GRIND INDEX FACTOR
Ground limestone
80t- micron i
129
113
98
85
74
62
58
51
44
40
37
31
24
oroduct size
-200 mesh
60
65
70
75
80
85
86
90
93
95
distributipn
% -325 mesh
70
75
80
85
90
95
Index faotor (HPTONW)
ho/ ton
1.11
1.22
1.35
1.51
1.72
2.04
2.19
2.54
3.04
3.40
3.64
4.44
5.70 base
Data from KVS Rock Talk Manual, Kennedy Van Saun Corporation, Danville,
Pennsylvania, 1974. Total ball mill horsepower is calculated using the
limestone hardness work index factor, wi, and the fineness of grind index
factor as follows: hp = (ton/hr limestone)(wi)(fineness of grind index
factor).
C-21
-------
C-22
-------
Appendix D
BASE CASE SHAWNEE COMPUTER MODEL INPUT AND PRINTOUT
D-l
-------
TABLE D-l. BASE CASE SHAWNEE COMPUTER MODEL PRINTOUT
11111
111111111111
11111
SHAWNEE COMPUTER USER MANUAL BASE
2 500 9500 11700 39 300 2 1 0 90 0 84.14 12.162 .3 175 470 751.9
1 66.7 3.8 5.6 1.3 3.36 0.1 15.1 4.0 95 80 2 0.06 0.03
106 20 5 10 25 4 .6 8 0 1.40 1 0 .15 0.0 1500 3 4.85 500
8 85 0.0 40 2 95 2.5 85 1.2 5.2 0 9 0 14.7 1
1 0 3 0 35 .0000005 32 10 5.70 1 4 1 .1
5 0 0.0 9999 6000 75 95 5280 1 12 6
7 2 16 5 10 8 15.6 10 8 3 6 1 60 1.886 14.7 0.0
1 4 3.5 6 0 1 1.5 1 2 1 8 5 20 0
15.0 90 510 1500 19 24 4.0 .16 .055 1.6 26 366.8 292.2 1985 1987
4 .6 30 1 5 .8 1.0 3 .65 1 1 1.1 1985 363.4
END
(Continued)
-------
TABLE D-l. (Continued)
TENNESSEE VALLEY AUTHORITY
SHAWNEE LIMESTONE OR LIME SCRUBBING PooCES?
COMPUTERIZED DESIGN-COST ESTIMATE MODEL
REVISION DATE OCTOBER It 1984
SHAWNEE COMPUTER USER MANUAL BASE
*** INPUTS ***
BOILER CHARACTERISTICS
MEGAUATTS = 500.
BOILER HEAT RATE = 9500. BTU/KWH
EXCESS AIR = 39. PERCENT, INCLUDING LEAKAGE
HOT GAS TEMPERATURE r 300. DEG F
COAL ANALYSIS, HT * AS FIRED :
C H 0 N S CL ASH M20
66.70 3.80 5.60 1.30 3.36 0.10 15.10 ».00
SULFUR OVERHEAD = 95.0 PERCENT
ASH OVERHEAD = 80.0 PERCENT
HEATING VALUE OF COAL = 11700. BTU/LS
EFFICIENCY, EMISSION,
FLYASH REMOVAL * LBS/M BTU
UPSTREAM OF SCRUBBER 99.4 0.06
WITHIN SCRUBHER 50.0 O.C3
(Continued)
-------
TABLE D-l. (Continued)
EMISSION STANDARD
1979 NSPS
COST OF UPSTREAM FLYASH REMOVAL EXCLUDED
ALKALI
LIMESTONE :
CAC03 = 95.00 WT * DRY BASIS
SOLUBLE M60 = 0.15
INERTS r 4.85
MOISTURE CONTENT = 5.00 LB H20/100 LBS DRY LIMESTONE
LIMESTONE HARDNESS WORK INDEX FACTOR = 10.00
LIMESTONE DEGREE OF GRIND FACTOR = 5.70
FLY ASH :
SOLUBLE CAO = 0.0 WT *
SOLUBLE MGO - 0.0
INERTS - 100.00
RAW MATERIAL HANDLING AREA
--- -------- -------- ----
NUMBER OF REDUNDANT ALKALI PREPARATION UNITS =
SCRUBBER SYSTEM VARIABLES
NUMBER OF OPERATING SCRUBBING TRAINS := 1
NUMBER OF REDUNDANT SCRUBBING TRAINS = 1
SPRAY TOWER LIQUID-TO-GAS RATIO = 106. GAL/1000 ACF(SATD)
SPRAY TOWER GAS VELOCITY = 10.0 FT/SEC
INDUCED DRAFT SCRUBBER FAN OPTION
SCRUBBER PRESSURE = 14.7 PSIA
STOICHIOMETRY = l.»0 MOLE CAC03 ADDED AS LIMESTONE
PER MOLE CS02+2HCL) ABSORBED
ENTRAIN"ENT LEVEL = 0.10 WT X
"EHT RESIDENCE TI«E = fl.O MIN
S02 OXIDIZED IN SYSTEM = 95.0 PERCENT
AIR STOICHIOMETRY = 2.50 G-ATOM 0 /G-MOLE S02 ABSORPED
SOLIDS IN RECIRCULATED SLURRY = 8.0 WT t
(Continued)
-------
TABLE D-l. (Continued)
SOLIDS DISPOSAL SYSTEM
COST OF LAS'- = 6000.00 DOLLARS/ACRE
SOLIDS !'. SYSTEP SLuDGE DISCHARGE = 85.C k.* X
LANDFILL DISPOSAL CDTION
SOLICS IS CLARIFIES DISCHARGE = AO.O WT X
SOLICS I'. FILTER CAKE = P5.0 WT t
FILTRATION SATE = 1.20 TONS DRY SOLIDS/FT2 Dll
LANDFILL DISPOSAL OPTION
STEAM REHEATF/R (IN-LINE)
SATURATED STFAM TEMPERATURE = 470. DEG F
HEAT OF VAPORIZATION OF STEAM ~ 752. BTU/L?
OUTLET FLUE GAS TEMPERATURE = 175. DEG f
SUPERFICIAL GAS VELOCITY (FACE VELOCITY) = 25.0 FT/SEC
WATER BALANCE INPUTS
RAINFALLIIN/YEAR) J5.
POND SEEPAGF(CM/SEC>«10«-8 50.
PONC1 EVAPORATION(IN/YEAR) 32.
ECONOMIC °RFHISES
1979 TV'-EPA ECONOMIC PREMISES
PROJECTED REVENUE PEOUIRF.MEN TS INCLUOE LEVELIZE" OPERATING AND MAINTENANCE COSTS
"ATE = i.e?6 TIMES FIRST YEAR OPERATING AND »AINTEN«NCE COSTS
FREIGHT INCLUDED IN DIRECT INVESTMENT
FREIGHT =ATT =: 3.5 I OF EQUIPMENT COST
SALES TAX INCLUDED IN DIRECT INVESTMENT
SALES T4X ^4TE = «.C X OF EQUIPMENT COST
LABOR CVfcTTxE INCLUDED IN DIRECT I^VESTMEN"
OVERTI-E CAT = 1.5
INFLATI'?1. C*TE = 6.C X
PROCESS "il'TENANCE : «.0 X OF DIRECT PROCiSS INVESTMENT
LANDFILL »i I •. T EN ANCE = ^.0 X OF LANDFILL DI = ECT INVESTMENT
(Continued)
-------
TABLE D-l. (Continued)
EMERGENCY
EMERGENCY E>Y-PA?S DESIGNED FOR 50.0
HOT G«S TO S?SUPBEP
PERCENT LE-MOLE/HR
C02
HCL
SO 2
02
N2
H20
12.317
:. DOS
0.221
•i.553
7C.1«9
t .703
0.2255E«-05
0.11A5F-02
0.4042E»03
0.1017E>05
0.1377?>06
0.1227E»05
0.9923E»06
0.SIA)
MW EQUIVALENT OF SCRJBBE" = 500 MEGAWATTS
CORRESPONDING COAL FIRING PATE = .»060E*06 LB/HR
HOT GAS HUMIOITY r O.OA3 LB H20/LB DRY GAS
WET BULB TEMPERATURE = 12*. DEG F
WET GAS FRO" SCRUBBER
MOLT PERCENT LB-MOLE/HR LB/HR
C02 11.709 0.22"»2E»05 0.1009E»07
HCL C.OCO 0.5726E»00 0.20P8E-02
S02 0.023 O.»0««?«02 0.2850E»0*
02 5.106 0.9990E*0« 0.3198E»06
N2 70.326 0.1377E«06 O.J857E«07
H20 12.836 0.2512E>05 0.»52feE»06
S02 CONCENTRATION IN SCRUBBER OUTLET GAS = 227. PPM
FLYASH EMISSION = 0.030 LRS/MILLION RTU TO POILER
= !»?. LP/HP
TOTAL WATER °ICKUP = »75. GP"
INCLUDING 1!.3 GO11 ENTRAINMENT
WET GAS FLOW RATE r ,12?6E»07 SCFM ( 60. DEG F, la.? PSIA)
= .13P9E-C7 tCFM (12«. DfG F, 1«.7 DSI«)
WET 6»S SATU=iTTON HUMIDITY = 0.067 LB H20/LB DRY G"S £
(Continued)
-------
TABLE D-l. (Continued)
O
FLUE GAS TO STACK
MOLE PERCENT
LB-MOLE/HR
C02
HCL
S02
02
N2
H20
11.690
0. ODO
0.023
5. 098
70.214
12.975
0.2292E-05
0.5726F*00
0.4449E«02
0.9994E»04
0.1377E»06
0.2544E«05
0.1009E«£)7
%2GP8E»02
C.2P50E*C4
3.319BE»06
9.3857E*07
J.45P3E»06
CALCULATED 502 PEMOl/AL EFFICIENCY = 89. n x
CALCULATED S02 EMISSION = 0.60 POUNDS PER MILLION P TU
CALCULATED S02 CONCENTRATION IN STACK GAS = 227. PPM
CALCULATED HCL CONCENTRATION IN STACK GAS = 7. PPM
FLYASH EMISSION = 0.030 LBS/MILLION BTU TO BOILER
= 1*3. LB/HR
STACK GAS FLOVI RATE = .1238E»07 SCFM ( 60. DEG F, 14.7 PSIA)
= .1512E»07 ACFM <175. DEG Ft 14.7 PSIA)
STEAM REHEATF.R (IN-LINE)
SUPERFICIAL GAS VELOCITY (FACE VELOCITY) r 25.0 FT/SEC
SQUARE PIPE PITCH : 2 TIMES ACTUAL PIPE O.D.
SATURATED STEAM TEMPERATURE = 470. PEG f
OUTLET FLUE GAS TEMPERATURE = 175. DEG r
REQUIRED HEAT INPUT TO REHEATER = 0.741PE»08 BTU/HR
STEAM CONSUMPTION ; 0.9P66E»05 LRS/H"
OUTSIDE PIPE
DIAMETERt IN.
1.00
INCONEL
CORTEN
TOTAL
PRESSURE DROP
IN. M20
0.75
REHEATER
OUTSIDE PIPE
ARE«, SO FT
PER TRAIN
0.15ME*04
0.1223E»04
0.27E4E*C4
HEAT TRANSFER NUMBER OF
COEFFICIENT PIPES PER
BTU/HR FT2 DEG f BANK PER TRAIN
0.?096E>02 °2
NU*PER OF
PflfjKS (ROWS)
PER TRAIN
5
T
C
OUTLET SCRUPPER DUCTS A'RE CORTEN
(Continued)
-------
TABLE D-l. (Continued)
WATC° BALANCf INPUTS
RAINFALL! IM/YrAR )
FKM SEEPAGE (C'/SEC )«10*«S
°0\2 EV4P00 t. TIO
35.
50.
3?.
WtTE" BALANCE OUTPUTS
WATER AVAILABLE
RAINFALL
ALKALI
TOTAL
WATER REQUIRED
HUMIDIFICATION
ENTRAINMENT
DISPOSAL WATEP
MYDRATION WATER
CLARIFIER EVAPORATION
POHD EVAPORATION
SEEPAGE
TOTAL WATER REQUIRED
NET WATER REOUIRED
SCRUBBER SYSTEM
163. GPH
11. 6P»
27. GP"
25. GP"
55. GP«
9. GPP
0. GPP
582. GPH
2691. LB/HB
2730. L1'/'"!
231586. LP/HR
1S27«. Lfl/MR
12*71. LS/HR
27728. LR/MR
0. LR/HR
0. LB/HP
290693. LB/HR
287963. LB/HR
TOTAL NUMBER OF SCRUBBING TRAINS <0°ERATING-PEDUNPANT ) - ;
S02 REMOVAL = ?9.0 PERCENT
PARTICULATE REMOVAL IN SCRUBBER SYSTEM = 50.0 PERCENT
SPRAY TOWER °RESSUPE DROP = 2.fc IN. H2C
TOTAL SYSTEM PRESSURE D"OP : 7." IN. H20
SPECIFIED SPRAY TOWER L/G PATIO : 106. GAL/1000 ACFCSATO)
LIMESTONE ADDITION = 0.53f)3E»05 LB/HR DRY LIMESTONE
SPECIFIED LIMESTONE STOICHlOMCT=Y r 1.40 "OLE CAC"3 ADDED AS LIMESTONE
PfO MOLE (S02»2HCL) ABSORBED
SOLUBLE CAO FROM FLY ASH = O.C "OL1' PER MOLE (S02»?HCL) APSOR6ED
TOTAL SOLUBLE "C-0 = O.Tl MOLC PEP MOLE (S02»2HCL) ABSORBED
TOTAL STOICHIOMETRY
MAKE UP UATEP = 576. GP"
OXiriTION AIR PATE = 0.«°72E»C;Lr/HC
= 0.1C03E-C? ^CF«- <£C PEG f,14.7
l.«! "OLt SCLUBLE (CA»"G)
PE° «OLE (SC2»2MCL)
(Continued)
-------
TABLE D-l. (Continued)
o
SOLIDS DISPOSAL SYSTEM
TOTAL CLARIFIER(S) CROSS-SECTIONAL AREA = 1813. SO FT
SYSTEM SLUDGE DISCHARGE
SPECIES
CAS03 .1/2 H20
CAS04 .2H20
CAC03
Tucni IIQI re"
INdUUUDULo
H20
CA»»
MG**
S03--
S04--
CL-
LB-MOLE/HR
0.1797E»02
0.3416E+83
0.1481E»03
0.7368E+03
0.3799E*01
0.2069E+01
0.2415E-01
0.2J37E*00
0.1088E*02
LB/HR
0.2320E»Ot
0.5879E»05
0.1*82E«05
09TR^F* f>&
• «: I D Jt* u^
0.1327E»05
0.1523E*03
0.503ir»02
0.1933E«01
0.21«8E>02
0.3857E*03
iULiU
COMPt
UT %
2.95
74.72
18.83
3c n
. D U
LI UU1U
CO HP,
PPM
10966.
3623.
139.
1547.
27776.
TOTAL DISCHARGE FLOW RATE = 0.9257E+05 LB/HR
= 88. GPM
TOTAL DISSOLVED SOLI3S IN DISCHARGE LIQUID = 44037. PPM
DISCHARGE LIQUID PM = 7.08
CLARIFIER SOLIDS SETTLING RATE = 8.54 FT/HR
(Continued)
-------
TABLE D-L. (Continued)
SCRUBBER SLURRY BLEED
SPECIES
CAS03 .1/2 H20
CAS04 .2H20
CAC03
I NSOLU BLES
H20
CA + +
MG* +
S03--
S04 —
CL-
AO--
LR-KOLE/HR
0.1797E+02
0.3116E-03
O.M81E»03
0.4813E*05
0.2400E»03
0.1307E»03
0.1526E»01
0.1413E*02
0.6874E*03
0.0
LB/HR
0.2320E+0*
0.5879E»05
0.1482E»05
Do 7 c T c 4. na
• if fjot.*U*t
0.8671E»06
0.962DE»0«
0.3178E+04
0.1221E+03
0.1357E»OA
0.2437E»05
0.0
TOTAL FLOW RATE =
0.9815E»06 LB/HR
1873. GPM
TOTAL SUPERNATE RETURN
SPECIES
H20
CA» +
MG»»
S03 —
S04--
CL-
AO —
LB-MOLE/HR
0.4581E+05
0.2362E+03
0.1287E»03
0.1501E»01
0.1391E*02
0.676*E»03
0.0
LB/HR
O.R257E+06
0.9467E«01
0.3128E»0«
0.1202E»03
0.1336E»0«
0.2398E+0?
0.0
TOTAL FLOW RATE = 0.8633E»06 LB/HR
= 1727. GPM
SUPERNATF TO WET BALL HILL
SPECIES
H20
CA»»
MG + *
S03--
S09r»01
0.fil66E*02
0."273E»03
0.0
TOTAL FLOW RATE = 0.3339E+05 LB/HR
= 67. GPH
(Continued)
-------
TABLE D-l. (Continued)
LIMESTONE SLURRY FEED
SPECIES
CAC03
SOLUBLE MGO
H20
CA*»
S03 —
S04--
CL-
AO —
LB-10LE/HR
0.5109E+03
0.2003E+01
0.1904E*04
LB/HR
O.B074E»02
0 .3t30E*05
0.3661E»03
0.1210F+03
0.5806E-01
0.5378E*00
0.2616E*02
0.0
0.9273E»03
0.0
TOTAL FLOW RATE = 0.8971E*05 LB/HR
= 113. GPM
SUPERNATE RETURN TO SCRUBBER OR EHT
SPECIES
H20
CA»»
MG»*
CL-
AO—
LB-HOLE/HR LB/HR
0.2271E«03
0.1237E+03
0.1t«E>01
0.1337E+02
0.6503E»03
0.0
0.7934E*Ofi
0.9101E»0»
0.1156E*03
0.1284^*0*
0.2305E»05
0.0
TOTAL FLOW RATE = O.B299E»06 LB/HR
= 1660. GPM
RECYCLE SLURRY TO SPRAY TOUER
LB/HR
SPECIES
CAS03 .1/2 H20
CAS04 .2H20
CAC03
H20
CA + *
MG»»
S03 —
S04 —
CL-
AD—
LB-10LE/HR
0.1»11E*0«
0.2589E*05
0.1165E»05
0.3779E+07
0.1889E»05
0.1029E+05
0.1201E»03
0.1112E*04
0.506
0.*627E»07
0.1166E+07
0.6808F + 08
0.7571E*06
0.2502E+06
0.9613E*0»
0.1068E*06
0.191SE+07
0.0
TOTAL FLOW RATE = 0.7741E+08 LB/HR
= 1*7261. GPW
(Continued)
-------
TABLE D-l. (Continued)
FLUE GAS COOLING SLURRY
G
i—>
N>
SPECIES
CAS03 .1/2 H20
CAS04 .2H20
CAC03
IN SOLUBLES
H20
CA+ +
*IG*»
S03--
S04 —
CL-
AD —
TOTAL FLOW RATE
LB-MOLE/HR
0.5337E*02
0.1015E»01
0.*397E»03
0.1426E*06
0.7128E»03
0.3B83E+03
0.«531E*01
0.«197E*02
0.2041E»0*
0.0
= 0.2921E»07
= 5557.
LB/HR
0.6890E»04
0.1746E*06
0.4401E*05
u .0 1 77 L* U*t
0.2569E*07
0.2857F*05
0.9440E»04
0.7628E»03
0.4031E+04
0.723TE*05
0.0
LB/HR
GPH
CLARIFIER UNDERFLOW SLURRY
SPECIES
CAS03 .1/2 H20
CAS04 .2H20
CAC03
INSOLU 6L ES
H20
CA* +
HG*»
S03 —
S04--
CL-
AD —
TOTAL FLOW RATE
SUPERNATE F«OM
SPECIES
CAS03 .1/2 H20
CAS04 .2H20
CAC03
T M *; n i M R i re;
INoULUOLto
H20
CA»»
HG»»
sos--
sot —
CL-
AD —
LB-HOLF/HR
0.1797E*02
0.3*16E»03
0.1«81E*03
0.6126E»0«
0.3159E»02
0.1721E*02
0.2008E»00
0.1860E*01
0.90*6E*02
0.0
= 0.1941E«06
= 293.
CLARIFIER
LP-MOLF/HR
0.0
0.0
0.0
0.4045E+05
0.20B6E*03
0.1136E+03
0.1326E»01
0.1228E»02
0.5974E«03
0.0
LB/HR
0.2320E*04
0.5879E+05
O.I482E»05
0*9 7 RTF* fl A
• z. f O J C. * U^
0.1104E»06
0.1266E*04
0.418?E»03
0.1608E«02
0.1786E«03
0.3207Er»04
0.0
LB/HR
GPM
LB/HR
0.0
0.0
0.0
0 0
0.728PF»06
O.B360E»04
0.2762E»0«
0.1062E+03
0.1180E*04
0.2118E»05
0.0
TOTAL FLOU RATE = 0.7624f»06 LB/HR
= 1525. GPU
(Continued)
-------
TABLE D-l. (Continued)
FILTER CAKE SLURRY
U
SPECIES
CAS03 .1/2 H20
CASOt . 2H20
CAC03
Tkl^ni IIDI C"C
1 N dULUDL to
H20
CA**
MG»»
S03 —
S0« —
CL-
AD--
LB-10LF/HR
0.1797E*02
0.3416E»03
0.1481E*03
0.7368E+03
0.3799E»01
0.2069E*01
0.2415E-01
0.2237E*00
0.108BE+02
0.0
LB/HR
0.2320E+Ot
0.5879F*05
0.1482E>05
On f c T c A n L.
• £. r 3 J L * U *t
0.1327E»05
0.1523E»03
0.5031E*02
0.1933E»01
0.2148E»02
0.3857E*03
0.0
TOTAL FLOW RATE = 0.9257E*05 LB/HR
= 88. GPM
FILTRATE FROM FILTER
SPECIES
CAS03 .1/2 H20
CAS04 .2H20
CAC03
TMcni tim F~Q
INdULU DLC.O
H20
CA»»
MG»*
S03—
S0<>~
CL-
AO —
LB-MOLE/HR
0.0
0.0
0.0
0.535*E»04
0.2761E»02
0.150*E»02
0.1755E»00
0.1625E*01
0.7906E*02
0.0
LB/HR
O.C
0.0
0.0
Dn
• V
0.1106E*0*
0.3656E»03
0.1405E+02
0.1561E»03
0.280?E»C4
0.0
TOTAL FLOW RATE = 0.1009E*06 LB/HR
= 202. GPM
(Continued)
-------
TABLE D-l. (Continued)
LANDFILL DESIGN
LANDFILL DIMENSIONS
HEIGHT OF LANDFILL
HEIGHT OF LANDFILL CAP
SLOPE OF LANDFILL CAP
LENGTH OF LANDFILL DISPOSAL SIDE
LENGTH OF LANDFILL TRENCH
LENGTH OF PERIMETER FENCE
SURFACE AREA OF LANDFILL
FILL AREA LAND EXPOSED TO RAIN
SURFACE AREA OF RECLAIM STORAGE
DISPOSAL LAND AREA OF LANDFILL
LAND AREA OF LANDFILL SITE
LAND AREA OF LANDFILL SUE
VOLUME OF EXCAVATION
VOLUME OF RECLAIM STORAGE
VOLUME OF SLUDGE TO BE
DISPOSED OVER LIFE OF PLANT
DENSITY OF DISCHARGE CAKE
DENSITY OF COMPACTED CAKE
DEPTH OF CATCHMENT POICO
LENGTH OF CATCHMENT PO«ID
VOLUME OF CATCHMENT POM:
112.27
92.27
6.
1856.
7569.
1657.
3495.
3673.
520.
3444.
4930.
113.
FT
FT
DEGREES
FT
*T
FT
THOUSAND
THOUSAND
THOUSAND
THOUSAND
THOUSAND
ACRES
FT2
FT2
FT2
FT2
FT2
301. THOUSAND YD3
300. THOUSAND YD3
5955. THOUSAND YD3
3691. ACRE FT
75.00 L8S/FT3
95.00 LBS/FT3
21.44 FT
373.33 FT
96. THOUSAND YD3
(Continued)
-------
TABLE D-l. (Continued)
LANDFILL COSTS (THOUSANDS OF DOLLARS)
LANDFILL EQUIPMENT
TAX AND FREIGHT
LANDFILL EQUIPMENT TOTAL
CLEARING LAND
EXCAVATION
DISCHARGE TRENCH
GRAVEL
LINING! 12. IN. CLAY)
DRAINAGE LANDFILL
SEEDING LANDFILL SITE
ROAD CONSTRUCTION
PERIMETER COSTS, FENCE
RECLAMATION EXPENSE
RECLAMATION CLAY COVER
MONITOR WELLS
SUBTOTAL DIRECT
TAX AND FREIGHT
TOTAL DIRECT LANDFILL INVESTMENT
ENGINEERING DESIGN AND SUPERVISION
LABPP MATERIAL
21=).
596.
25.
56. 65.
932.
10. 102.
89. 53.
81. 17.
66. 74.
281.
439.
6. 5.
2830. 347.
26.
2830. 373.
( 2. 0 )
ARCHITECT AND ENGINEERING CONTRACTOP( 1.0 )
CONSTRUCTION EXPENSES < 8.0 )
CONTRACTOR FEES < 5.0 >
CONTINGENCY 120.0 )
TOTAL FIXED INVESTMENT
LAND COST
1189.
87.
1277.
TOTAL
24«f.
596.
25.
121.
932.
113.
142.
128.
140.
2fll.
439.
11.
3177.
26.
3203.
64.
32.
256.
160.
998.
5990.
679.
REVENUE QUANTITIES
LANDFILL LABOR
DIESEL FUEL
ELECTRICITY
HATER •
ANALYSIS
29120. MAN-HRS
103596. GALLONS
145178. KWH
3867. K-GALLONS
42. MAN-HRS
(Continued)
-------
TABLE D-l. (Continued)
WPSUL CONTENT :
ASH CONTENT (X):
BTU RATING:
BOILER TYPE:
NO. OF SCRUBBERS:
SCRUBBER VELOCITY (FT/M):
PLANT SIZE (MW):
OPERATING HRS/YR:
PUMPING RATE (GAL/1000 ACF):
SCA RATIO:
(ACTUAL SQ.FT./CALC. SQ.FT.
PARTICULATE REMOVAL INVESTMENT AND OPERATING COST
PARTICULATE EMISSION REGULATION (LB ASH/MILLION BTU): 0.06
3.36 FLUE G»S TEMPERATURE (COLD) (F): 300.0
15.10 FLUE GAS TEMPERATURE (HOT) : 700.0
11700 COST OF ELECTRICITY (t/KWHR): 0.06
DRY PULVERIZED COAL COST OF STEAM (I/THOUSAND LB): 4.00
* FIRST YEAR CAPITAL CHARGE FACTOR: 0.18
600.0 BAGHOUSE RATIO (OPER. SO.FT./ACTUAL SQ.FT.): 0.60
500 BAG COST (S/SQ.FT.): LOO
5500 BAG LIFE(YEAPS): 3.00
20.00 FLUE GAS REHEAT TEMPERATURE (F): 175.00
1.100 CHEMICAL ENGINEERING PLANT INDEX: 346.0
ELECTROSTATIC PRECIPITATORS
REQUIRED REMOVAL EFFICIENCY (*>:
DRIFT VELOCITY (FT/M):
SPECIFIC COLLECTION AREA (SQ.FT./ACFM ):
COLLECTION AREA (SB.FT.):
TOTAL CORONA POWER (KH>:
AUXILIARY POUER (KW):
FAN POWER (KW):
PUMP POWER (KW):
TOTAL POUER (KU>:
OPERATING AIR/CLOTH RATIO:
INSTALLED AIR/CLOTH RATIO:
REQUIRED PRESSURE 3ROP (INCHES):
DIAMETER (FEET):
REQUIRED REHEAT (BTU/HRK
STEAM SUPPLY/YR (THOUSAND LB):
INSTALLED COST (19S5 DOLLARS):
FIRST YEAR CAPITALIZED COST:
ANNUAL POWER COST:
ANNUAL OPERATING AND
MAINTENANCE COST (1985 DOLLARS):
REPLACEMENT COST (1985 DOLLARS):
ANNUAL REHEAT COST:
COLD
99.42
27.19
208.27
351952.9
460.1
296.6
26«.5
1021.1
1.0
S 6653621
S 1199869
* 308892
* 125718
HOT
99. 42
20.00
283.lt
730312.4
702.2
666.3
403.7
1772.2
1.0
1 12334274
S 2224280
J 536086
t 188652
BAGHOUSE FABRIC FILTERS
99.42
768846.0
490.8
1322.?
1813.1
2.7
2.7
5. 0
$ 1«27928C
S 3476696
S 548457
9633ft
SCRUBBE
99.42
8480.6
6022.8
14503.5
32.1
34
64377216.0
393416.2
* 29723120
* 5360068
1 «387298
» 2036472
t 1573665
TOTAL ANNUAL COST:
ANNUALIZEO COST OF POWER(MILLS/KWH°> :
1634479
0.59
$ 2949018
1.07
* 4560469
1.66
t 13357503
4.86
(Continued)
-------
TABLE D-l. (Continued)
RAM MATERIAL HANDLING
ITEM
DESCRIPTION
NO. MATERIAL LABOR
I
I—1
--J
CAR SHAKER AND HOIST
CAR PULLER
UNLOADING HOPPER
UNLOADING VIBRATING FEEDER
UNLOADING BELT CONVEYOR
UNLOADING INCLINE BELT
CONVEYOR
UNLOADING PIT DUST COLLECTOR
UNLOADING PIT SUMP PUMP
STORAGE BELT CONVEYOR
STORAGE CONVEYOR TRIPPER
MOBILE EQUIPMENT
RECLAIM HOPPER
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOR
RECLAIM INCLINE BELT CONVEYOR
RECLAIM PIT DUST COLLECTOR
RECLAIM PIT SUMP PUMP
RECLAIM BUCKET ELEVATOR
FEED BELT CONVEYOR
FEED CONVEYOR TRIPPER
FEED BIN
20HP SHAKER 7.5HP HOIST
25HP PULLER, SHP RETURN
16FT DIA, 10FT STRAIGHT
INCLUDES f> IN SO GRATING
3.5 HP
20FT HORIZONTAL. 5HP
310 FT, 50 HP
POLYPROPYLENE BAGTYPE,
INCLUDES OUST HOOD
60 GPM, 70 FT HEAD, 5 HP
200 FT, 5 HP
30 FPH, 1 HP
SCRAPPER TRACTOR
TFT WIDE, 4.25FT HT, 2FT
WIDE BOTTOM, CS
3.5 HP
200 FT, 5 HP
19? FT, 40 HP
POLYPROPYLENE BAG TYPE
60GPM, 70 FT HEAD, 5 HP
90 FT HIGH, Z* HP
60 FT HORIZONTAL 7.5 HP
30 FPM, 1 HP
13FT DIA, 21FT STRAIGHT
SIDE HT, COVERED, CS
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
3
85232.
70391.
16566.
6987.
11490.
85641.
10835.
4476.
73387.
27264.
166916.
2576.
13973.
42182.
60587.
7511.
4476.
54294.
21091.
27264.
46096.
14392.
21586.
6837.
586.
1639.
5521.
5922.
870.
4521.
10443.
0.
1876.
1175.
3277.
3842.
2961.
870.
7606.
1639.
10443.
27734.
TOTAL RAW MATERIAL HANDLING EQUIPMENT COST
(Continued)
839234.
133741.
-------
TABLE D-l. (Continued)
RAW MATERIAL PREPARATION
INCLUDING 2 OPERATING «NO 1 SPARf PREPARATION UNITS
ITEM DESCRIPTION NO. M»TE°IAL
LA80P
I
I—'
oo
BIN UEIGH FEEDER
GYRATORY CRUSHERS
BALL HILL DOST COLLECTORS
BALL KILL
MILLS PRODUCT TANK
MILLS PRODUCT TANK AGITATOR
MILLS PRODUCT TANK SLURRY
PUMP
SLURRY FEED TANK
SLURRY FEED TANK AGITATOR
SLURRY FEED TANK PUMPS
11 FT PULLEY CENTERS, 2HP 3
75 HP
POLYPROPYLENE BAG TYPE
2200 CFM, 7.5 HP
CYLINDRICAL 13.5TPH, 767.HP3
5500 GAL 10FT DIA, 10FT
HT, FLAKEGLASS LINED CS
7.5 HP
57.GPM, 60 FT HEAD .
2 HP, 2 OPERATING
ANO 1 SPARE
59803.GAL, 21.7FT DIA,
21.7 FT HT, FLAKEGLASS-
LINEO CS
50 HP 1
28 GPH, 60 FT HEAD , R
1 HP, 4 OPERATING AND
4 SPARE
3
3
3
3
3
3
3
63137.
402825.
28820.
1724395.
17963.
38317.
7240.
2661
7374
8883
114997
13257
4069
3051
24050.
49744.
18858.
20132.
4120.
8137.
TOTAL FEED PREPARATION EQUIPMENT COST
2775647.
1R66R1.
(Continued)
-------
TABLE D-l. (Continued)
GAS HANDLING
INCLUDING 1 OPERATING AN3 1 SPARE SCRUBBING TRAINS
ITEM DESCRIPTION NO. MATERIAL
LABOR
l.D. FANS
7.9IN H20, WITH 664.
HP MOTOR AND ?PI VE
TOTAL GAS HANDLING EQUIPMENT COST
3490060.
3490060.
63725.
63725.
S02 SCRUBBING
INCLUDING 1 OPERATING AND 1 SPARE SCRUBBING TRAINS
ITEM DESCRIPTION NO. MATERIAL
LABOP
I
I—'
\o
SHELL
NEOPRENE LINING
<
-------
TABLE D-l. (Continued)
o
N>
o
OXIDATION
INCLUDING 4 OPERATING AND 1 SPARE SC^UBRING TRAINS
ITEM
KECIRCULATION TANK
RECIRCULATION TANK AGITATOR
OXIDATION BLEED PUMPS
OXIDATION AIR BLOWER
OXIDATION SPARGER
DESCRIPTION
NO. MOTERIAL
59.HP
469.GPM, 60 FT HEAD
12.HP, 4 OPERATING
AND 4 SPARE
2709.SCFM, 267.HP
19.0 FT DIA RING
6 20*276.
5 66414.
LABOR
202434.GAL 3P.1FT OIA, 5 319840. 264831.
38.OFT HT, FLA
-------
TABLE D-l. (Continued)
ITEM
SOLIDS SEPAOATICN
OESC=IPTION
NO. MATERIAL
LABOR
iBSCNBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATO*
THICKENER FEED PUMP
THICKENER
THICKENER UNDERFLOW SLURRY
PUMPS
THICKENER OVERFLOW PUMPS
THICKENER OVERFLOW TANK
FILTER FEED TANK
FILTER FEED TANK
AGITATOR
FILTER FEED SLURRY PUMP
FILTER
FILTRATE PUMP (PER FILTER)
FILTRATE SURGE TANK
FILTRATE SURGE TANK PUMP
FILTER CAKE CONVEYO"
TOTAL EQUIPMENT COST
T9D5.C-4L. 1".OFT CIA. I
3°.OFT -T, FL»KGL»tS-
LINED Ct
41 HP 1
1B73.GP-, 60rT HEAD, 2
50.HP, 1 OPERATING
AND 1 SPARE
l?43.SQ.rT. t 48.FT DIA, 1
5.STANK FT HT
I. RAKE "F
293.GPM. 9.» FT HEAD, 2
2 HP , 1 OPERATING
AND 1 SDARE
1525.GPM, 7?.OFT HEADt 2
48.HP, 1 OPfRATING
AND 1 SPARE
25169.GAL,
5.5FT HT
28.OFT OIA,
4632.GAL. 9.4FT DIA,
9.4 FT HT, FLAKEGLASS-
L1NED CS
7 HP
1*6.GPM, 50FT HEAD,
«.HP, 2 OPERATING
AND 1 SPARE
3=3.SO FT FILTRATION
ASEA, 49. VACUUM HP
2 OPERATING AND 1 SPARE
101.GPM, 20.CFT HEAD,
l.HP, 2 OPEROTINC-
AND 2 SP4RE
3331.GAL,
P.3FT HT
8.3FT DIA,
J02.GP", 85. OFT HEAD,
7. HP, 1 OPERATING
«ND 1
'5 FT. "ORI70NTAL
100 FT. INCLINE
1.5 wc
(Continued)
37036.
23292.
88611.
9657.
10517.
7223.
4496.
11201.
511867.
13939.
1848.
7496.
42066.
2835?.
3067.
8221.
69845.
3654.
1633.
5475.
3763.
699.
4049.
77905.
2165.
1164.
35°2.
811550.
-------
TABLE D-l. (Continued)
LANDFILL DISPOSAL
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
O
IsJ
ts}
TRUCKS
WHEEL LOADER
TRACK-DOZER
COMPACTOR
UHEEL LOADER
WATER TRUCK
SERVICE TRUCK
TRAILER
WATER TREATMENT SYSTEM
16.0 CU YD, 1 SPARE
7.0 CU YDS-BUCKET
133.HP,STRAIGHT-BLADE
SHEEP-FOOT
3.5 CU YDS BUCKET,CLEANUP 1
1500 GALLON TANK AND
SPRAY HEADERS
WRECKER RIG, TOOLS
12 FT X 30 FT, OFFICE,
BREAK ROOM,FACILITIES
PU«PS, TANKS
T
1
1
1
1
1
1
1
152135.
385265.
154103.
195749.
138423.
37990.
54649.
10917.
0
0
0
0
0
0
0
1130
32861.
25947.
TOTAL EQUIPMENT COST
(Continued)
1162389.
27077.
-------
TABLE D-l. (Continued)
LIMESTONE SLURRY PROCESS — 9ASIS: 500 MW SC"UB0INr, UNIT - 500 MU GENEBATING UNIT,
PROJECTED CAPITAL INVESTMENT REQUIREMENTS - SHAWNEE COMPUTE" USER MANUAL BASE
INVESTMENT, THOUSANDS OF 1985 DOLLAPS
MAT HAND FEED PREP
0
1
OJ
EUUIPMENT
MATERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTWORK
MATERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
BUILDINGS
MATERIAL
LABOR
SALES TAX ( 4.0 X) AND FREIGHT < 3.5 X)
TOTAL PROCESS CAPITAL
SERVICES AND MISCELLANEOUS ( £.0 X)
TOTAL DIRECT PROCESS INVESTMENT
LANDFILL EQUIPMENT
LANDFILL CONSTRUCTION
LANDFILL SALES TAX ( 4.0 X) AND FREIGHT ( 7.5 X)
TOTAL DIRECT INVESTMENT
ENGINEERING DESIGN AMD SUPERVISION ( 7.0 X)
ARCHITECT AND ENGINEERING CONTRACTOR ( 2.0 X)
CONSTRUCTION EXPENSES (15.0 X)
CONTRACTOR FEES ( 5.0 X)
CONTINGENCY (10.0 X>
LANDFILL INDIRECTS ( 2.0, 1.0, 8.0, 5.0, 20.0 X)
SJBTOTAL FIXED INVESTMENT
STARTUP s MODIFICATION ALLOWANCE ( 9.0, o.o x>
INTEREST DURING CONSTRUCTION (15.6 < )
ROYALTIES ( 0.0 X)
LAND ( i 6000. ACRE )
WORKING CAPITAL
839.
134.
37.
n.
a.
0.
215.
524.
142.
36.
171.
540.
1.
0.
0.
0.
105.
2762.
166.
2927.
0.
0.
0.
2927.
205.
59.
468.
146.
381 .
C.
• let.
335.
653.
0.
15.
192.
2376.
187.
416.
192.
0.
0.
114.
219.
67.
124.
178.
365.
167.
24.
161.
166.
261.
5015.
301.
5316.
0.
0.
0.
5316.
372.
106.
851.
266.
6"1.
0.
7602.
608.
1186.
0.
1.
349.
GAS HANC
3490.
64.
0.
0.
2918.
2424.
49.
88.
0.
0.
338.
1103.
60.
12.
0.
0.
514.
11059.
664.
11723.
0.
0.
0.
11723.
821.
234.
1876.
586.
1524.
0.
16764.
1341.
2615.
C.
2.
769.
SO? SC°UB
949°.
1127.
5723.
735.
0.
0.
103.
208.
393.
722.
437.
78 C.
94?.
127.
0.
0.
12S2.
22079.
1325.
23403.
0.
C.
0.
23403.
1638.
468.
3745.
1170.
3?42.
0.
73467.
2677.
5221.
0.
1.
1535.
0»n
98C.
35°.
25.
57.
102.
182.
45.
9C.
0.
0.
20?.
226.
69.
If.
34.
34.
109.
2525.
152.
2677.
C.
o.
n.
2677.
1"7.
54.
4?8.
134.
348.
r«
3»2P.
306.
597.
r.
1.
17*.
.EHE.T
3292.
20F.
55°.
267.
?.
r.
C.
<}.
0.
0.
66.
67.
32.
7.
0.
0.
?9f .
4790.
287.
5077.
C.
r.
"..
5077.
355.
10?.
P12.
254.
660.
r.
7261.
58!.
1131.
0.
G.
337.
soLir srp
812.
215.
851.
271.
0.
0.
35.
69.
0.
0.
250.
529.
54.
72.
61.
61.
155.
3434.
206.
3640.
11«9.
3177.
113.
8120.
2?5.
73.
5P2.
1P2.
473.
1511.
111=6.
416.
1747.
0.
6P4.
5?3.
DISTRIBUTION
TOTAL
21287.
2293.
7611.
1536.
3320.
2606.
561.
1197.
602.
882.
1641.
3610.
1325.
252.
256.
260.
2723.
51665.
3100.
54764.
1189.
3177.
113.
59244.
3834.
1095.
«762.
2738.
7119.
1511.
84303.
€265.
13151.
0.
704.
?B85.
DOLLARS
42. C7
4.5S
15.2J
3.&7
6.04
5.21
1.12
2.3"
1.20
1.76
3.28
7.22
2.65
0.50
0.51
0.52
5.45
103.3!
6.2T
109.53
2.3(
6.35
0.23
118.49
7.67
2. IS
i7.s:
5.48
14.24
3.0:
168.61
12.5!
26. 3C
0.0
1.41
7.77
TOTAL CAPITAL INVESTMENT
5381.
9745.
21491.
42901.
4908.
9307.
14576.
10B309.
(Continued)
216.6S
-------
TABLE D-l. (Continued)
LIMESTONE SLURRY PROCESS -- BASIS: 500 MW SCRUBBING UNIT - 500 MW GENERATING UNIT, 1987 STAPTUP
PROJECTED REVENUE REQUIREMENTS - SHAWNEE COMPUTER USER MANUAL BASE
DISPLAY SHEET FOR YEAPr
ANNUAL OPERATION KW-HR/KU =
39.38 TO>4S PER HOUR
TOTAL CAPITAL INVESTMENT
1
5500
10830ROOO
ANNUAL QUANTITY UNIT COST.t
DIRECT COSTS
RAW MATERIAL
LIMESTONE
SUBTOTAL RAW MATERIAL
CONVERSION COSTS
118.0 K TONS
15.CO/TON
OPERATING LABOR AND
SUPERVISION
LANDFILL LABOR AND
SUPERVISION
UTILITIES
STEAM
PROCESS WATER
ELECTRICITY
DIESEL FUEL
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
INDIRECT COSTS
«:LU03E
TOTAL
.ANNUAL
COST,*
P220400
2220400
43860.0
29120.0
542640.0
194000.0
56943180.0
103600.0
4990.0
MAN-HR
MAN-HR
K LB
K GAL
KWH
GAL
HR
19
.OC/MAN-HR
24.00/MAN-HR
*
0
0
1
26
,00/K LB
.It/K GAL
,055/KUH
.SO/GAL
,00/HR
833400
698900
2170500
31TOO
3131=00
165POO
4515500
129700
11676700
13897100
OVERHEADS
PLANT AND ADMINISTRATIVE < 6o.ox OF CONVERSION COSTS LETS UTILITIES) 3706500
FIRST YEAR OPERATING AND MAINTENANCE COSTS 17603*00
LEVELIZED CAPITAL CHARC-ESC 14.70X OF TOTAL CAPITAL INVESTMENT) 15921*00
FIRST YEAR ANMJAL "EVENUE °EOUIREMENTS 33525000
EQUIVALENT FIRST YEA* UNIT REVENUE R EOUIREMENTS, "ILLS/KWH irr ( 1.886 TIMES FIRST YEAR TPE*. S "HIM.) 3320D«00
LEVELIZED CAPITAL CHARC-ESC 1«.70X HF TOTAL CAPITAL INVESTMENT) 15921«00
LEVELIZED ANNUAL REV-INUE REQUIREMENTS 4O121BQO
EQUIVALENT LEVELIZEO UNIT REVENUE REQUIREMENTS, MILLS/KUH (MU SCRUBBED) 17.B6
HEAT RATE 9500. 6TU/KW-1 - HEAT VALUE OF COAL 11700 BTU/L^ - COAL RATr
llltSOO TONS/YR
-------
Appendix E
ADIPIC ACID INTERACTIVE MODEL
E-l
-------
E-2
-------
ADIPIC ACID INTERACTIVE MODEL
The adipic acid computerized model in the Shawnee computer model is
available as an interactive model that allows the user to optimize the adipic
acid enhanced flue gas desulfurization (FGD) system by calculating operating
conditions at various input conditions. The optimized values can then be
input to the Shawnee model and executed in "forced-through mode" to determine
the entire system design and cost.
Adipic acid is an organic acid which serves to buffer the pH of the
limestone slurry in the range of M.6-5.8, thus maintaining a higher driving
force for SC>2 removal while operating at a lower limestone stoichiometry.
It has been found at the Shawnee test facility at TVA's Shawnee Steam Plant
that a stoichiometric ratio of 1.07 mol CaCOg/mol (S02 + 2HC1) absorbed
provides the optimum conditions. Higher stoichiometric ratios have little
effect on S02 removal, can cause scaling, and will increase operating costs.
The data generated at the test facility have been reduced to mathematical
equations that project a material balance based on input L/G, SC>2 removal,
adipic acid concentration, and pH. It is recommended that both pH and lime-
stone stoichiometries be input with the values described above. The model
projects the remaining condition when any two of the values for L/G, S02
removal, or adipic acid concentration are input.
The adipic acid model requires user knowledge of adipic acid-enhanced
systems. Unless L/G, 862 removal, or adipic acid concentrations are known
or specified, it is recommended that the model be executed several times to
optimize conditions.
The FORTRAN variable names are presented in Table E-1 and they are
defined in Table E-2. An example COMMAND procedure to interactively execute
only the adipic acid model is presented in Table E-3. The results of an
interactive computer run are illustrated in Table E-H.
E-3
-------
TABLE E-1. FORTRAN VARIABLE NAMES FOR
ADIPIC ACID INTERACTIVE MODEL
Line ~
1 SR LG PH ISR ISCRUB
2 S02R AD OX
3A VLG VPD
3B V
3C V NSTAGE NGRID HS
it IREAD
E-4
-------
TABLE E-2. ADIPIC ACID INTERACTIVE MODEL INPUT DEFINITIONS
Line Variable
Definition
Unit or value
SR
1 LG
1 PH
1 ISR
ISCRUB
2 S02R
2 AD
2 OX
Stoichiometry (see ISR option below)
L/G ratio (see ISR option below)
Scrubbing liquid pH
This option controls the method of
determining L/G ratio, S02 removal,
and adipic acid concentration.
LG, S02R, and AD will be processed
as input values (there will be no
check for validity and consistency)
LG and S02R will be processed as
input values and AD will be
calculated by the model.
AD and S02R will be processed as
input values and LG will be
calculated by the model.
LG and AD will be processed as
input values and S02R will be
calculated by the model.
Absorber type
Spray tower
TCA
Venturi-spray tower, two effluent
tanks
Venturi-spray tower, one effluent
tank
Venturi-TCA, two effluent tanks
Venturi-TCA, one effluent tank
S02 removal
Adipic acid in the scrubbing liquid
Oxidation of sulfite in the scrubbing
liquid
(Continued)
mols CaC03 added
as limestone per
mol S02 + 2HC1
absorbed
gal/kaft3
1
2
3
5
6
ppm (wt)
mol %
E-5
-------
TABLE E-2. (Continued)
Line
3A
3A
3B
3C
3C
3C
3C
4
Variable
VLG
VPD
V
V
NSTAGE
XGRID
HS
IREAD
Definition
L/G ratio in venturi
Venturi throat velocity
Spray tower superficial gas
velocity
TCA superficial gas velocity
Number of TCA stages
Number of TCA grids
Height of TCA sphere bed per stage
Terminate model program
Unit or value
gal/kaft3
ft/sec
ft/sec
ft/sec
in.
0
Continue with next case
E-6
-------
TABLE E-3. EXAMPLE COMMAND PROCEDURE FOR EXECUTING THE ADIPIC ACID MODEL INTERACTIVELY
10 FREE FHFT03F001«FT05F001 ,FT06F001>
20 ALLOC FHFT03F001) DA<«)
30 ALLOC FKFT05F001) DA(O
40 ALLOC FKFT06F001) OA(»)
50 CALL •JL»LQ01.INVEST.LOAD(ADIPIC)•
-------
TABLE E-4. EXAMPLE RESULTS ILLUSTRATING
INTERACTIVE ADIPIC ACID MODEL OUTPUT
TENNESSEE VALLEY AUTHORITY
COMPUTERIZED ADIPIC ACIP MODEL
REVISION DATE APRIL Ofl. 1982
USER SHOULD VARY PH, L/G.AND ADIPIC ACID CONCENTRATION
IN ATTEMPS TO IMPROVE S02 REMOVALS
SEE USER MANUAL FOR VARIABLE DEFINITIONS
*** VALUES ARE CALCULATED FOR SPRAY TQWE" *•*
U> ENTER SR, L6, PHf ISR, ISCRU8
C2> ENTER S02R, ADt OX
OBJ ENTER SCRUBBER VELOCITY
W INPUT VALUES SR= 1.C70 LG = 80.000 REMOVAL: >»O.ODO PHr 5.200 AD= 1500.00 VEL = 10.
00
OUTPUT VALUES SR= 1.070 LG = 80.000 REMOVAL^ 94.8CO PHr 5.200 AD= 1500.00 VEL= 10.
ENTER S02R, AO, OX
<3C> ENTER TCA SCRUB VEL, STAGES, GRIDS, SPHERE HT
INPUT VALUES SR= 1.070 LG: 45.000 REMOVAL^ 90.000 PH= 5.200 AD= 1500.00 VEL= 10.
OUTPUT VALUES SR= 1.070 LG= 45.000 REMOVAL^ 93.741 PH= 5.200 A0= 1500.00 VELr 10,
14) ENTER 1 TO CONTINUE PR 0 TO STOP
**• VALUES BELOW »RE FOR VENTURI-SPRAY TOWE" **•
<1) ENTER SR, LG, PH, ISR, ISCRUB
<2I ENTER S02R, AO, OX
C3A) ENTER VLG,VPD
INPUT VALUES SR= 1.070 LG- 40.000 REHOVAL= °O.OOC PH= 5.2'oO AD= 1500.00 VEL= 10.
OUTPUT VALUES SR= 1.070 LG= 40.000 REMOVAL= 95.176 PH= 5.20C BD= 1500.00 VEL= 10.
I4» ENTER 1 TO CONTINUE OR 0 TO STOP
-------
Appendix F
POND INTERACTIVE MODEL
F-l
-------
F-2
-------
POND INTERACTIVE MODEL
The pond model in the Shawnee computer model can be executed in an inter-
active mode to project pond designs and costs independent of the scrubbing
model. In this mode, the pond design is based on the final volume of the
waste, which is specified by the GPMSS and THRS input variables. GPMSS
specifies the waste input rate in gal/min using the final dry bulk density and
THRS specifies the lifetime hours of pond disposal site operation.
The FORTRAN variable names are presented in Table F-1 and they are
defined in Table F-2. An example COMMAND procedure to interactively execute
only the pond model is presented in Table F-3. The results of an interactive
computer run are illustrated in Table F-4.
F-3
-------
TABLE F-1. FORTRAN VARIABLE NAMES FOR
POND INTERACTIVE MODEL
Line ,_ —. .
1 IOTIME OTRATE
2 UA RMI RLI
3 IECON
4 PENGIN PARCH PFLDEX PFEES PCONT PSTART PCONIN
5 ITAXER TXRAT FRRAT
6 GPMSS THRS
7 EMAX AMAX
8 LINER
9 XLINA XLINB
1OA No entry
10B PDEPTH
10C DBEG DEND DINC
10D VBEG VEND VINC
11 PCLEAR PDEXEC SODM SODL PERIMM PERIML ROADMM ROADLL
12 WELLM WELLL RECLAM
F-A
-------
TABLE F-2. POND INTERACTIVE MODEL INPUT DEFINITIONS
iMng Variable
Definition
Unit or value
1 IOTIME Overtime construction labor option
No overtime labor
Overtime labor on 1% of total labor
based on the OTRATE rate below
1 OTRATE Overtime labor rate (applied to 7$ of
total labor) Example: 1.5
2 UA Land cost
2 RMI Chemical Engineering material cost index
(see premises)
2 RLI Chemical Engineering labor cost index
(see premises)
3 IECON Economic premises option
Current premises
Premises prior to 12/5/79
Pond construction engineering design and
supervision expenses
Pond construction architect and
engineering contractor expenses
Pond construction field expenses
Pond construction contractor fees
Pond construction contingency
Allowance for pond startup and
modification
Interest during construction
Sales tax and freight option
No sales tax or freight
Sales tax and freight rates
specified by TXRAT and FRRAT below
TXRAT Sales tax rate (applied only when
ITAXFR above set to 1)
(Continued)
F-5
4
4
4
4
4
4
4
5
PENGIN
PARCH
PFLDEX
PFEES
PCONT
PSTART
PCONIN
ITAXFR
0
1
$/acre
1
0
0
1
-------
TABLE F-2. (Continued)
Line Variable
Definition
Unit or value
5 FRRAT
GPMSS
6
7
7
8
THRS
EMAX
AMAX
LINER
9 XLINA
9 XLINB
10A
10B PDEPTH
1OC DBEG
1OC DEND
10C DINC
10D VBEG
1OD VEND
10D VINC
Freight rate (applied only when
ITAXFR above set to 1)
Accumulation rate of settled sludge
(settled bulk density)
Total lifetime disposal operating time
Maximum excavation depth
Maximum site area
Pond lining option
Clay liner
Synthetic liner
No liner
(Refer to the XLINA and XLINB variables
that immediately follow.)
If LINER = 1, XLINA = clay depth
If LINER = 2, XLINA = material unit cost
If LINER = 3, XLINA = 0
If LINER = 1, XLINB = clay cost
If LINER = 2, XLINB - labor unit cost
If LINER = 3, XLINB = 0
Not required, optimum pond
Pond depth (fixed-depth option)
Minimum pond depth (pond depth table
option)
Maximum pond depth (pond depth table
option)
Pond depth increment (pond depth table
option)
Minimum pond volume (pond volume table
option)
Maximum pond volume (pond volume table
option)
Pond volume increment (pond volume table
option)
(Continued)
F-6
gpm
hr
ft
acres
1
2
3
in.
$/yd3
$/yd2
ft
ft
ft
ft
Mgal
Mgal
Mgal
-------
TABLE F-2. (Continued)
Line Variable
Definition
Unit or value
11
11
11
11
11
11
11
11
12
PCLEAR
PDEXEC
SODM
SODL
PERIMM
PERIML
ROADMM
ROADLL
WELLM
12 WELLL
12 RECLAM
Clearing cost
Excavation cost
Revegetation material cost
Revegetation labor cost
Perimeter fence and lights material
Perimeter fence and lights labor
Road construction material cost
Road construction labor cost
Monitor well, material cost
(60 ft of M-in.-diameter pipe)
Monitor well, labor cost
Reclamation cost
$/acre
$/yd3
$/yd2
$/yd2
$/ft
$/ft
$/yd3
$/yd3
$
$
$/acre
F-7
-------
TABLE F-3. EXAMPLE COMMAND PROCEDURE FOR EXECUTING THE POND MODEL INTERACTIVELY
10 FREE FI(FT03F001tFT05F001 .FT06FOC1)
20 ALLOC FKFT03F001) OA<*)
30 ALLOC FKFT05FOC1) DA(*>
50 CALL 'SLALCD!.INVEST.LOAO«
-------
TABLE F-4. EXAMPLE RESULTS ILLUSTRATING INTERACTIVE POND MODEL OUTPUT
TENNESSEE VALLEY AUTHORITY
POND COMPUTE°IZED DESIGN-COST ESTIMATE "ODEL
REVISION DATE APRIL 11. 19P3
ENTER TYPE OF RUN!
1 - OPTIMUM POND
2 - FIXED DEPTH POND
3 - POND DEPTH TABLE
4 - POND CAPACITY TABLE
5 - TERMINATE
ID ENTER OVERTIME FLAG AND RATE.
IF UNKNOWN USE It 1.5
(2) ENTER COST OF LAND AND MATERIAL AND LABOR INDEXESt FOR DESIRED YEA R
IF UNKNOWN USE 6000* 366.8, 292.2
hrj <3> ENTER ECONOMIC PREMISES FLAG (NEW = 1« OLD=01
I
^ (4) ENTER OVERHEAD PERCENTAGES ENGIN. ARCTEC, FLDEXP, FEEStCONT, START , AND CONINT
IF UNKNOWN ENTER 2, It *', 5, lOt 8t 15.6
15) ENTER TAX AND FREIGHT FLAS AND RATES AS A PERCENTAGES
IF UNKNOWN USE It 4, 3.5
C6> ENTER NET ACCUMULATION OF SETTLED SLUDGE IN G PM AND TOTAL EQUIV. POND LIFE IN HOURS
IF UNKNOWN USE 88, 165000
(7) ENTER MAX. EXCAVATION IN FEET AND MAX. ACREAGE.
IF UNKNOWN USE 9999, 9999
<8> ENTER 1 IF CLAY LINING DESIRED; ENTER 2 IF SYNTHETIC LINING DESIRE D! OR ENTER 3 FOR NO LINING
(9) ENTER CLAY LINING DEPTH IN INCHES AND UNIT COSTS IN DOLLARS PER CUBIC YAPO
IF UNKNOWN USE 12.0, 6.16
(10) NO ENTRY FOR THIS OPTION
(11) ENTER CLEARING COSTS/ACRE, EXCAVATION COSTS/YD3,SEED-FERTILIZER COSTS/YD2 M8L,
PERIMETER M&L COSTS/FT, 30AD COST.S/YD3 H8L
IF UNKNOWN USE : 1950t1.75t.3t.19t7.0t6.05t6.0t8.5
(12) ENTER MATERIAL AND LABOR COST MONITOR WELLS $ RECLAMATION COSTS/ ACRE
IF UNKNOWN USE: 5000,5100,3100
(Continued)
-------
TABLE F-4. (Continued)
3DND DESIGN
OPTIMIZED TO MIMMIZE TOTAL COST PLUS OVERHEAD
POND DIMENSIONS
I
(—•
o
DEPTH OF POND 20.29 FT
DEPTH OF EXCAVATION 3.8» FT
LENGTH OF DIVIDER DIKE 1797. FT
LENGTH OF POND "ERIPETER DIKE 9962. ^T
LENGTH OF POND PERIMETER FENCE 10968. FT
SURFACE AREA OF BOTTOM 589.
SURFACE AREA Of INSIDE WALLS 96.
SURFACE AREA Oc OUTSIDE WALLS 70.
SURFACE AREA OF RECLAIM STORAGE 57.
LAND AREA OF POND 678.
LAND AREA OF POND SITE 881.
LAND AREA Qf POND SITE 182.
VOLUME OF EXCAVATION 815.
VOLUME OF RECLAIM STORAGE 255.
VOLUME OF SLUDGE TO BE 431*.
DISPOSED OVER LIFE OF 3LANT 267*.
THOUSAND YD2
THOUSAND rD2
THOUSAND YD2
THOUSAND YD2
THOUSAND YD?
THOUSAND Y02
ACRES
THOUSAND YD3
THOUSAND Y03
THOUSAND YD3
ACPE FT
(Continued)
-------
TABLE F-4. (Continued)
POND COSTS (THOUSANDS DF DOLLARS)
LABOR
MATERIAL
TOTAL
CLEARING LAND
EXCAVATION
DIKE CONSTRUCTION
LINING! 12. IN. CLAY)
SEEDING DIKE WALLS
ROAD CONSTRUCTION
PERIMETER COSTS, FENCE
RECLAMATION EXPENSE
MONITOR WELLS
SUBTOTAL DIRECT
TAX AND FREIGHT
401 .
1616.
193R.
1105.
123.
16.
66.
543.
5.
611* .
73.
22.
76.
5.
176.
13.
401.
1616.
1938.
1405.
202.
37.
142.
543.
10.
6289.
13.
TOTAL DIRECT PPND INVESTMENT
6114.
ENGINEERING DESIGN AND SUPERVISION ( 2.0 )
ARCHITECT AND ENGINEERING CONTPACTOR( 1.0 )
CONSTRUCTION EXPENSES ( P.O )
CONTRACTOR FEES ( 5.0 )
CONTINGENCY (10.0 )
1P9.
6302.
126.
63.
504.
315.
731.
TOTAL FIXED INVESTMENT
LAND COST
S042.
1092.
MORE? NO
ENTER TYPE OF RUN:
1 - OPTIMUM POND
2 - FIXED DEPTH POND
3 - POND DEPTH TABLE
4 - POND CAPACITY TABLE
5 - TERMINATE
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F-12
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Appendix G
LANDFILL INTERACTIVE MODEL
G-l
-------
-------
LANDFILL INTERACTIVE MODEL
The landfill model in the Shawnee computer model can be executed in an
interactive mode to project landfill designs and costs independent of the
scrubbing model. In this mode, the landfill design is based on the final
volume of the waste, which is specified by the GPMSS and TOPHRS input varia-
bles. GPMSS specifies the waste input rate in yd3/hr at the compacted
volume and TOPHRS specifies the lifetime hours of landfill disposal site
operation.
The FORTRAN variable names are presented in Table G-1 and they are
defined in Table G-2. An example COMMAND procedure to interactively execute
only the landfill model is presented in Table G-3. The results of an inter-
active computer run are illustrated in Table G-M.
G-3
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TABLE G-1. FORTRAN VARIABLE NAMES FOR
LANDFILL INTERACTIVE MODEL
.1 IOTIME OTRATE
2 ACRE$ RATMAT RATLAB
3 IECON
4 PENGIN PARCH PFLDEX PFEES PCONT PSTART PCONIN
5 ITAXFR TXRAT FRRAT
6 GPMSS TOPHRS OPP DISTPD STORM
7 A1 HLIFT SW(3)
8 DEND DENS
9 ILINER
1OA CLAYIN CLAYUC
10B ULFC(1) ULFC(2)
11 ULFC(3) ULFC(4) ULFC(5)
12 ULFC(6) ULFC(7)
13 PCLEAR PDEXEC SODM SODL PERIMM PERIML ROADMM ROADML
U WELLM WELLL RECLAM
15 UC(6) UC(10) CAP CAPS
16 INEXT
G-4
-------
TABLE G-2. LANDFILL INTERACTIVE MODEL INPUT VARIABLE DEFINITIONS
Line
1
Variable
IOTIME
Definition
Overtime construction labor option
No overtime labor
Overtime labor on 7$ of total labor
Unit
0
1
or value
1 OTRATE Overtime labor rate (times standard
rate) Example: 1.5
2 ACRE$ Land cost
2 RATMAT Chemical Engineering material cost index
(see premises)
2 RATLAB Chemical Engineering labor cost index
(see premises)
3 IECON Economic premises option
Current premises
Premises prior to 12/5/79
4 PENGIN Landfill construction engineering
design and supervision expenses
4 PARCH Landfill construction architect and
engineering contractor expenses
4 PFLDEX Landfill construction field expenses
4 PFEES Landfill construction contractor fees
4 PCONT Landfill construction contingency
4 PSTART Allowance for landfill startup and
modifications
4 PCONIN
5 ITAXFR
Interest during construction
Sales tax and freight option
No sales tax or freight
Sales tax and freight rates as
specified by TXRAT and FRRAT
TXRAT Sales tax rate (applied only when
ITAXFR above set to 1)
(Continued)
$/acre
1
0
0
1
G-5
-------
TABLE G-2. (Continued)
Line
5
6
6
6
6
6
7
7
7
8
8
9
10A
10A
10B
10B
11
11
Variable
FRRAT
GPMSS
TOPHRS
OPP
DISTPD
STORM
A1
HLIFT
SW(3)
DEND
DENS
ILINER
CLAYIN
CLAYUC
ULFC(1)
ULFC(2)
ULFC(3)
ULFCU)
Definition
Freight rate (applied only when
ITAXFR above set to 1)
Waste disposal rate
(compacted volume)
Total lifetime disposal operating time
First-year operating hours
Transportation distance from scrubber
area to landfill site
Rainfall for 10-year storm, 24-hour
period
Landfill cap slope
Landfill height at perimeter
Offset width
Uncompacted bulk density of waste
Compacted bulk density of waste
Landfill liner option
Clay liner
Synthetic liner
No liner
Clay liner thickness (if ILINER = 1)
Clay cost (if ILINER = 1)
Synthetic liner unit material cost
(if ILINER = 2)
Synthetic liner unit labor cost
(if ILINER = 2)
8-inch drain, material and labor cost
4-inch drain, material and labor cost
Unit or value
%
yd3/hr
hr
hr/yr
ft
in.
degrees
ft
ft
Ib/ft3
Ib/ft3
1
2
3
in.
$/yd3
$/yd2
$/yd2
$/ft
$/ft
(Continued)
G-6
-------
TABLE G-2. (Continued)
^ine
11
12
12
13
13
13
13
13
13
13
13
14
14
14
15
15
15
15
16
Variable
ULFC(5)
ULFC(6)
ULFC(7)
PCLEAR
PDEXEC
SODM
SODL
PERIMM
PERIML
ROADMM
ROADML
WELLM
WELLL
RECLAM
UC(6)
UC(10)
CAP
CAPS
INEXT
Definition
Drain pipe, 8-inch to 4-inch tees,
material and labor
Gravel material cost
Gravel labor cost
Clearing cost
Excavation cost
Revegetation material cost
Revegetation labor cost
Perimeter fence and lights material
costs
Perimeter fence and lights labor costs
Road gravel material cost
Road gravel labor cost
Monitor well material cost, 60 feet of
4-inch pipe
Monitor well labor cost
Reclamation cost
Landfill transportation and operating
labor
Diesel fuel
Final soil cover, material and labor
Synthetic cover, material and labor
Terminate program
Continue with next case
Unit or value
$/each
$/ft3
$/ft3
$/acre
$/yd3
$/yd2
$/yd2
$/ft
$/ft
$/yd3
$/yd3
$
$
$/acre
$/hr
$/gal
$/yd3
$/yd2
0
1
G-7
-------
TABLE G-3. EXAMPLE COMMAND PROCEDURE FOR EXECUTING THE LANDFILL MODEL INTERACTIVELY
10 FREE FI
20 ALLOC FHFT03F001) D/U*>
30 ALLOC FKFT05F001) DA<»)
40 ALLOC FKFT06FOC1) DA(*>
50 CALL 'SLALQ01.INVEST.LOAD(LANDF)'
00
-------
TABLE G-4. EXAMPLE RESULTS ILLUSTRATING INTERACTIVE LANDFILL MODEL OUTPUT
TENNESSEE VALLEY AUTHORITY
LANDFILL COMPUTERIZED DESIGN-COST ESTIMATE MODEL
REVISION DATE APRIL It. I<>fl3
ALL UNIT COSTS MUST BE IN OPERATIONAL YEAR DOLLARS,
THOSE LISTED 19B5! INDEX ONLY APPLIES TO EQUIPMENT. IF
SPECIFIED, OVERTIME DOLLARS ARE INCLUDED IN LAPOR COSTS
<1> ENTER OVERTIME FLAG AND <<«TE.
IF UNKNOWN USE 1,1.5
<2) ENTER COST OF LAND AND MATERIAL AND LABOP INDEXES FOR DESIRED YEAR
IF UNKNOWN USE 6000. 366.B, 292.2
(31 ENTER ECONOMIC PREMISES FLAG
<*) ENTER OVERHEAD AND PERCENTAGES ENGIN, ARC TEC, FLDEXP,FEES,CONT,START,AND CONINT
IF UNKNOWN ENTER 2, 1, 8, 5, 20, 0, 15.6
O
^Q (5) ENTER TAX AND FREIGHT FLAG AND RATES AS A PERCENTAGE
IF UNKNOWN ENTER 1, *, 3.5
(6> ENTER NET ACCUMULATION OF COMPACTED SLUDGE IN YD3/HR AND TOTAL EQUIV. LANDFILL LIFE IN HOURS
FIRST YEAR OPERATING, AND DISTANCE TO SITE,STORM INCHES,
IF UNKNOWN USE 36.1, IfSOOO, 5500, 5280, «
17) ENTER CAP SLOPE IN DEGREES, LIFT HEIGHT AND OFFSET WIDTH IN FEET
IF UNKNOWN USE 6, 20, 10
(B> ENTER DISCHARGE AND COMPACT DENSITY IN LBS/FT3.
IF UNKNOWN USE 75 ,95 FDR OXIDIXED SLUDGE
<9» ENTER 1 IF CLAY LINING DESIRED; ENTER 2 Ic SYNTHETIC LINING DESIRED; OR 3 FOR NO LINING
<10A) ENTER CLAY LINING DEPTH IN INCHES AND UNIT COSTS IN DOLLARS PER CUBIC YARD
IF UNKNOWN USE 12.0, 6.72
(11) ENTER DRAIN INVESTMENT R INCH, ENTER MATERIAL AND LABOR COSTS MONITOR WFLLS $, PECLAIMATION COST t/ACPE :
IF UNKNOWN USE : 5*00, 5550, 3385
(15) ENTER LABOR IN t/HR AND FUEL IN S/GALLON ,R EC AP IN J/YD3 CLAY AND S/YD2 SYNTHETIC M*L
IF UNKNOWN USE 26.20, 1.75, 6.72, 5.25
(Continued)
-------
TABLE G-4. (Continued)
LANDFILL DESIGN
LANDFILL DIMENSIONS
O
HEIGHT OF LANDFILL
HEIGHT OF LANDFILL CAP
SLOPE OF LANDFILL CAP
LENGTH OF LANDFILL DISPOSAL SIDE
LENGTH OF LANDFILL TRENCH
LENGTH OF PERIMETER FENCE
SURFACE AREA OF LANDFILL
FILL AREA LAND EXPOSED TO RAIN
SURFACE AREA OF RECLAIM STORAGE
DISPOSAL LAND AREA OF LANDFILL
LAND AREA OF LANDFILL SITE
LAND AREA OF LANDFILL SITE
VOLUME OF EXCAVATION
VOLUME OF RECLAIM STORAGE
VOLUME OF SLUDGE TO BE
DISPOSED OVER LIFE OF PLANT
DENSITY OF DISCHARGE CAKE
DENSITY OF COMPACTED CAKE
DEPTH OF CATCHMENT POND
LENGTH OF CATCHMENT POND
VOLUME OF CATCHMENT POSD
112.28
92.28
6.
1856.
7570.
9658.
3496.
3671.
520.
3445.
4931.
113.
FT
FT
DEGREES
FT
FT
FT
THOUSAND
THOUSAND
THOUSAND
THOUSAND
THOUSAND
ACRES
FT2
FT2
FT2
FT2
FT2
301. THOUSAND YD3
300. THOUSAND YD3
5957. THOUSAND Y03
3692. ACRE FT
75.00 L8S/FT3
95.00 LBS/FT3
24.44 FT
373.36 FT
96. THOUSAND YD3
(Continued)
-------
TABLE G-4. (Continued)
LANDFILL COSTS (THOUSANDS OF DOLLARS)
LANDFILL EQUIPMENT
TAX AND FREIGHT
LANDFILL EQUIPMENT TOTAL
CLEARING LAND
EXCAVATION
DISCHARGE TRENCH
GRAVEL
LININGt 12. IN. CLAY)
DRAINAGE LANDFILL
SEEDING LANDFILL SITE
ROAD CONSTRUCTION
PERIMETER COSTS. FENCE
RECLAMATION EXPENSE
RECLAMATION CLAY COVER
MONITOR WELLS
SUBTOTAL DIRECT
TAX AND FREIGHT
LABOR
250.
596.
25.
55.
956.
10.
90.
81.
66.
281 .
450.
6.
2866.
MATERIAL
66.
102.
53.
47.
74.
5.
348.
26.
1 190.
97.
1277.
TOTAL
250.
596.
25.
122.
956.
113.
143.
128.
140.
281.
450.
11.
3214.
26.
TOTAL DIRECT LANDFILL INVESTMENT
2866.
374.
3241.
ENGINEERING DESIGN AND SUPERVISION < 2.0 )
ARCHITECT AND ENGINEERING CONTRACTOR* 1.0 )
CONSTRUCTION EXPENSES ( 8.0 )
CONTRACTOR FEES ( 5.0 )
CONTINGENCY (20.0 )
65.
32.
259.
162.
1 007.
TOTAL FIXED INVESTMENT
LAND COST
REVENUE QUANTITIES
6043.
679.
LANDFILL LABOR
DIESEL FUEL
ELECTRICITY
HATER
ANALYSIS
29120.
103600.
145202.
3867.
42.
MAN-HRS
GALLONS
KWH
K-GALLONS
MAN-HRS
(Continued)
-------
TABLE G-4. (Continued)
LANDFILL EQUIPMENT
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
I
t—'
N3
TRUCKS
WHEEL LOADER
TRACK-DOZER
COMPACTOR
WHEEL LOADER
WATER TRUCK
SERVICE TRUCK
TRAILER
lf.0 CU YD,1 SPARE
7.0 CU VDS-BUCKET
1?3. HP, STRAIGHT-BLADE
SHEEP-F03T
3.5 CU YDS BUCKET
CLEANUP
1500 GALLON TANK AND
SPRAY HEADERS
WRECKER RIG. TOOLS
12 FT X 30 FT, OFFICE
RPEAKROOM- FACILITIES
3
1
1
1
1
1
1
1
WATER TREATMENT PUPPS, TANKS
SYSTEM
152435.
385265.
15*13*.
195801.
1 38*23.
37990.
51661.
10917.
32867.
0.
0.
0.
0.
0.
0.
0.
1130.
25952.
EQUIPMENT TOTAL
1162*89.
270S2.
(16) ENTER 1 TO CONTINUE , 0 TO STOP
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TECHNICAL REPORT DATA
(Please read fuitnie lions on the reverse before completing)
1 REPORT NO.
EPA-600/8-85-006
2.
4. TITLE AND SUBTITLE
Shawnee Flue Gas Desulfurization Computer Model
Users Manual
3. RECIPIENT'S ACCESSION NO.
5.,
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
F. A. Sudhoff and R. L. Torstrick
8. PERFORMING ORGANIZATION REPORT NO
9. PERFORMING ORGANIZATION NAME AND ADDRESS
10. PROGRAM ELEMENT NO.
TVA, Office of Power
Division of Energy Demonstrations and Technology
Muscle Shoals, Alabama 35660
11. CONTRACT/GRANT NO.
EPA IAG-79-D-X0511
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
ERIOD COVERED
14. SPONSORING AGENCY CODE
EPA/600/13
,5.SUPPLEMENTARY NOTES AEERL project officer is J. David Mobley, Mail Drop 61, 919/
541-2612.
16. ABSTRACT
The manual describes a Shawnee flue gas desulfurization (FGD) computer
model and gives detailed instructions for its use. The model, jointly developed by
Bechtel National, Inc. and TVA (in conjunction with the EPA-sponsored Shawnee
test program), is capable of projecting preliminary design and economics for lime-
and limestone-scrubbing FGD systems, including spray tower, turbulent contact ab-
sorber (TCA), and venturi/spray-tower scrubbing options. It may be used to project
the effect on system design and economics of variations in required SO2 removal,
scrubber operating parameters (gas velocity, liquid/gas ratio, alkali stoichiometry,
and liquor holdtime in slurry recirculation tanks), reheat temperature, and scrub-
ber bypass. It may also be used to evaluate alternative waste disposal methods or
additives (MgO or adipic acid) on costs for the selected process. Although the model
is not intended to project the economics of an individual system to a high degree of
accuracy, it allows prospective users to quickly project comparative design and
costs for limestone and lime case variations on a common design and cost basis. The
manual describes and explains the user-supplied input data which are required (e.g. ,
boiler size, coal characteristics, and SO2 removal requirements). Outputs include
a material balance, equipment list, and capital investment/annual revenue needs.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Pollution Scrubbers
Vlathematical Models
Flue Gases Calcium Oxides
Desulfurization Limestone
Design Waste Disposal
conomics
b.IDENTIFIERS/OPEN ENDED TERMS
Pollution Control
Stationary Sources
c. COSATI 1 leld/Croup
13B 131
12 A
21B 07B
07A.07D 08G
14G
05C
3. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (This Report)
Unclassified
•1. NO. Ol
273
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
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