EPA-R2-73-148a
January 1973 Environmental Protection Technology Series
A Process Cost Estimate
for Limestone Slurry Scrubbing
of Flue Gas
Part I
Office of Research and Monitoring
U.S. Environmental Protection Agency
Washington, D.C. 20460
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EPA-R2-73-148a
A Process Cost Estimate
for Limestone Slurry Scrubbing
of Flue Gas
Part I
by
E. L. Calvin
Catalytic, Inc.
1515 Mockingbird Lane
Charlotte, N. C. 28209
Contract No. 68-02-0241
Task No. 11
Program Element No. 1A2013
Project Officer: J. S. McSorley
Control Systems Laboratory
National Environmental Research Center
Research Triangle Park, North Carolina 27711
Prepared for
OFFICE OF RESEARCH AND MONITORING
U.S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D. C. 20460
January 1973
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ACKNOWLEDGEMENT
Valuable assistance In the preparation of this report was received
from personnel of the Tennessee Valley Authority, Office of Agricultural
and Chemical Development.
Catalytic, Inc., is sincerely grateful for this assistance.
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PART I
TABLE OF CONTENTS
Page
SUMMARY 1
FOREWORD 3
PROCESS DESCRIPTION 6
DESCRIPTION OF MECHANICAL EQUIPMENT 21
INSTRUMENTATION 33
PIPING AND VALVES 36
ELECTRICAL 38
CIVIL AND STRUCTURAL 44
ENVIRONMENTAL IMPACT 48
COST ESTIMATE 52
APPENDICES 60
Appendix 1 - Estimating Summary and Sub-Summary Sheets 61
Appendix 2 - Annual Operating Cost 75
Appendix 3 - Drawings 78
PART II
DETAILED ESTIMATE SHEETS
(Under Separate Cover)
PART III
SUPPORTING DATA
(Under Separate Cover)
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I. SUMMARY
A conceptual design and cost estimate were prepared for a wet
limestone scrubbing system for removal of sulfur dioxide (802) from
the flue gas of a 500 megawatt (raw) steam boiler plant fired with
coal that has a concentration of 3.5 per cent sulfur by weight. The
wet limestone process is based upon data developed by TVA, Office of
Agricultural and Chemical Development, Division of Chemical Develop-
ment, Process Engineering Branch. This branch has offices in Muscle
Shoals, Alabama, and a pilot plant at the Colbert Steam Plant near
Muscle Shoals.
The TVA Wet Limestone Scrubbing System removes the S02 by con-
tacting a slurry of finely pulverized limestone with the flue gas
in a turbulent contact absorption (TCA) scrubber. In the scrubber,
the S02 in the gas reacts with the limestone, producing a mixture
of unreacted limestone and gypsum (CaSO^ • 2H2°)• Before scrubbing
in the TCA scrubber, the flue gas passes through a venturi scrubber
to remove fly ash. The slurries from the two scrubbers are combined
for disposal in a settling pond.
The capital cost for the scrubbing system installed with a new
boiler plant was estimated to be $20.15 million, or an incremental
cost of $40.30 per kw of installed power. This total cost is broken
down in the following table into the total of material, labor, and
subcontracts, and the total estimated cost for each of the nine major
process areas In the plant.
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Table 1
CAPITAL COSTS (IN THOUSANDS OF DOLLARS)
Direct Cost
Indirect Cost
Total Cost
(Matl., Labor
and Subc.)
$ 217
859
5,046
1,988
390
37
4,560
232
330
681
$14,340
( Insur . , Taxes ,
Engr., Superv.,
Constr., Equip.,
Ovhd., Fee, etc.)
$ 101
345
2,078
,821
160
19
1,695
110
121
360
$5,810
(Direct
and
Indirect)
$ 318
1,204
7,124
2,809
550
56
6,255
342
451
1,041
$20,150
Group I Limestone Handling
Unit
Group II Slurry Prep. Unit
Group III Scrubbing System
Group IV Flue Gas. Disch. Unit
Group V Reheat System
Group VI Ammonia Unit
Group VII Waste Disposal
Group VIII Entrain. Separ.
Recirc.
Group IX Major Elec. Equip.
Misc. Field Direct Costs
(Temp. Constr., Supplies,
Petty Tools, Field Office
Supplies, Telephone, etc.)
TOTALS
The operating cost of the wet limestone scrubbing system was estimated
to be $7.20 million per year, or 2.06 mills per kilowatt hour of electricity
generated. This operating cost includes 11,300 kw of electricity required
to operate the scrubbing system, and the fuel for reheating the stack gas
with a total heat value of 95.2 MM Btu per hr. The power requirements
amount to 2.25 per cent of the total power generated by the boiler plant.
The fuel consumption is equal to 1.9 per cent of the total heat input to
the boiler.
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II. FOREWORD
A. Scope
This report presents the results of the conceptual design
and definitive cost estimate for a wet limestone scrubbing sys-
tem applied to a 500 mw electric generating plant. The estimate
covers all equipment from the boiler breeching to the boiler
stack. The processing areas included in the design are as fol-
lows:
(1) Limestone storage and processing.
(2) Slurry scrubbing system with stack gas reheater and
accessories.
(3) Spent limestone slurry settling system and water
recovery.
The estimate does not include the normal electrostatic pre-
cipitator associated with the boiler. Also limestone unloading
and handling systems are not included.
B. Design Basis
The wet limestone scrubbing system was designed to be part
of a new installation of a 500 mw power generating plant con-
structed for utilities use. The boilers will be fueled full
time with coal with a maximum concentration of 3.5 per cent
sulfur by weight. The detailed design of the system is based
upon pilot plant work by TVA, Office of Agricultural and Chem-
ical Development. When placed on stream, the boiler system
with wet limestone scrubbing will meet EPA standards for sulfur
dioxide (S02> emission of 1.2 pounds of S02 per million Btu heat
input.
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C. Basic Assumptions
The design of the wet limestone scrubbing system required
certain assumptions to be made to provide a basis for the de-
sign. The basic assumptions that were made are as follows:
(1) Plant location will provide land availability for
location of settling pond and limestone storage
without limitations.
(2) An adequate supply of process water and other
utilities is available from the boiler area.
(3) Facilities included with the power house for
unloading coal and transportation to storage
can be used also for unloading limestone and
transporting to the storage pile.
(4) The power plant will be built near an adequate
supply of the appropriate grade of limestone
for use in the process.
(5) The plant will be constructed in the Midwest
area where Cincinnati construction labor rates
apply.
In addition to these basic assumptions, other assumptions
were necessary and are enumerated in the sections that follow.
D. Future Developments
Pilot plant testing is still in progress, and improvements
in the process equipment will probably provide higher efficiency
and more reliability in future designs. The first improvement
that will contribute to increased reliability is modification
of the S02 scrubber which now requires excessive maintenance
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because of frequent plugging. A second area where improvements
will be made is in the design of the entrainment separator and
the ductwork connecting it to the S02 scrubber. This equipment
has been a source of plugging problems in the past.
The part of the design that needs the most basic develop-
ment is the spent slurry handling and disposal system. Although
the system Included in the design will function adequately to
dispose of the waste slurry, a large amount of land is needed
for the slurry disposal pond, and the life of the pond is short.
Also, construction cost of this portion of the plant is a sig-
nificant part of the total cost.
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III. PROCESS DESCRIPTION
A. General Process Information
The design of this wet limestone scrubbing process for SC>2
removal from flue gas was based primarily upon design data from
the TVA, Office of Agricultural and Chemical Development, with
modifications suggested by TVA and EPA to incorporate improve-
ments indicated by pilot plant operation.
The process is a scrubbing system of four parallel trains,
each with a capacity equivalent to 125 mw. Each train consists
of a venturi scrubber, turbulent contact absorption (TCA) scrub-
ber, horizontal entrainment separator, and a flue gas reheater
in series. The scrubbers are fed with a limestone slurry.
The limiting size of existing equipment requires four trains
for a 500 mw boiler plant. Each train is controlled separately.
The flow of flue gas divides equally to the four trains and
passes through the venturi scrubber. In this unit, participates
(fly ash) are removed by contact with the limestone slurry. The
gas then passes through the TCA scrubber where the S02 is ab-
sorbed in the limestone slurry and reacts to form calcium sul-
fite and calcium sulfate. The gas then passes through an en-
trainment separator to remove entrained slurry before being re-
heated in a direct-fired gas heater. The gas is re-heated to
give it sufficient buoyancy for proper stack operation. An in-
duced draft fan overcomes the pressure losses incurred in passing
the gas through the system.
Limestone for slurry production is transferred from a stock-
pile with a 30-day supply to a silo containing a one-day supply
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from which it is fed at a controlled rate into the recirculating
scrubber stream. Overflow from the scrubber system is pumped to
a settling pond where the solids settle out producing a clear
overflow that is recycled back to the system.
B. Venturi Scrubber
Approximately 385,000 actual cfm of gas enters each venturi
scrubber where it is quenched with water and accelerated to a
velocity of 75-125 ft per sec. The water Is atomized. A fine
dispersion of slower moving water droplets is produced, that
captures (by impaction) the particles contained in the gas.
The wetted particles decelerate after passing through the ven-
turi throat and grow as a result of agglomeration and condensa-
tion. The wetted particles are discharged in slurry form into
the sump, and only a small fraction is carried over and col-
lected in the TCA scrubber.
Efficiency of the venturi scrubber is directly related to
operating pressure drop. At the specified pressure drop, the
scrubber is conservatively rated at five grams per standard
cubic foot maximum loading. The pressure drop is controlled
automatically to nine inches water column (W.C.) by varying
the throat diameter. Satisfactory operation can be attained
as low as five inches W.C.
Slurry is reclrculated from a collection tank, with small
retention time, to the venturi at a minimum liquid-gas (L/G)
ratio of 18 gal per 1,000 standard cubic feet per minute. The
discharge opening from the scrubber is large to prevent plugging.
The gas flow varies with boiler load. The recirculating
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liquid flow is held relatively constant; therefore, the L/G
ratio will increase at low gas flow rates. This variation
does not affect the operation adversely. The venturi scrub-
ber slurry is obtained by overflow from the TCA scrubber,
and the concentration is not controlled, so it will depend
on the TCA slurry solids content, participates removed by
the venturi, and the water evaporated in the venturi. The
concentration should be 20 per cent maximum solids at de-
sign conditions and full load.
The slurry in the recirculation tank requires a small
agitator with a 10 hp drive motor to prevent settling. If
left unagitated for several hours, the solids will pack hard and
be very difficult to remove.
The temperature of the entire scrubbing system, including
recirculating water, is determined by the adiabatic satura-
tion temperature of the inlet gas, which is 127F for 300F gas.
Fresh make-up water to the system will cool this to as low as
114F. An automatic temperature-actuated emergency cooling
water system will feed 750 gpm of process water to the tower
in case of recirculating pump failure. This will prevent
heat damage to the scrubber coating. In the venturi scrubber,
the dry flue gas carrying dry particulate matter first comes
in contact with the slurry, producing a point where plugging
may occur. Frequent cleaning of the venturi scrubber may
be required.
C. TCA Scrubber
The turbulent contact absorption (TCA) scrubber is a floating
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bed type, where the gas flows at ten ft per sec upward through
a bed of hollow plastic balls, causing them to move violently
in random fashion. The bed is about eight to ten inches in
static depth and requires about three inches W.C. to fluidize
each of two stages. The limestone slurry is fed into the top
of the scrubber and flows down through the floating beds. The
S02 transfers into the liquid and reacts with the limestone as
indicated by the following equations:
S02 +(© «=5t H+ + HS03~ (1) -
C02 +(H|fr a=* H+ + HC03~ (2)
CaC03 + HC03~ + H+ 2=. Ca(HC03)2 (3)
Ca(HC03)2 + HS03" + rf~ *- CaS03 + 2H2C03 (4)
CaS03 + *s02 —» CaS04 (5)
CaS03 + *s»20 —*• CaS03 • *sH20 (6)
CaSO^ + 2H20 —*> CaS04 • 2H20 (7)
Approximately ten per cent of the calcium sulfite is oxidized to
calcium sulfate.
The slurry rate is roughly controlled for a minimum L/G ratio
of about 40 gpm per 100 standard cubic feet per minute. Higher liq-
uid flow rates or higher gas velocities can result in a sharp in-
crease in pressure drop until "flooding" is reached. At this point,
the gas upflow will reduce the liquid downflow, causing liquid hold-
up in the scrubbers. The pressure drop will climb steeply, surging
will take place, and the scrubber will become inoperable.
The diffused mobile packing utilized in the TCA scrubber allows
high liquor and gas flow rates to be used without excessive pres-
sure drops.
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Slurry from the scrubber flows into a sump and then into a
reclrculation tank. Limestone flow to the tank is proportioned
by the flow rate of gas through the scrubber train. The set
point of a ratio controller is set manually to accommodate
changes in coal sulfur content, stoichiometric limestone/802
ratio, and limestone feed slurry solids concentration.
The process is designed for 150 per cent of the stoichio-
metric rate of limestone required to react with 100 per cent
of the S02 from 3.5 per cent sulfur coal with 100 per cent con-
version of sulfur to S02« The system is expected to remove at
least 80 per cent of the S02 in the combustion gas, and virtual-
ly 100 per cent of the particulates.
The solids concentration of the recirculating slurry is
automatically controlled to ten per cent solids by adding water
to the recirculation tank.
A problem occurs in pH control of the TCA system when the
pH drops below the operating range of 5.8 to 6.2. At a pH of
approximately 5.4, the limestone becomes unreactive and is in-
capable of raising the pH. At this point, the pH continues to
drop sharply. To counteract this problem, an emergency pH con-
trol system and an emergency discharge provision have been in-
cluded. At a pH of 5.6, liquid ammonia is automatically injected
at a stoichiometric rate of 50 per cent by weight required to re-
act with 100 per cent of the S02 in the gas. After ammonia is
injected, the pH is monitored manually to determine if pH control
has been restored within the expected adjustment period of 15
minutes. If control is not restored, the TCA recirculation tank
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can be discharged manually. The system Is designed to discharge
and refill completely one tank with limestone slurry and process
water in 30 minutes. There is enough slurry in the limestone
slurry holding tank to refill completely 24 individual tanks at
the proper concentration. Complete replacement of the slurry
should not be required frequently since the ammonia system will
maintain the pH above the critical value.
The recirculation tank is equipped with a small agitator
powered by a 15 hp motor. If left unagitated several hours,
the solids will settle and pack hard and be very difficult to
break up and remove.
The TCA scrubber is a high maintenance item, subject to
scaling and plugging. The polypropylene balls composing the
beds have roughly a 1,000 hour operating life. Spray nozzles
wear out rapidly, and their use is not recommended.
Due to rapid plugging of other types of demisters, a hori-
zontal two-stage entrainment separator is required to remove
carry-over from the TCA scrubber. The entrainment separator
includes two chevron fin-type demisters with five gal per min
per sq ft of recirculated wash water.
Fresh water with low solids content is needed in the second
stage so all process make-up water is introduced at the bottom
of the tank, near the outlet to the first stage pumps. Make-up
flow is 1,400 gpm, which is about ten per cent of the recircu-
lation flow at full operation. Only a minute quantity of TCA
slurry is carried through the entrainment separator. When the
stack gas is reheated, it contains about 0.06 grams per standard
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cubic feet of solids, none of which is fly ash.
D. Combustion Gas Reheater
A reduction in stack gas temperature by wet scrubbing will
reduce both the momentum and buoyancy of the stack gas, reducing
the distance the plume will rise above the stack after it is
emitted. Thus, the effective stack height and plume dispersion
will be reduced by wet scrubbing. Humidification of the stack
gas is also objectionable because condensation may cause forma-
tion of a visible plume giving the appearance of undesirable
emissions.
Gas-metal contact heat exchangers that use flue gas or steam
are subject to plugging. Therefore, a direct-fired reheater is
used to reheat the flue gas for proper operation of the stack.
Reheat also reduces the relative humidity of the gas and elim-
inates possibility of a visible plume. Present and future avail-
ability of natural gas is questionable, so low sulfur No. 2 fuel
oil is specified in this process. If this fuel is in short
supply in the future, desulfurized residual oil can be used.
Oil is fed at controlled pressure from a 700,000-gallon fuel
tank (30-day supply) to each of the four trains. The oil flow
to each reheater is controlled by the exit gas temperature from
the train. The process is designed to reheat the gas to 200F,
although lower temperatures may be used, depending upon stack
and fan design.
E. Scrubbing System Draft
The scrubbing system is controlled to provide equal flow
through each of the parallel trains. -This is accomplished by
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a damper controlling the pressure differential across each fan.
The damper is actuated by a controller with its set point pro-
vided by a controller sensing the total pressure drop through
the scrubber system. This results in a constant pressure drop
across the system and equal flow through each train, while in-
dividual scrubber resistances may vary due to plugging.
The system is designed to handle the following pressure
drops in the scrubbing system:
(1) Venturi scrubber 9 inches W.C.
(2) TCA scrubber 6 inches W.C.
(3) Entrainment separator 1 inch W.C.
(A) Plugging allowance, 2 inches W.C.
Maximum
Total 18 inches W.C.
When the pressure drop across one scrubber train rises to
two inches W.C above normal, the control damper will be com-
pletely open, indicating that particular train needs cleaning.
This may occur from once per week to once per month in each
train in normal operation.
Bypass dampers are included that will permit operation
at full load when a train is removed from service.
F. Limestone Unloading and Handling
Crushed limestone smaller than 3/4-inch size will be de-
livered to the plant by boat or train in the same manner as
the coal supply. The limestone will be unloaded with the same
equipment used for coal.
Limestone is stored in a stockpile containing a 30-day
supply or 23,000 tons. This pile will occupy a space about
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160 ft in diameter and will be about 80 ft high. A conveyor
will transport the limestone from the stockpile to a storage
silo containing 770 tons or a one-day supply. This silo can
be filled by the conveyor in four hours. A front-end loader
will be used to feed the limestone into the conveyor hopper,
permitting the complete stockpile to be used.
From the silo, the limestone is fed to three tube mills
at a controlled rate through weigh-belt feeders. The feed
flow is recorded and totalized for inventory control.
G. Limestone Grinding
The limestone is ground by three tube mills (one spare).
Each one measures 7 ft diameter by 21 ft long. The tube mills
are arranged for once-through operation with no classification
and recycle. A screen is installed on the mill outlet to pre-
vent discharge of oversized product.
Manual control of the water added to the tube mills is
adequate to produce a slurry within specifications because
the grinding operation is at a constant rate.
An alarm signal from the level controller on the limestone
slurry holding tank signals for either one, two, or three tube
mills to be In operation if the tank is 90, 80, or 70 per cent
full, respectively. The mills are then put on stream by the
operator. When the tank is 95 per cent full, the level con-
troller automatically shuts down the mills that are running.
The tube mill control strategy requires the operator to
put the tube mills on stream and set the feed water flow, as
indicated by a rotameter, to give a product with correct
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solids content at the discharge sample point. The limestone
feed rate is adjusted to produce a discharge particle distri-
bution of 70 per cent minus 200 mesh. This size mill should
grind 16 tons per hour to the required size, but grindability
of the limestone could cause a variation of 30 per cent, re-
ducing the capacity of the mill to 11 to 12 tons per hour with
a product size of 70 per cent minus 200 mesh.
If grinding capacity is critical, it will be necessary to
run grindability tests on the limestone before purchase.
H. Limestone Slurry Transfer and Storage
Limestone slurry from the grinding system is discharged
into a surge tank at 60 per cent solids. This concentration
has been chosen because it provides good handling properties
and will not settle out easily. Slurry of this concentration
has been reported to remain suspended in an unagitated tank
for several days without settling, while a 10 to 20 per cent
solids slurry will settle in a few hours.
From the surge tank, the slurry is transferred to a lime-
stone slurry holding tank that provides a one-day supply
(150,000 gallons). Since the surge and holding tanks may be
located some distance apart, a water flush system is included
to wash limestone out of the transfer line, if it is expected
to be idle for long periods of time.
The slurry is pumped to each scrubbing train, at controlled
pressure, where it is fed through a flow controller to each TCA
recirculation tank.
Quick refill of the TCA recirculation tank is accomplished
by using the spare pump and a separate six-inch emergency fill
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line. One tank can be filled in about ten minutes.
I. Solids Handling and Disposal
Slurry overflow from the scrubbing trains is gravity fed
to a surge tank and pumped to the settling pond.
The solids contained in this slurry are generally difficult
to settle out, concentrating only to about 40 per cent solids.
Because of the low compaction of the settled solids, a 250-acre
lake, 50 ft deep, is required for a 19-year operating period.
When dry, the solids produced by this process have a low bulk
density and remain fluid even after stacking for long periods
of time. These characteristics make cleaning of the pond and
long-term handling difficult. The poor settling characteristics
result from the flake-like shape of the CaSO^ • 2H20 crystal.
If any alternatives for quick settling and periodic disposal of
the solids are explored, the settling properties must be care-
fully considered. A settling rate of 0.04 ton per sq ft per
day was assumed to design the settling pond. On this basis,
a 0.8-acre settling area is required. The assumed settling
rate may be high, and a larger settling area may be necessary.
J. Process Water
Process water feed to the system includes about 1,200 gpm
pond overflow and 400 gpm raw make-up water totaling 1,600 gpm
of process water required. In addition, the system must be
capable of delivering 6,000 gpm emergency fill water; therefore,
a 3,000 gpm emergency water pump is supplied in addition to a
spare 1,600 gpm process water pump.
The 4,500 gpm of water required for emergency filling, in
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addition to normal process water flow, will be obtained prefer-
ably, from the pond overflow. An alternate source for emergency
fill water could be the raw water make-up system that must have
sufficient capacity to provide the total demand of 6,000 gpm.
The source and supply will vary, depending on the particular
layout of the facilities and the nature of the raw water system
available.
The design data for this pond system provided for raw make-
up water from an outside source. Water requirements were based
on typical rainfall of 50 in. per yr, evaporation loss of 25 in.
per yr, seepage of 12.4 in. per year, and only the lake area was
considered to catch the rainfall. However, if the pond is self-
sealing or has a drainage area greater than the pond area, a
net yearly overflow may be encountered. Consideration must be
given to proper handling and disposal of this overflow and will
be discussed in Section IX, Environmental Impact.
K. Reliability, Control, and Operation
Reliability and ease of operation are paramount in power
plant operation because of the critical service provided.
Therefore, the system includes a large amount of spare equipment.
Spare equipment includes complete spare tube mill wet grinder,
spare pumps on every vital flow, and bypasses around all criti-
cal control valves. An entire spare scrubbing train has been
suggested by some power plant operators, although the extra cost
involved is fully recognized.
In order to continue operating for reasonable lengths of time
when supply problems such as strikes and other disruptions are
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encountered, storage for a 30-day supply is provided for fuel
oil, limestone, and ammonia. In addition, to permit continued
operation during plant disruptions, a one-day supply of limestone
grinder feed and limestone slurry is provided. Normally, it is
expected that only one train will break down at a time, enabling
the plant to operate at a 75 per cent load while maintaining
emissions within specifications.
The control systems included in this design were selected
on the basis of providing a moderate degree of instrumentation.
Any individual operator may prefer either more or less controls.
The system is designed to be operated from a control room
with one limestone area operator and one scrubbing area operator.
All train start-up and shutdown operations are manual, but
once the system is on stream, it should run automatically, re-
sponding to varying boiler load. The scrubbing system can be
expected to operate satisfactorily down to half scrubber load
and possibly less, so the boiler load may be greatly reduced
without shutting down individual trains. However, it would be
advisable to operate with as few trains as possible to keep the
scrubbers at, or near, full capacity, since they are more ef-
ficient and easier to control at high flow rates. A prolonged
reduction in boiler load would warrant taking one or more of
the scrubber trains off stream.
Start-up, shutdown, and operating procedures must be de-
veloped, but no particular difficulty in operating the plant
is foreseen.
L. Ammonia System
The ammonia system includes a 13,000-gallon tank containing
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10,000 gallons of ammonia, leaving a 3,000-gallon vapor space.
The tank pressure is controlled to 100 psig by regulating steam
to a heating coil. This is sufficient pressure to force liquid
anmonia to the scrubbing system at a maximum rate of 6,600 Ib per
hr (1,650 Ib per hr each train). This is 50 per cent of the
stoichiometric rate to react with 100 per cent of the S02 in the
gas.
The system is required to operate immediately at full rate
after remaining idle for long periods of time, so the tank heater
has a large steam capacity to compensate for sudden pressure
losses. The control system will be adjusted to reduce the steam
supply gradually after a period of use to prevent control over-
shoot. A pressure relief valve is installed on the tank to re-
lieve over pressure if the control system malfunctions.
There is enough ammonia storage for about thirty 15-minute
adjustments for each train, or a 30-day supply. The tank volume
is based on one adjustment per day to all four tanks (four ad-
justments per day to one tank). This should be a conservative
estimate of a«nonla usage.
M. Slurry Handling
Properties of the limestone slurry used in this system re-
quire special materials and design in the equipment to prevent
settling and erosion.
Settling is not a large problem with slurry containing 60 per
cent solids. Several days may be required for the solids to
settle. At lower concentrations, 10 to 30 per cent solids, the
solids settle out in a few hours, pack hard, and are very
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difficult to remove, requiring a large amount of maintenance
time.
Since this is a very abrasive slurry and the pH can drop
to three or four, rubber lined pipes are specified for all
slurry process and transfer lines, recirculation tanks, and
pumps. Straight transfer lines may give satisfactory service
without the coating, but coated lines are specified to ensure
adequate protection.
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IV. DESCRIPTION OF MECHANICAL EQUIPMENT
A. General - Mechanical
Specifications and data sheets for the major mechanical equip-
ment have been developed for the limestone slurry system. The
items are outlined below and form the basis for the cost estimate.
Reference numbers, such as "D-100" are equipment numbers as shown
on the drawings in the appendix. All equipment will meet Occupa-
tional Safety and Health Act (OSHA) requirements.
B. Limestone Storage - Area I
1. Stockpile Feeder (D-100) and Limestone Silo Conveyor (D-101)
This equipment comprises the limestone conveyor system.
The stockpile feeder will be the mechanical vibrating type
complete with a hopper and a manually adjustable hopper plow.
The conveyor unit will be a 24-inch belt, 260 feet long with
a vertical lift of 80 feet, complete with supporting frame-
work and a head discharge chute. The system will be designed
to handle 200 tons per hr of crushed limestone.
2. Limestone Storage Silo (V-103)
This unit is to be of carbon steel construction designed
for atmospheric pressure and temperature. The silo will have
a volume of 20,000 cu ft and will be complete with required
ladders, safety cages, guard rails, and nozzles. All material
will meet American Society for Testing Materials (ASTM) re-
quirements.
C. Slurry Preparation - Area II
1. Limestone Slurry Hold Tank (V-105) and Agitator (A-102)
The limestone slurry hold tank will be a 30 ft diameter
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by 30 ft high, rubber-lined carbon steel vessel. The tank
will be equipped with a top entering agitator to maintain
solids suspension. All material will meet ASTM requirements.
2. Limestone Slurry Feed Pump and Drive (P-103 A and B)
The limestone slurry feed pump requirements are:
Delivery: 350 gpm
Head: 50 ft
Liquid: Limestone slurry (60 per cent
solids)
Pumping Temperature: 80F
Special: All wetted parts to be rubber-
lined or equal
Type: Centrifugal
Location: Outside
3. Limestone Weigh Feeder (D-102 A to C)
Three weigh feeders will be installed under the limestone
storage silo to weigh, control, and convey the crushed lime-
stone to the ball mills.
Each feeder will include the following features:
(a) Variable speed drive.
(b) Continuous operation with a range of 20,000 to
44,000 Ib per hr (accuracy ± one per cent).
(c) Feeder will be complete with a hopper, skirt, and
a regulating gate.
4. Tube Mill Wet Grinder (F-100 A to C)
The wet grinding tube mill system will consist of three
steel ball mills suitable for open circuit grinding of
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limestone. Each mill will be capable of continuous flow of
32,000 Ib per hr of limestone solids, in a slurry with water,/
(60 per cent solids concentration, total flow rate 54,000 Ib
per hr). The mill will grind the 3/4-in. diameter'iimestone
chunks to a product size of 70 per cent concentration of minus
ZOO mesh limestone powder.
5. Limestone Slurry Transfer Pump and Drive (P-102 A and B)
The limestone slurry transfer pump requirements are:
Delivery: 129 gpm
Head: 100 ft
Liquid: Limestone slurry (60 per cent
solids)
Pumping Temperature: 80F
Special: All wetted parts to be rubber-
lined or equal
Type: Centrifugal
Location: Outside
6. Tube Mill Surge Tank (V-104)
The surge tank will be a 4 ft diameter by 4 ft high, car-
bon steel (coal tar epoxy coated) vessel. The tank will be
open top. Material will meet ASTM requirements.
D. Scrubbing System - Area III
1. Venturi Reclrculation Tank (V-100 A to D) and
Agitator (A-100 A to D)
The venturi recirculation tanks will be 20 ft diameter by
IS ft high, constructed of carbon steel (rubber-lined). Each
tank will be equipped with a top entering agitator to maintain
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solids suspension. All material is to meet ASTM requirements.
2. TCA Recirculation Tank (.V-101 A to D) and
Agitator (A-101 A to D)
The TCA recirculation tanks will be 20 ft diameter by 26
ft high, constructed of carbon steel (rubber-lined). Each
tank will be equipped with a top entering agitator to maintain
solids suspension. All material will meet ASTM requirements.
3. Venturi Scrubber (L-100 A to D)
The scrubber will be the venturi type equipped with an
automatically adjustable throat to maintain high particulate
removal efficiency at variable gas flow rates. The scrubber
is designed to operate under the following conditions:
(a) Characteristics of the inlet gas and slurry:
Inlet gas volume (standard cubic
feet per minute) ,249,000
Inlet gas temperature (F) 300
Inlet dust loading (grains per cu ft) 5.56
Inlet slurry temperature (F) 127
Inlet slurry rate (gpm) 4,589
(b) Characteristics of the outlet gas:
Gas outlet volume (standard cubic
feet per minute) 263,000
Gas outlet temperature (F) 127
Unit total pressure drop (inches W.C.) 9
(c) Guaranteed removal efficiency:
Up to 5.0 grams per standard cubic foot per minute in,
and 0.021 grams per standard cubic foot per minute
maximum out
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The unit will be constructed from carbon steel with Pla-
site 7122 (a plastic coating) and two-Inch Kaocrete (a cast-
able refractory) lining.
4. TCA Scrubber (L-101 A to D)
The scrubber will be the floating-bed type with two active
stages and an empty stage between the active stages. The scrub-
ber Is designed to handle the following conditions:
(a) Characteristics of the inlet gas and slurry:
Inlet gas volume (standard cubic
feet per minute) 263,000
Inlet gas temperature (F) - • -" 127
Inlet dust loading (grams per cu ft) 0.021
Inlet slurry temperature (F) 127
Inlet slurry rate (gpm) 10,500
(b) Characteristics of the outlet gas:
Gas outlet volume (standard cubic
feet per minute) 263,000
Gas outlet temperature (F) 127
Unit total pressure drop (inches W.C.) 6
(c) Guaranteed removal efficiency:
83 per cent S02 removal using 3.5 per cent sulfur
coal
The scrubber construction will be of rubber-lined Corten
steel.
5. Horizontal Two-Stage Entrainment Separator (L-102 A to D)
The function of this unit is to eliminate any entralnment
carry-over from the scrubber before the gas is reheated and
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exhausted to the atmosphere. The separator is designed for a
gas flow of eight ft per sec at a gas rate of 263,000 standard
cubic feet per minute at 125F. The complete unit will include
a casing (housing), built-in collecting tank, spray nozzles,
baffles, chevron type eliminator blades with supports and
mounting assembly, and all internal piping.
6. Venturi Recirculation Pump and Drive (P-100 A to L)
The venturi recirculation pump requirements are:
Delivery: 2,590 gpm
Head: 90 ft
Liquid: Limestone slurry
Pumping Temperature: 127F
Special:, All wetted parts to be rubber-
lined or equal
Type: Centrifugal
Location: Outside
7. TCA Recirculation Pump and Drive (P-101 A to L)
The TCA recirculation pump requirements are:
Delivery: 5,550 gpm
Head: 85 ft
Liquid: Limestone slurry
Pumping Temperature: 127F
Special: All wetted parts to be rubber-
lined or equal
Type: Centrifugal
Location: Outside
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8. Scrubber Sump (V-102 A to D)
This vessel is to be of Corten (rust resistant) steel con-
struction with polyester coating, such as Flakeline 103, and
two-inch castable refractory lining, such as Kaocrete. The
vessel design will be dictated by the scrubber design of the
manufacturer. The basic design includes one large sump (30 ft
by 30 ft) with two bottom outlets. The scrubbers will be
mounted on top of the sump.
E. Induced Draft Fan System - Area IV
!• Bppster Fan Retrofit (C-100 A to D)
This fan will be installed in the retrofit plant. The
booster fan will be the double inlet centrifugal type rated
at 360,000 cfm (19 in. W.C.). Accessories will include:
flanged inlet and outlet connections, wear strip, split hous-
ing, access door, dampers or vanes, and drain 'connection.
Fans will conform with standards established by Air Movement
Control Association (AMCA).
2. Boiler Induced Draft Fan. New Plant (C-101 A to D)
This fan will be incorporated in the equipment design
layout for a new plant. The boiler induced draft fan will
be the double inlet centrifugal type rated at 360,000 cfm
/
(32 in. W.C.). Accessories will include: flanged inlet
and outlet connections, wear strip, split housing, access
door, dampers or vanes, and drain connection. Fans will con-
form with standards established by Air Movement Control Assoc-
iation (AMCA).
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3. Venturi Damper (G-100 A to D) and Bypass Secondary
Damper (G-103 A to D)
The venturi and bypass secondary dampers will be used
for "shutoff" service and will be the parallel-blade multi-
louver type. Each damper will be pneumatically controlled.
4. Bypass Damper (G-101 A to D)
The bypass damper will be designed for positive "shutoff"
and will be the guillotine type. Each damper will be pneu-
matically operated.
5. Fan Damper (G-102 A to D)
The fan damper will be designed for volume control and
will be the opposed-blade multi-louver type. The dampers
will be located in the discharge duct from the system fans
and will be pneumatically operated.
F. Reheat System - Area V
1. Direct-Fired Combustion Gas Reheater (B-100 A to D)
These heaters will be installed in the duct between the
fan and entrainment separator exit for the purpose of heating
the flue gas to increase the stack draft. The heaters will
be the forced draft oil burner type using No. 2 fuel oil.
Design will meet Factory Mutual, Factory Insurance Association,
and local codes.
2. Fuel Oil Pump and Drive (P-105 A and B)
The fuel oil pump requirements are:
Delivery: 16 gpm
Head: 580 ft
Liquid: No. 2 low sulfur fuel oil
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Pumping Temperature: 80F
Type: Rotary
Location: Outside
3. Fuel Oil Loading Pump and Drive (P-110)
The fuel oil loading pump requirements are:
Delivery: 330 gpm
Head: 100 ft
Liquid: No. 2 fuel oil
Pumping Temperature: 80F
Type: Centrifugal
Location: Outside
4. Fuel Oil Storage Tank (V-108)
The fuel oil storage tank will be 50 ft diameter by 50 ft
high complete with rafter supported cone roof, stairway with
local platform, and required nozzles and vents. The tank
will be constructed of carbon steel and designed for atmos-
pheric pressure. Design will meet American Petroleum Insti-
tute (API)-650 standards.
G. Ammonia Injection System - Area VI
1. Liquid Ammonia Storage Tank (V-110)
This unit will be a horizontal pressure vessel complete
with a tube bundle for heating the ammonia. The vessel will
be 22 ft long by 10 ft diameter complete with required
nozzles and safety equipment. Tank will meet American So-
ciety of Mechanical Engineers (ASME) design criteria.
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H. Waste Disposal System Area VII
1. Slurry Overflow Transfer Pump and Drive (P-104 A to C)
The slurry overflow transfer pump requirements are:
Delivery: 635 gpm
Head: 100 ft
Liquid: Limestone slurry
Pumping Temperature: 127F
Special: All wetted parts to be rubber-
lined or equal
Type: Centrifugal
Location: Outside
2. Process Water Pump and Drive (P-106 A and B)
The process water pump requirements are:
Delivery: 1,540 gpm
Head: 400 ft
Liquid Water
Pumping Temperature: 80F
Type: Centrifugal
Location: Outside
3. Scrubbing System Sump Pump and Drive (P-109)
The scrubbing system pump requirements are:
Delivery: 100 gpm
Head: 50 ft
Liquid: Slurry
Pumping Temperature: 80F
Special: Rubber-lined or equal
Type: Self-priming centrifugal
Location: Outside
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4. Process Water Surge Tank (V-106)
The tank will be a 7 ft diameter by 7 ft high, carbon
steel (coal tar epoxy coated) vessel. The tank will be
open top. Material will meet ASTM requirements.
5. Slurry Overflow Surge Tank (V-109)
The tank will be a 6 ft diameter by 6 ft high carbon
steel (coal tar epoxy coated) vessel. Material will meet
ASTM standards.
6. Emergency Process Water Pump and Drive (P-lll)
The emergency process water pump requirements are:
Delivery: 3,000 gpm
Head: 400 ft
Liquid: Water
Pumping Temperature: 80F
Type: Centrifugal
Location: Outside
I. Entrainment Separator Recifculation - Area VIII
1. First Stage Entrainment Separator Recirculating Pump and
Drive (P-107 A and B)
The first stage separator pump requirements are:
Delivery: 7,210 gpm
Head: 130 ft
Liquid: Water
Pumping Temperature: 127F
Type: Centrifugal
Location: Outside
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2. Second Stage Entralnment Separator Recirculation Pump and
Drive (P-108 A to C)
The second stage separator pump requirements are:
Delivery: 6,550 gpm
Head: 130 ft
Liquid: Water
Pumping Temperature: 127F
Type: Centrifugal
Location: Outside
3. Entrainment Separator Recirculation Tank (V-107)
The tank will be a 25 ft diameter by 25 ft high carbon
steel (coal tar epoxy coated) vessel designed for atmospheric
pressure. A baffle in the tank divides the chamber into two
equal parts. Construction materials will meet ASTM require-
ments.
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V. INSTRUMENTATION
A. General
The Instrument system for the wet limestone scrubbing process
Is designed to provide control reliability and ease similar to
that found In most modern boilers. The scrubbing system Is de-
signed for full automatic control of normal operations from the
boiler control room with sufficient controls and Indications to
permit emergency operation from this location also. Initial
start-up of the scrubbing system will be accomplished by manual-
ly starting individual components locally and transferring con-
trol to the control room. The only routine manual operation
that will be required is the start-up of the limestone ball
mills, to maintain slurry tank level at the normal point. The
limestone scrubbing control system is connected to the boiler
emergency system for automatic shutdown and by-pass of the scrub-
bing system in case of boiler emergency. The type of instruments
selected for the scrubbing system is consistent with standard
chemical process instrument practice, and the installation will
be in accordance with the standard practice for this type of
plant.
B. Reliability
The requirements of boiler operation include reliability and
safety. The wet scrubbing system is designed to match the stan-
dards applied to boilers. Since control of firebox pressure is
critical to the boiler operation, the controls for the scrubbing
system are designed to assure no interruption in the flue gas
path. Automatic control of the booster fan provides full
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compensation for pressure drop across the scrubbing system to pre-
vent back pressure to the boiler. If the fan fails or if the
scrubber system becomes plugged, a bypass valve conducts the flue
gas directly to the stack. Emission standards severely limit the
duration and quantity of participate emissions to the atmosphere.
Direct by-pass of the flue gas to the stack will be permitted only
in extreme emergencies.
C. Choice of Instrumentation Types
In the design of the wet limestone installation, it was as-
sumed that process controls will be placed in a central centreI
room associated with the boiler controls. Since the distance
between the processing system and the control room may be 300 ft
or more, electronic Instruments were selected for the design.
With electronic instrumentation, the transmission distance does
not seriously affect the operation. The use of electronic in-
struments also reduces the anticipated maintenance on the system
and provides some Improvement in the reliability of the Instrument
system.
Reliability is Improved in that the instrument calibration
remains constant over a long period of time. An additional ad-
vantage of using electronic instrumentation is the possible appli-
cation of computer control to boiler systems. Many types of elec-
tronic instruments can be procured with built-in adaptation for
computer control. This feature makes electronic instruments com-
patible with a computer controlled boiler plant.
D. Installation
Miniature indicating controllers were selected for the limestone
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scrubbing system. These Instruments are mounted on a 12 ft long
control panel situated in the central control room. Transmitters,
control valves, and transducers are connected to the control panel
by using standard instrumentation wiring methods employing shielded
twisted-pair cable run in conduit. Standard electric practice is
followed in the installation of the conduit and wiring system.
Control valves used in this system are the standard pneumatic type
actuated by current to air transducers located at the valve posi-
tion. Special large size valves and dampers are equipped with
pneumatic actuators connected to the control system by transducers.
No electric operators have been used.
All important process variables are recorded on the control
panel using miniature strip chart recorders. These recorders use
several pens with recordings grouped on each recorder in a logi-
cal manner. For the same cost, single point recorders with
selector switches for monitoring a large number of less critical
variables on a single recorder could be provided. Sufficient
process alarms have been provided on the control panel to alert
the operator to abnormal conditions in all critical systems.
These alarms terminate in a standard annunciator system.
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VI. PIPING AND VALVES
A. General
The limestone scrubbing system is required to operate between
annual boiler inspections without major maintenance. Therefore,
special provisions must be made to prevent damage to the piping
and valve systems by the abrasive and corrosive fly ash and lime-
stone slurry. Most of the process streams in this unit contain
fly ash or limestone slurry. Also, care must be taken to prevent
the slurry from settling in the piping and process equipment.
Careful selection of valves and piping as well as provision for
flushing, draining, and cleaning helps alleviate this problem.
B. Provisions for Protection from Abrasion and Corrosion
Because of the extremely abrasive characteristics of the
limestone slurry, all major piping and equipment in the slurry
system are rubber-lined. The rubber-lined pipe and valves should
reduce the problem of erosion, thereby extending life of the
pipe. As an alternate, some of the straight runs of pipe that
will endure a minimum amount of erosion could be supplied in
stainless steel. The comparative cost and service life of these
two treatments must be investigated to determine the optimum
approach. Tanks containing agitated limestone slurry are rubber-
lined to prevent abrasion of the tank walls. Agitator impellers
and internal parts of slurry pumps are also rubber-lined to pre-
vent wear.
C. Prevention of Settling
The solids contained in the slurry will tend to settle out
in any dead space in the piping system. Butterfly valves were
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chosen because these valves do not have pockets like those found
in gate valves. Butterfly valves are also less expensive for the
large sizes needed. The piping design provides for continuous re-
circulation of slurry through all lines normally in service.
Flush connections are provided for those lines that are used
infrequently. Access connections for draining and cleaning are
provided at strategic points to permit flushing. Cleaning will
prevent slurry solids from settling and clogging the system when
it is not in operation.
D. Installation
Rubber-lined pipe for all slurry systems is installed with
flanges and seals for the rubber lining at each joint. All piping
is Installed above grade on pipe supports to provide easy access
for maintenance and inspection. Sufficient flanges are included
in the pipe to permit easy assembly without handling excessively
large pieces.
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VII. ELECTRICAL
A. General
Cost estimates were developed based upon the following design
philosophy. The electrical installation is assumed to be a stan-
dard Industrial type meeting requirements of the National Elec-
tric Code and National Electric Manufacturers Association (NEMA).
I
B. Power Distribution
Process equipment in the plant is supplied electrical power
from motor control centers and unit load centers. The 13.8 kv,
three phase, 60 Hz power will be supplied from at least two
sources to provide reliability. The cost of installation of
these power sources is not included in the estimate. Four load
centers with tie breakers will transform and feed power to four
motor control centers at the 480-volt level. A double-ended
load center will transform and feed power to two 4,160 volt-
motor control switchgear groups. The tie breakers are normal-
ly open in both of the load centers. Motors of 200 hp or less
are controlled from the 480-volt motor control centers. Motors
over 200 hp are controlled by the 4,160-volt motor control
switchgear groups. Each of the four 480-volt motor control cen-
ters feeds one of four scrubbing units. Common equipment is
divided among the four motor control centers (MCC).
C. Load Centers
1. 480-Volt Load Centers
The 480-volt load centers are of outdoor weatherproof
construction. The 13.8 kv incoming line on each transformer
is connected to a single source of power. If a primary
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disconnect switch or selective switches to provide alter-
nate connection of sources are used, additional funds must
be included in the estimate. Transformers are specified
as oil-filled, 65C temperature rise units. The 480-volt
switchgear housing is metal-clad, outdoor, walk-in type.
This switchgear unit houses the four main and three tie
breakers with provisions for four future breakers. All
breakers are manually operated with standard trip units
and without ground fault relaying. A main ammeter and volt-
meter, with switches, is provided on each train. Neutral
and ground leg are common at this point which is considered
the source. The load centers are located as close to the
control centers as practical.
2. 4,160-Volt Load Centers
The 4,160-volt load centers are of outdoor, weatherproof,
metal-clad construction. A 13.8 kv incoming line on each
transformer is connected to a single source of power. If
switches to provide alternate primary connections are in-
stalled, additional funds must be included in the estimate.
The two transformers are specified as oil-filled, 65-degree
temperature rise. The 4,160-volt motor control housing is
of outdoor, metal-clad, walk-in construction. This equip-
ment is fed by one transformer at each end and is isolated
by a secondary main breaker. A tie breaker is placed in the
middle of the bus. Eight 4,160-volt motors will be placed
on one bus and seven on the other with provisions for one
to be accommodated in the future. The 4,160-volt motor
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controllers are all of the full voltage, non-reversing
start type. Three phase overload protection is provided.
No interlocking, voltmeters and ammeters, or ground fault-
detection are included. The load center and the motor
control center will be located as close to the loads as
possible, preferably half way between the most distant
motors.
D. Motor Control Centers
Motor control centers for 480-volt motors are the weather-
proof, non-valk-in type. Main disconnects are not provided be-
cause of the close proximity of the load center feeder breaker.
A neutral bus is provided in the one motor control center
equipped with the lighting feeder breaker. A ground bus is
provided in all motor control centers. Starters are equipped
with combination circuit breakers, and are full voltage, non-
reversing types with overload protection in all three phases.
Individual 120-volt control power transformers and external
reset buttons are also included. No ammeters, running lights,
or stop-start pushbuttons are included in the motor control
centers. The motor control centers will be located as close
to the loads as space permits.
E. Power Supply
The cost of installing incoming power supplies is not in-
cluded in this estimate. At least two feeders from two sources
are required for the six transformers. This cost estimate in-
cludes all equipment at the primary terminals and beyond. The
method of wiring (that is, conduit, aerial, or underground cable)
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used In Installing the power supplies is to be specified by the
organization providing the power source.
F. Wiring Methods
The basic wiring method applied uses galvanized rigid conduit
with single conductor cables. Conduit is run exposed on pipe
supports. Each motor is fed by a separate conduit. Motors over
50 hp have separate conduits for control wiring. Wire for 480-
volt service is Type THW. Control wiring is standard No. 14TWN
type wire. Control runs to the control panel are grouped in
multi-conductor control cable. All wire will be color coded.
Cable for 4,160-volt service is a shielded single conductor,
with 5 kv cross-linked, polyethylene insulation. Pushbuttons
and other wiring devices are mounted near equipment served in
cast weatherproof boxes. Myers hubs, or equivalent, are used
to attach conduit to sheet metal enclosures that are of the
seam-welded type with gasketed covers. No explosion proof equip-
ment is included.
G. Grounding
A ground loop is provided with No. 4/0 bare copper wire.
The steel structure is grounded at every other column. All
major vessels are grounded to the ground loop. All large motors,
load centers, transformers, and motor control centers are also
grounded to the main ground loop.
H. Lighting and Receptacles
General area lighting is provided by 277-volt mercury vapor
fixtures. Lighting level is provided for incidental night time
inspection only and is estimated at 25 foot-candles. One
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lighting panel will serve all four units, and fixtures will be
switched at the panel. Weatherproof 120-volt service recep-
tacles are provided in the area so that any spot may be reached
with a 100-foot drop cord. Two 60-amp welding receptacles are
provided for the four units. No special instrument or gage
lighting is included in this estimate.
I. Electrical Instrumentation Controls
Motor control wiring for motors 50 hp and below is installed
in the same conduit with the motor power wiring. Motors above
50 hp require a separate conduit for control wiring from the
motor control center. A local stop-start pushbutton is provided
at each motor. Wiring for pressure switches and other devices
associated with control of a particular motor may be installed
with the pushbutton wiring for that motor. Instrument wiring
is grouped where possible. Master terminal boxes and multi-
conductor control cable are used where economically feasible.
Labor is included for component installation, adequate
labeling of all wiring and termination. Remote pushbuttons,
running lights, and shutdown alarms are included on a main con-
trol panel for all critical motors. Instrument connections are
estimated on a per unit basis, and a wiring allowance is made
for each field instrument. The cost for wiring panel instru-
ments and material cost for panel pushbuttons is included in
the instrument budget.
J. Miscellaneous
Cost of communications, telephone systems, or fire alarm
systems is not included in this estimate. No allowance has been
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made for any special treatment such as polyvinyl chloride (PVC)
coated conduit for salt mist areas.
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VIII. CIVIL AND STRUCTURAL
A. Slurry Settling Pond Design Parameters
1. General
Design criteria specify a settling basin having a water
surface area of 250 acres and a liquid depth of 50 feet.
Such a basin would have a useful life of 19 years, based
upon an inflow rate of 1,060 gpm and 80 per cent service
factor. Precipitation gain was estimated to be 595 gpn,
and losses due to evaporation and seepage were estimated
at 368 gpm and 148 gpm respectively. The resultant over-
flow rate was 1,139 gpm.
2. Settling Pond Design
No specific data were available regarding terrain, and
no ground water information was available. Therefore, a
hypothetical settling basin was designed as a perfect square.
Waterline dimensions were established at 3,165 feet per side,
and dike slopes were specified at 2:1 maximum. This con-
figuration yields 10,780 acre-feet of storage capacity.
3. Dike Design
The retaining structure is specified as an earth dike
with a 24-Inch clay blanket liner on the dike sides and
bottom within the reservoir. The pond bottom may be left
unlined if ground water does not flow into the pond, and
if seepage from the pond does not contaminate ground water
in the vicinity. The unlined bottom permits seepage to
reduce the probability of a net overflow. If environmental
damage is possible from the seepage, the pond must be lined
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as designed with a 24-in. clay blanket throughout. This
problem is discussed further in Section IX, Environmental
Impact. The berm of the dike was made sufficiently wide
to accommodate a 20-ft service road around its entire pe-
riphery, although the roadway was not included in the
estimate.
4. Erosion Control
Erosion control against wave action (waves were calcu-
lated at 2.5 feet in height under an assumed 40-mph. wind)
is provided by a 26-foot wide butyl rubber sheet laid from
the top of the berm to a position below the normal water
level.
5. Inlet Structure
The inlet structure was assumed to be a simple concrete
splash apron set into the interior face of the dike berm.
6. Outlet Structure
The outlet structure was designed to provide positive
control of water depths in increments of ten feet. Control
is accomplished by using coupled slide headgates covering
18-in. by 18-in. openings. The openings are in a conven-
tional reinforced concrete box culvert set into the in-
terior face of the dike. The outlet of the culvert dis-
charges through the dike slightly below the ten ft water
level. It is assumed that the outlet gates will be used
below maximum level only during the initial filling period.
Normal operating level will be controlled by the 50-ft or
40-ft gates.
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B. Structural and Foundation Design Basis
The design basis for the structural supports and foundations
for process equipment and piping is listed below:
(1) Structural steel:
(2) Reinforcing steel:
(3) Concrete:
(4) Soil bearing value:
(5) Frost line:
(6) Wind:
(a) 0 ft to 30 ft
(b) 30 ft to 49 ft
(c) 50 ft to 99 ft
(7) Wind shape factor:
(8) Equipment weight
to mass ratio:
American Society for Testing
Materials (ASTM) A36
Grade 40 ASTM A615
Compressive strength of 3,000
psi
3,000 psf
1 ft 6 in. below finished grade
25 psf height zone
20 psf
25 psf
30 psf
0.6 for silos
3 to 1
22 ft
(9) Roadway clearance:
C. Facility Description
1. The flue gas scrubbing facility is located outside of the
boiler building, with a slab-on-grade 146 feet wide and 198
feet long. Trenches are provided that discharge into a
chemical sump pit.
2. The horizontal two-stage entr&inment separators, gas re-
heaters, bypass secondary dampers, TCA scrubbers, venturi
scrubbers, and scrubber sumps are supported with structural
steel columns and beams, braced vertically and laterally.
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Stairs are provided to the service platforms, and one
escape ladder is provided for emergency use.
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IX. ENVIRONMENTAL IMPACT
A. General
Any process designed to remove pollution from any phase of
nature cannot eliminate the polluting substance, but can only
change it from one form to another. The ideal situation would
be to change the pollutant from its original form to a second
form which is not a pollutant and has value in the economy.
The removal of sulfur dioxide from powerhouse stacks, fol-
lows this pattern, changing the sulfur dioxide from a gas to a
pure concentrated liquid or to a liquid or solid compound. The
resulting product must be in a form to produce the minimum amount
of pollution and require the lowest cost for handling and dis-
posal. Any consideration of the wet limestone scrubbing process
must take into account certain aspects of possible pollution
that will be encountered.
B. Sources of Possible Pollution
The wet limestone scrubbing process is designed to reduce
the sulfur dioxide emissions from powerhouse stacks to below the
level required by the standards when burning coal that has a max-
imum of 3 to 3.5 per cent sulfur content. If coal with a higher
sulfur content than this range is used, the sulfur dioxide emis-
sions from the stack may exceed the limits provided for in the
standards. If it is necessary to use coal with a higher sulfur
content, improvements in the efficiency of this process or the
substitution of a more efficient process will be required. Con-
trol of particulate emissions is provided by the wet limestone
scrubbing process. However, a failure in the process requiring
-48-
-------
bypassing of flue gas directly to the stack will violate the
standard for particulates as well as sulfur dioxide. No pro-
visions are made for removing particulates from stack gas when
the limestone system is out of service; therefore, the amount
of particulate emissions will be large when the system is not
in operation. A failure of part of the system, requiring the
shutdown of one of the parallel scrubbing trains, will not nec-
essarily produce emissions exceeding the standard if the remain-
ing trains are capable of handling the full flow of stack gas.
If the larger flow of gas through the remaining trains exceeds
their capacity, sulfur dioxide emissions will increase. Liquid
and solid materials entrained in the gas from the limestone
scrubber are removed by the entrainment separators. A failure
of the separators will cause an increase in particulate matter
from the stacks. This particulate emission will be limestone
and limestone derivatives from the slurry scrubber.
The wet limestone scrubbing system can contribute to water
pollution in several ways. The most likely source of pollution
will be from overflow of excess water from the settling pond
where the net rainfall exceeds the evaporation, seepage, and
process losses. When these conditions exist, a net overflow
from the pond may require further processing to prevent con-
tamination of water courses receiving effluent from the plant.
Short periods of excess rainfall can be accommodated by the
freeboard existing in the settling pond. The amount of freeboard
can be adjusted to accommodate requirements for short term in-
creases in the amount of water accumulated. Short periods of
-49-
-------
rainfall should cause no serious complications because the set-
tling pond is designed to collect only the rain that falls di-
rectly into the pond. If there is excess seepage of liquid
from the pond, streams and ground water will be contaminated.
Water pollution factors vary according to location and climate;
therefore, a thorough evaluation of all conditions will be re-
quired for each instance.
Additional air and land pollution can be caused by dust from
dry storage facilities for limestone and the residue materials.
Although the limestone arriving at the plant will have a parti-
cle size of approximately 3/4-in., the loading, storage, and
handling operations may produce sufficient dust to constitute
a nuisance in the local area. If this situation arises, it
may be necessary to provide water sprays or other means to re-
duce the amount of dust. If at any time limestone, gypsum, and
fly ash are removed from the slurry pond and dried, the problem
of dust contamination exists for the surrounding area.
The wet limestone scrubbing system will be installed in power
plants to permit use of high sulfur coal or oil. Using high sul-
fur fuel In larger plants will conserve the low sulfur fuel for
use where scrubbing systems are unsuitable. The low SOo emis-
sions from the scrubber system must be maintained while re-
heating the flue gas after the scrubber. Therefore, reheat re-
quires low sulfur fuel. A net saving In low sulfur fuel is ob-
tained because the re-heat fuel quantity is small compared to
the primary boiler fuel (about five per cent). The availability
of limestone of the proper quality must also be considered when
-50-
-------
planning a limestone scrubbing system. The quantity of limestone
required Is large and must be disposed of after use in the pro-
cess. Therefore, limestone supply and disposal are Important to
long-tern successful operation.
C. Precautions Against Pollution
Precautions against water, air, and land pollution are includ-
ed In the design. Other precautions must be observed in plant oper-
ation to prevent pollution. Four parallel scrubber trains are in-
cluded In the design. This parallel arrangement will permit shut-
down of one train at a time for maintenance while the other three
trains continue to operate with the boiler at reduced capacity.
In this way, 862 and particulate emissions can be maintained
within limits while maintenance is performed. A stockpile of lime-
stone and a supply of slurry are provided so normal maintenance can
be performed on the conveyor and slurry system without a plant
shutdown. Normal leakage from the process equipment In the scrub-
bing area will be collected in trenches and a sump and will be
pumped to the slurry settling pond.
The design for a specific location must take into considera-
tion all possibilities of accidental spillage. Methods must be
included to prevent spills from reaching water courses.
-51-
-------
X. COST ESTIMATE
A. Introduction
The estimated capital cost for a wet limestone scrubbing sys-
tem for installation with a new 500 megawatt coal-fired steam
boiler plant is $20,150,000. This total which represents approx-
imately $40.30 per raw of installed capacity will be explained in
detail in the sections following.
Summaries of capital cost for the complete plant, and by areas,
are given in Appendix I. Also included is detailed information
such as the cost of the induced draft fan and unit cost for duct-
work. The ductwork cost can be used for estimating the ductwork
In a retrofit installation in an existing power plant.
The operating cost for this plant is estimated to be approx-
imately $6.95 million per year. This total operating cost repre-
sents 2.0 mills per kilowatt hour of power generated.
B. Capital Costs
1. General
The capital cost estimate developed for this plant is
based upon the factors described in the following sections.
The cost as presented in the summary sheets in the appendix
is broken down into eight sections representing logical
operating units. As far as possible, the common services
for these units are prorated for each unit. However, such
items as substations, waste disposal systems, and water supply
are listed separately as common units.
The construction labor for installation of the wet lime-
stone scrubbing plant is based upon labor rates for the City
-52-
-------
of Cincinnati, Ohio, estimated for the year 1973 (see Sched-
ule in Appendix I). These labor rates are used to present a
maximum cost for the installation. The amount of labor re-
quired for construction of each portion of the installation
is based upon standard labor units used by Catalytic, Inc.,
in its normal engineering procedures.
Subcontracts for installation of equipment are included
only when installation was quoted by the vendor of the equip-
ment for erection of the equipment on the jobsite. All other
installation costs are Included in the general estimate to
provide a better picture of labor and material costs.
A contingency factor of ten per cent was added to the
total cost.
Some services and facilities such as process water supply,
fencing for the general scrubber area, land for installation
of the scrubber system, and instrument-air facilities are con-
sidered to be included in the adjoining power plant. No cost
was added for providing separate facilities for the scrubbing
system
2. Major Equipment
The price of all major equipment was obtained from vendor
quotations. Where possible, several quotations were obtained,
and the least expensive quotation that met the specifications
was selected for Inclusion in the estimate. In several in-
stances, only one quotation could be obtained and each is in-
cluded as a typical cost. The Corten steel breeching mater-
ial costs were quoted by the vendor, and the fabrication and
-53-
-------
erection costs on site were estimated using standard Cata-
lytic labor units. Similarly, installation costs were esti-
mated for all other major items of equipment. If the scrub-
bing system was installed in an existing plant, the labor
cost would increase 30 per cent to 50 per cent because of
reduced efficiency.
3. Piping and Field Testing
A detailed pipe, valve, and fitting list was made from
piping and instrument diagram (P&ID) flowsheets and equipment
and piping layout drawings. Most of the carbon steel mater-
ials were estimated by using quoted prices, although some
small size pipe was estimated using standard rates. Most of
the neoprene-lined pipe, valves, and fittings were estimated
based upon quoted costs. Some items of neoprene-lined equip-
ment were estimated, based upon earlier equipment costs from
Catalytic, with an escalation factor added for updating to
1973 costs. All of the large size neoprene-lined valves in-
cluded in the estimate are sizes and types which were quoted
and are available from vendors.
All of the pipe fabrication except neoprene lining is
priced as fabricated on the jobsite, using standard Catalytic
man-hour units.
The cost of testing piping systems after construction was
estimated by using a percentage of the labor for installing
the pipe.
4. Sewers
Storm sewers for the scrubbing area are not included in
-54-
-------
the estimate but are assumed to be a portion of the general
site facilities for the boiler plant. Chemical drains, in-
cluding concrete trenches and a sump, are provided in the
scrubber area. The cost of the concrete trenches and sump
are included in the concrete section.
5. Instrumentation
The cost of instrumentation for the plant was determined
from a detailed instrument list, using vendor quoted prices
for all field and panelboard instrumentation. Installation
materials for mounting instruments was estimated and based
upon Instrument hardware cost. The cost of the panel for
centrally mounting control instruments is included in the
estimate, but no control room costs are provided because it
was assumed that the instrument panel will be mounted in the
central boiler control room.
6. Electrical Installation
The estimate of cost for the electrical system was deter-
mined from a detailed list of hardware from the electrical
one-line diagram. Major electrical equipment was priced
through vendor quotations, and field installation costs were
determined by estimating length of conduit runs from prime
movers to motor control centers. The cost of all motors is
included in the price of the equipment being driven. Instal-
lation labor for the electrical system is based upon Catalytic
standard labor units.
7. Concrete
The amount of Concrete required for installation of
-55-
-------
equipment foundations and operating area concrete pad was de-
termined from detailed designs based upon equipment size and
weights. The estimated cost of the concrete is based upon
standard Catalytic units for material and labor costs.
8. Structural Steel
The quantity of structural steel required is based upon
detailed design of equipment and piping supports. Access
platforms, stairways, and ladders are provided for all major
equipment located above grade. Steel is included for construc-
tion of a pipe bridge across one road between the scrubbing
unit and settling pond. The material and labor cost for struc-
tural steel work was estimated by using the quantity obtained
from the design and application of Catalytic standard unit
prices for material and labor.
9. Site Work
The only site preparation Included in the estimate is for
construction of the waste slurry settling basin. The major
site preparation of the scrubbing area will be included in
the construction of the boiler plant site. The cost of earth-
work for construction of the settling basin and dikes is based
upon actual quantities of earth to be moved and a standard
unit price for earth moving. The special rubber lining used
to prevent erosion of the dike is based upon vendor quotations.
A fence is provided around the settling pond approximately
ten feet outside the dike area. No fence is included for the
scrubber area because this area will be within the battery
limits of the boiler plant. The estimate does not include
-56-
-------
roads to the settling pond. Roads In the scrubbing area are
Included In the boiler plant cost estimate.
10. Insulating and Painting
Insulation Is provided on the breeching to prevent Injury
to persons In accessible areas. Insulation Is provided to pre-
vent freezing of exposed water lines. No Insulation Is pro-
vided on the process equipment.
The cost of painting was estimated by using Catalytic stan-
dard unit prices for the equipment and pipe length. Pipe quan-
tities are based upon a detailed pipe list.
11. Fire Protection
Fire protection is provided in the estimate by the inclu-
sion of four dry chemical wheeled fire extinguishers mounted
in storage houses. No other type of fire protection is in-
cluded in the estimate.
12. Contractor Overhead
Miscellaneous direct costs on the jobsite, for items such
as construction supplies, small tools, and temporary facili-
ties, were estimated by applying appropriate percentages to
the total direct labor.
Risk insurance is provided in the estimate at 0.4125 per
cent of the total job cost.
Sales tax was estimated for an installation in Ohio at
four per cent of the cost of appropriate materials.
Payroll burden was estimated at 11.9 per cent of the
total construction labor.
Supervision and office personnel costs on the jobsite
-57-
-------
were estimated at 15 per cent of the total labor cost. The
cost of construction equipment was estimated at 12 per cent
of the total cost of labor required for construction.
13. Engineering Costs
The cost of engineering design of the wet limestone scrub-
bing system is included in the estimate at 12 per cent of the
subtotal of material, subcontracts, labor, and other costs on
the jobsite.
The engineering contract overhead and fee is included at
five per cent of the job subtotal.
14. Land Requirements
The cost of land for installation of the scrubbing unit
was not included, because this unit will be installed adja-
cent to the power plant and within the power plant battery
limits. Additional land must be provided for limestone stor-
age and the limestone settling pond. These facilities require
300 acres, and the cost of this land is not included in the
capital cost estimate.
C. Capital Cost - Retrofit Installation
The detailed capital cost estimate presented in this report is
for a wet limestone scrubbing system engineered and Installed as
part of a new power plant installation. If the scrubbing system
is to be installed in an existing plant, the total unit cost will
be higher than for the new installation. This cost increase is
primarily because of the less efficient arrangement of the equipment
and the increased difficulty in completing the installation with
minimum disruption of the power plant operation.
-58-
-------
The additional cost of installing the same process in the
"retrofit" example was estimated on an "order of magnitude" basis
using the equipment arrangement of the TVA Colbert Steam Plant as
a typical model. Escalation factors were applied to the parts of
the estimate that are affected by the change in arrangement and
work efficiency. The estimates include all indirect as well as
direct costs.
Areas of increased cost and the assumed escalation factors are
as follows: The amount of piping was assumed to be 30 per cent
higher for a total increase of $423,000. The longer duct work
required was estimated by using the incremental cost shown on
page 62 and a 100 per cent increase in the length. The increased
cost is $1.7 million. The supporting structure was assumed to
increase by 50 per cent at an increased cost of $662,000. Labor
efficiency was estimated at 80 per cent for the new installation
but was assumed to be only 50 per cent for the retrofit case. This
reduction in efficiency will increase the overall labor cost by
$2.03 million for construction labor and by $1.1 million for sub-
contract labor.
The total increase in cost of the retrofit ($6 million) does
not include cost of removal of existing equipment to permit con-
struction of the scrubbing system or additional cost of the waste
disposal settling pond that may be required for a specific location.
The total capital cost estimate for the wet limestone scrubbing
system installed on an existing 500 megawatt power plant is $26.15
million. This corresponds to an incremental cost of $52.30 per
kilowatt of installed capacity.
-59-
-------
D. Operating Cost
Thi- fir.st year operating cost for the S0~ removal system is
estimated at $7.2 million or 2.06 mills per kilowatt hour generated.
A tabulation of the operation cost is given in Appendix 2. This
estimate is based upon unit cost data taken from the Kellogg Reportd)
and from design factors of the process described in this report. A
breakdown of the cost of operating materials and utilities by pro-
cessing area is also presented in Appendix 2.
Two men per shift should meet the minimum manpower requirement
after normal operations are achieved. No operating labor was in-
cluded for limestone unloading and handling, security, laboratory
testing, or other services that may be required. These services
are integrated with the powerhouse services and are part of the
powerhouse overhead costs. The scrubbing system will share op-
erating supervision with the powerhouse.
Maintenance cost for the proposed system is uncertain because
of lack of experience in operating a plant of this kind and size.
Initial maintenance cost may be higher if problems are encountered
with materials of construction and plugging.
The cost of capital invested in the plant was fixed at eight
per cent to agree with the Kellogg Report. The eight per cent rate
is variable and must be considered on a current basis for any detailed
evaluation of operating cost. Other factors, such as accelerated
depreciation and tax credits, may affect the financial portion of
the estimate.
• Evaluation of SOX - Control Processes. Kellogg, M. W. Co., Task
No. 5. Final Report to Environmental Protection Agency, Contract CPA
70-68. October 15, 1971. PB 204-711.
-60-
-------
XI. APPENDICES
Appendix 1
Estimating Summary and Sub-Summary Sheets
-61-
-------
Appendix 1
LABOR RATE BREAKDOWN
Union Labor Rates for Cincinnati, Ohio
(Period. Jan. 1973 to June 1973)
Journeymen ($ per hr) Foremen ($ per hr)
Asbestos Workers 10.70 11.20
Boilermakers 10.33 10.83
Bricklayers 10.56 10.81
Carpenters 10.35 10.90
Cement Masons 10.34 10.59
Electricians 9.80 10.68
Ironworkers 10.65 11.00
Laborers 8.10 8.35
Millwrights 10.58 11.08
Operating Engineers 10.45 10.95
Painters 9.28 9.53
Pipefitters 10.92 11.42
Teamsters 6.50
Sheetmetal Workers 10.29 10.54
INCREMENTAL COST OF BREECHING SYSTEM
Cost of Main Breeching Duct - Incl. Insul., All Indirect Costs
Total Cost $1,330,000 - For 1,500 linear ft
Unit Cost $ 890 per linear ft
Cost of Bypass Breeching Duct - Incl. Insul., All Indirect Costs
Total Cost $ 362,000 - For 550 linear ft
Unit Cost $ 660 per linear ft
Cost of One Induced Draft Fan - Incl. Insul., Foundation, All Indirect Costs
Total Cost $ 54,000
Unit Cost $ 54,000 per fan
-62-
-------
15018-27IP
UAIALIIIb. IHV
PHILADELPHIA, PENNSYLVANIA
Page 63
SUMMARY SHEET
riTiuirr/iAf MA 41940 (Task No. 11 - EPA 68-02-0241)
mtTAMffi Environmental Protection Agency
BATS August 30. 1972 _
Page 1 of 12 J
LOCATION. Site Undetermined J
nc«rii»TiAN A Process Cost Estimate for Limestone Slurry Scrubbing of Flue Gas _J
MATERIAL
SUBCONTRACTS AND SHOP LABOR
ALL RISK INSURANCE, LEBAL LIABILITY, ETC. (.4125 % x Total Job)
SPECIAL TAXES. ( *•!••. UM. ttc. ) (4 % x Non. Proc. Matl.)
TOTAL MATERIAL, SUBCONTRACTS 1 SHOP LABOR
FIELD LABOR
PAYROLL BURDEN 11.9%
TOTAL FIELD LABOR
FIELD SUPERVISION
1 FIELD OFFICE PERSONNEL
1 FIELD OFFICE EXPENSE 15 % x Labor and Burden
1 FIELD COST ANALYSIS
START-UP OPERATORS
CONSTRUCTION EQUIPMENT AND TOOLS 12 % x Labor and Burden
TOTAL OTHER FIELD CHARGES
MECHANICAL ENGINEERING
PROCESS ENGINEER INB 12 %
ESTIMATING AND COST ANALYSIS x
HOME OFFICE TRAVEL EXPENSE Sub-Total
PURCHASING. EXPEDITING AND SNOP INSPECTION Above
ACCOUNTING. INDUSTRIA. REL. . GEN. ADM. t CONSTRUCTION MANAGEMENT
TOTAL HOME OFFICE EXPENSES
SUB-TOTAL
OVERHEAD 5%
TOTAL CHARGES
CONTINGENCIES 102
GRAND TOTAL
6.
5
u
2
2
1
1
17
ift
1
20
BEUABItt
218.
546,
82,
57,
904.
575,
305.
. 880.
433.
347.
780,
880,
880.
, 444,
872,
. 316
834.
150,
700
300
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
-
-------
10
II
\)
13
14
IS
u
17
ie
19
20
21
22
23
24
25
26
27
26
29
30
31
3.1
33
34
31
n
il
MATERIAL SHEET
ESTIMATE N
CUSTOMER
CODE
0 41940 (Task No. 11 - EPA 68-02-0241) a|TF August 30, 1972
f.ny 1 ropmental Protection Agency
DESCRIPTION
job Summary
Group I Limestone Handling Unit
Group II Slurry Prep. Unit
Group III Scrubbing System
Group IV Flue Gas Disch. Unit
Group V Reheat System
Group VI Ammonia Unit
Group VII Waste Disposal -
Group VIII Entrainment Separation
Group IX Major Elect. Equip.
Subtotal -
Misc. Direct Charges: (4% and 10
3onstr. Supplies & Petty Tools
Testing Welders f. 41 and 1.42 x P
Temporary Constr. Facilities (6% x
SIZE
Recirc.
Groups I through IX
x Labor)
(6% x Labor)
p-tng T.Abor^
4% x Labor)
TOTAL MATERIAL, LABOR AND SUBCONTRACT
LOCATION
%
FAG
Site Un
E 2 OF 12
determined
MATERIAL
'I,
1,
'
5,
6.
74,
667,
455,
592,
216,
19
412,
122,
301,
862.
88,
133 1
2,
132 j
218,
890
340
410
360
380
770
270
850
000
270
710
000
700
000
700
LABOR
2,
2,
66
145
990
395
72
1 fi
453
Rn
29
250
771
10
93
575
550
570
460
590
650
7in
870
Tin
200
930
nvn
-
000
000
000
SUBCONTRACT
1,
3,
5,
5,
76,
46,
600,
101,
694.
23
S4fi,
S46.
000
300
000
-
500
000
500
-
inn
_
-
-
inn
W
pq
(1)
Oi
£>.
-------
ALL AREAS - GROUPS I THROUGH IX
Page 65
IT
r
r
II
s u
CUSTC3ER
LOCATION
CODE
r oioo
" 0200
. 0400
P
II
1
Envlrpmnental. Pro tecfci
Site Undetermined
B - S U C3 M A R Y
on A«encv ESYOnflTTI? Dffl. 41940
DESCRIPTION
FIREO HEATERS Am BQILEBS
BREECHING
MATERIAL
156,000
11 ' 930,000
REACTORS AM IttTEffflAlS
0500 ]| TODERS AH INTERNALS
0600
0700
HEAT EKCHflNGE EfllHOTT
COOLING YOOERS
(T 6800 II VESSELS. TANKS,, 0£»S 6 IttTERHALS
i
0900 II PUHPS AND DRIVERS
M|p August 30T 1972
PAfiF 3 flF 12
LA»
13,200
100,000
SUiCTOTRACT
-
—
• II II
II II
II II
17,650 || 1,580
|| 207,760 || 42,370
IflOO II BLOttERS AC30 COQPRESSORS-
1100 y ELEVATORS. COCNOOBS. DAYIEHIALS
MAcming ;O;JJP.
1200 H BISCELLAREOUS QECHACIIGAL EQUIOTY
1
L
f
K
1
'__
2500 H TANAAGE
2000 P FILTERS, CENTRIFUGES, SEP. EflOl
2900 H AGITATORS AH9 D1HOS
344.500 II 26*640
77.900 II 17*500
623*200
100,000
••
—
1
_
58,400 II
10,000 || 579,300
K3EHT -II II
|| 84,300 || 2,350
3000 ] SC8CPB8H& & EHTBAItKJEHT SEPARATflBS
3100 ,- MACHINE T08LS 6 DfleHIME SMQf (E@
JUJUL.. .
J40P
IJtOTY
^AT!|3Gr VIEMYILAY1SH, AIB C»8in®ma(L
itJST COaTWIL (PrecGSS enl
5)
PflEKfiEE UdlYS
-
384,000 I 73,500 || 1,240,000
II
II
1 II ... II
II II 1
II II II
•SUB -TOTAL - MAJW EPIIPMC
I30H |{ PIPING
UOC 11 SEWERS Concrete Trenches
1600 1 ELECTRICAL
1700 II COtJCfJilE 2,300 cy
1800 II STRUCTURAL STEKf, 570 tons
1900 II HftEPRODFIHG
jywfl
,- 2100
L
p
i
p
L
2200
2300
2400
2600
??00
3300
EOT
2,925,310
345,540
1,819,300
|| 1,573,200 || 721,700 ||
II - II - II
[| 326,000 || 116,100 || - |
|j 533,600 j| 209,300 ||
jj 72,940 |j 314,040
|| 348,360
II
_JlMJUULLtJG$
SiYI DEVELOPMENT V
IBSULflTlfJN
PAIMTIMG & PROTECTIVE C0ATIMGS
FIELD TESTING
208,710
II
-
1
1
i
1 - II 3,727,000 p
|| 50,750 | 101,600 |f - j
|| 23,230 I 93,680 || - I
II 4,480 II 39.660 II - i
CHEOICflLS AMD CAYaLVST ||
PILING
FIRE PROTECTION
1 - 35150 II QISCELLANEOUS FUBIJITURE FOR PLfl
r-
i •
!
L
1 — \_
Sy§=T@TAL
3700
JMO
CIIKELUBEJUISJUIJLCT CHABBES/A
4,400
;:T guiigines ||
^jKJlQl^^LJUahQrJL
ST0HEWOUSE ACC0UC3YS
•3SDO 1 CfraSYRUCTI@C3 SULLIES 6 PETTV Y
_yio 6 TESTIMG OELOEBS (.4% x 1.4% x
5,862,270
88,730
II
II
600 ||
II
_2_,250,930
5,546,300
221,070 ||
II II
MLS (6% x Labor) II 133,000 11-11
Piping Labor) || 2,700 H 10,000 ||
(00 1BOO 5 TEQPORflRV ^!P!C3C & ELECY0ICAL FACILITIES (6%, 4% || || ||
?OuO f
TCtH?9RflRV CQHSYROCY1SN |Ult,DIN6
?>oo JLJEtiPoflAav SITE egmeraY
TOTAL DIRECT C
S „ II 132nOOO || 93,000 ||
Labor) |( II II
0 S T S
6,218,700
. 2.'>7e>.r\(\(\
5^546.300
-------
i02t-27l
GROUP I - LIMESTONE HANDLING UNIT
Page 66
SUB-SUMMARY
' CUSTOMER
f LOCATION
t
~ CODE
oino
- 0200
0400
0500
- 0600
0/00
OBOO
_ 0900
> 1000
1100
1200
2500
2800
2900
- 3000
3100
3200
___
3400
—
1300
I40C
-Tsdu
1600
1700
— IBOO
1900
2000
2100
2200
2300
2400
~2BOO
2700
3300
-3500
_3700
3BOO
39DO
1300
1300 I60C
Jooo
2100 j
Environmental Protection Agency ESTIMATE NO. 41940 (Task No. 11)
Durham, North Carolina
DESCRIPTION
FIRED HEATERS AND BOILERS
STACKS
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TOWERS
VESSELS. TANKS. DRUMS & INTERNALS
PUMPS AND DRIVERS (1)
BLOWERS AND COMPRESSORS
ELEVATORS. CONVEYORS. MATERIALS HANDLING EQUtP. (2)
MISCELLANEOUS MECHANICAL EQUIPMENT
TANKAGE (D
FILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS
SCRUBBED & ENTRAINMENT SEPARATORS
MACHINE TOOLS & MACHINE SHOP EQUIPMENT
HEATING. VENTILATION. AIR CONDIT ON ING.
OUSI CONTROL (Process only)
PACKAGE UNITS
SUB-TOTAL - MAJOR EQUIPMENT
PIPING
SEWERS
INSTRUMENTATION
ELECTRICAL
COPrRTTE 233 cy
STRUCTURAL STEEL
F (REPROOFING
BUILDINGS
SITE DEVELOPMENT
INSULATION
PAINTING & PROTECTIVE COATINGS
FIELD TESTING
CHEMICALS AND CATALYST
PILING
FIRE PROTECTION
MISCELLANEOUS FURNITURE FOR PLANT BUILDINGS
SUB-TOTAL
MISCELLANEOUS DIRECT CHARGES
STOREHOUSE ACCOUNTS
CONSTRUCTION SUPPLIES & PETTY TOOLS
TESTING WELDERS
TEMPORARY PIPING & ELECTRICAL FACILITIES
TEMPORARY CONSTRUCTION BUI .0 INGS
TEMPORARY SITE DEVELOPMENT
TOTAL DIRECT COSTS
MATERIAL
550
56,500
57,050
200
8,500
8,400
30
_
700
10
74,890
OITP August 30. 1972
Pir.F 4 OF 12
LABOR
320
15,000
15,320
600
8.100
39.200
40
_
3,260
30
66,550
SUBCONTRACT
76,000
76,000
76,000
-------
xi -
rittr . UINJ.I
Page 67
SUB-SUMMARY
CUSTOMER Environmental Protection Agency ESTIMATE NO 41940 (Task No. 11)
. LOCATION
•CODE
"". 0100
0200
i 0400
0500
OGOO
0700
~ 0800
osoo
1000
- noo
1200
2500
- 2800
2900
| 3000
_ 3ion
3200
3400
••••
— 1300
1400
1500
_ 1600
1700
1800
1900
2000
[ '2100
2200
-2300
t 2400
1 2600
]_270a
1 3300
•3500
Durham, North Carolina
DESCRIPTION
FIRED HEATERS AND BOILERS
STACKS
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TOWERS
VESSELS. TANKS. DRUMS & INTERNALS (1}
PUMPS AND DRIVERS (4)
BLOWERS AND COMPRESSORS (1)
ELEVATORS. CONVEYORS. MATERIALS HANDLING EQUIP. (3^
MISCELLANEOUS MECHANICAL EQUIPMENT (3)
TANKAGE (1)
FILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS W
SCRU3BBS & ENTRAINMENT SEPARATORS
MACHINE TOOLS & MACHINE SHOP EQUIPMENT
HEJTIHG. VENTILATION. AIR COND T ONIN6.
OUST CONT OL (Process on y
PAWGE UNITS
SUB-TOTAL - MAJOR EQUIPMENT
PIPING
SEWERS
INSTRUMENTATION
ELECTRICAL
CONCRETE 244 cy
STRUCTURAL STEEL 4 ton
FIREPROOFING
BUILDINGS
SITE DEVELOPMENT
INSULATION
PAINTING ft PROTECTIVE COATINGS
FIELD TESTING
CHEMICALS AND CATALYST
PILING
FIRE PROTECTION
MISCELLANEOUS FURNITURE FOR PLANT BUILDINGS
- SUB-TOTAL
1 ' 3700 1 MISCELLANEOUS DIRECT CHARGES
1 3000 | STOREHOUSE ACCOUNTS
l~3800 1 CONSTRUCTION SUPPLIES & PETTY TOOLS
I 1300 ' TESTING WELDERS
! M)9 'BOB
1 _ 3666
2106
TEMPORARY PIPING ft ELECTRICAL FACILITIES
TEMPORARY CONSTRUCTION BUILDINGS
TEMPORARY SITE DEVELOPMENT
TOTAL DIRECT COSTS
MATERIAL
1.500
5,100
12,500
21,400
550,000
26,900
617,400
15 , 500
6,000
16,800
7,590
3,270
-
700
80
667,340
QITF August 30, 1972
PIRF 5 OF 12
LABOR
150
2,660
640
2,500
50,000
sbo
56,450
14,200
2,000
22,900
44,260
2,240
-
2,780
740
145,570
SUBCONTRACT
46,300
46,300
46,300
-------
Of 1-271
GROUP III - SCRUBBING SYSTEM
Page 68
1 SUB-SUMMARY
|" CUSTOMER
t_ loeanon
,_ ce°E
OlOO
: 0200
\" 0400
\ 0500
°IS5
— oloo
i oa&G
{ 0900
i- 1000
' 1100
: 1200
L_ 2500
1 2890
i 2100
j 3000
"" 3100
3200
-3400
I30G
MQQ
'•5te
ISOO
II 00
1800
~ 1900
. 2BflO
2100
-2200
2300
2400
2BOO
2700
3300
3SM 1
3700
-mm
mm
1300
jJflO |BO°
Ati
2100
Environmental Protection Agency ESTIMATE HO. 41940 (Task No. 11)
Durham, North Carolina
DESCRIPTION
FIRED HEATERS AND BOILERS
STACKS
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
i COOLING TOWERS
VESSELS. TANKS. DRUMS I INTERNALS
PUMPS AND DRIVERS (20)
BLOWERS AND COMPRESSORS
ELEVATORS. CONVEYORS. MATERIALS HANDLING EQUIP.
MISCELLANEOUS MECHANICAL EQUIPMENT
TANKAGE (12)
FILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS W
SCRUBBERS & ENTRAINMENT SEPARATORS (12)
MACHINE TOOLS & MACHINE SHOP EQUIPMENT
HEATING. VENTILATION. AIR CONDIT ONIN6.
OUST CONTIOL (Process only)
PACKAGE UNITS
SUB-TOTAL - MAJOR EQUIPMENT
PIPING
SEBE8S
IfttlftUBOnATiBM
ELECTRICAL
CONCRETE 992 cy
STRUCTURAL STEEL 324 ton
FIREPROOF ING
BUILDINGS
SITE DEVELOPMENT
INSULATION
PAINTING & PROTECTIVE COATINGS
FIELD TESTING
CHEMICALS AND CATALYST
PILING
FIRE PROTECTION
MISCELLANEOUS FURNITURE FOR PLANT BUILDINGS
SUB-TOTAL
MISCELLANEOUS DIRECT CHARGES
STOREHOUSE ACCOUNTS
CONSTRUCTION SUPPLIES ft PETTY TOOLS
TESTING WELDERS
TEMPORARY PIPING 1 ELEC R CAL FACILITIES
TEMPO IARY CONS Tl IUI JTIM .DNiS
TEMPO IA IV SITE IEVELOPM NT
~ TOTAL DIRECT COSTS
MATERIAL
138,600
100,000
57,400
384.000
680,000
1 ,218,700
211,000
115,600
30,570
184,350
1,300
11,390
2,500
2,455,410
niTF August 30, 1972
P»SiF 6 OF 12
LABOR
25.000
10.000
1,850
73.500
110.350
A04 inn
75,000
115,800
107.900
106,100
2,700
46,010
22,500
990,460
SUBCONTRACT
360,000
1.240.000
1.600.000
,
1,600.000
-------
021-271
GROUP IV - FLUE GAS DISCHARGE UNIT
Page 69
SUB-SUMMARY
CUSTOMER
" LOCATION
* CODE
* 0100
0200
"* 0400
0500
0600
- OJCO
MOO
0900
- 1000
1100
1200
2500
2600
2900
3000
3100
3200
- 3400
!JC»
I40C
1500
"1600
1700
1800
- 1900
2000
2100
- 2200
* 2300
2400
2600
2700
• 3300
3500
3700
~3§00
3900
1300
_JDO 1600
rt!K5o
2100
Environmental Protection Agency ESTIMATE NO. 41940 (Task No. 11)
Durham, North Carolina
DESCRIPTION
El RED HEATERS AND BOILERS
XXUISC Breeching
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TOWERS
VESSELS. TANKS. DRUMS fc INTERNALS
PUMPS AND DRIVERS
BLOWERS AND COMPRESSORS (4)
ELEVATORS. CONVEYORS. MATERIALS HANDLING EQUIP.
MISCELLANEOUS MECHANICAL EQUIPMENT (16}
TANKAGE
EILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS
SCRUBBERS & ENTRAPMENT SEPARATORS
MACHINE TOOLS & MACHINE SHOP EQUIPMENT
MUTING. VENTILATION. AIR CONO TIONIN6.
OUST IIONTROI (Process on y)
PACKAGE UNITS
SUB-TOTAL - MAJOR EQUIPMENT
PIPING Minor Util. Piping Only
SEW :RS
INSTRUMENTATION
ELECTRICAL
CONCRETE 381 cy
STRUCTURAL STEEL 200 ton
FIREPROOFING
BUILDINGS
SITE DEVELOPMENT
INSULATION
PAINTING I PROTECTIVE COATINGS
FIELD TESTING
CHEMICALS AND CATALYST
PILING
FIRE PROTECTION
MISCELLANEOUS FURNITURE FOR PLANT BUILDINGS
SUB-TOTAL
MISCELLANEOUS DIRECT CHARGES
STOREHOUSE ACCOUNTS
CONSTRUCTION SUPPLIES I PETTY TOOLS
TESTING WELDERS
TEMPORARY PIPING I ELECTRICAL FACILITIES
TEMPORARY CONSTRUCTION BUI .DINGS
TEMPORARY SITE DEVELOPMENT
- TOTAL DIRECT COSTS
MATERIAL
930,000
332,000
73,200
1,335,200
(Included wit
62,000
15,000
12,250
117,450
47,200
3,260
-
1,592,360
01TP August 30, 1972
Pint 7 IIF 12
LABOR
100.000
26,000
8,400
134,400
i Group III P
22.000
15,600
66^200
49,950
94,400
13,040
-
395,590
•
SUBCONTRACT
_
Pin*)
_
-------
GROUP V - REHEAT SYSTEM
Page 70
SUB-SUMMARY
CUSTOMER
*;
, LOCATION
CODE
0100
0200
l 0400
[ 0500
0600
0/00
0800
0900
1000
1100
1200
2500
[ 2800
1 2900
3000
E3IOO
3200
_ 3400
1300
1400
1500
r 1600
1700
1800
r 1900
2000
2100
2200
2300
2400
2600
r 2700
1 3300
3500
r
3700
3800
1 3900
' 1300
1300 1600
~ JoBfl
2100
Environmental Protection Aeencv ESTIMATE MO. AiQAn (Task No. 11)
Duham, North Carolina
DESCRIPTION
FIRED HEATERS AND BOILERS (4)
STACKS
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TOWERS
VESSELS. TANKS. DRUMS ft INTERNALS
PUMPS AND DRIVERS (5)
BLOWERS AND COMPRESSORS
ELEVATORS. CONVEYORS. MATERIALS HANDLING EQUIP.
MISCELLANEOUS MECHANICAL EQUIPMENT
TANKAGE (1)
FILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS
SCRUBBERS t ENTRAINMENT SEPARATORS
MACHINE TOOLS ft MACHINE SHOP EQUIPMENT
HEAT4MC. VENTILATION. AIR CONOIT ONIN6.
OUST CONTl6l (Proctss only)
PACKAGE UNITS
SUB-TOTAL • MAJOR EQUIPMENT
PIPING
SEWERS
INSTRUMENTATION
ELECTRICAL
CONCRETE 45 cy
STRUCTURAL STEEL
MREPROOFING
BUILDINGS
SITE DEVELOPMENT
INSULATION
PAINTING ft PROTECTIVE COATINGS
FIELD TESTING
CHEMICALS AND CATALYST
PILING
FIRE PROTECTION
MISCELLANEOUS FURNITURE FOR PLANT BUILDINGS
SUB-TOTAL
MISCELLANEOUS DIRECT CHARGES
STOREHOUSE ACCOUNTS
CONSTRUCTION SUPPLIES ft PETTY TOOLS
TESTING WELDERS
TEMPORARY PIP!NG ft ELECTRICAL FACILITIES
T 1PORIRY CONSTRUCT ON 1 1 .1 NGS
T1PORARY SITE DEVELOP NT
TOTAL DIRECT COSTS
MATERIAL
156,000
770
156,770
5,500
36,000
8.800
1^400
2,280
-
1,070
160
4,400
216,380
niTF August 30, 1972
P1P.F 8 fit 12
LABOR
13,200
370
13,570
16.200
13,000
15.200
7,640
1,340
• -
4,280
t52D
600
72,650
SUBCONTRACT
68.500
68,500
33,000
101,500
-------
M2I-271
GROUP VI - AMMONIA UNIT
Page 71
SUB-SUMMARY
1 CUSTOMER
v ,
r IOC* II ON
r CODE
1-
1 0100
r 0200
0400
0500
0600
5W
0800
i 0900
" 1000
1100
1200
- 2500
2600
2900
- 3000
3100
3?flO
3400
—
I30f)
1400
_ ISbo
1600
1700
1800
1900
2000
2100
~ 2200
2300
2400
— 2600
2700
'3300
__3500
*
3700
"3100
3800
1300
Tjpo 1600
2000
2100
Environmental Protection Agency ESTIMATE NO.
Durham, North Carolina
DESCRIPTION
FIRED HEATERS AND BOILERS
STACKS
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TOWERS
VESSELS. TANKS. DRUMS & INTERNALS U)
PUMPS AND DRIVERS
BLOWERS AND COMPRESSORS
ELEVATORS. CONVEYORS. MATERIALS HANOLIN6 EQUIP.
MISCELLANEOUS MECHANICAL EQUIPMENT
TANKAGE
FILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS
SCRUBBERS 1 ENTRAINMENT SEPARATORS
MACHINE fOOLS I MACHINE SHOP EQUIPMENT
HEATING. VENTILATION. AIR CONDI T ONIN6.
OUST CONTROL (Process only)
PACKAGE UNITS
SUB-TOTAL - MAJOR EQUIPMENT
PIPING
SEWERS
INSTRUMENTATION
ELECTRICAL
CONCRETE 20 cv
STRUCTURAL STEEL
FIREPROOF ING
BUILDINGS
SITE DEVELOPMENT
INSULATION
PAINTING t PROTECTIVE COATINGS
FIELD TESTING
CHEMICALS AND CATUYIT
PILING
FIRE PROTECTION
MISCELLANEOUS FURNITURE FOR PLANT BUILDINGS
SUB-TOTAL
MISCELLANEOUS DIRECT CHARGES
STOREHOUSE ACCOUNTS
CONSTRUCTION SUPPLIES 1 PETTY TOOLS
TESTING WELDERS
TEMPORARY PIPING I ELECTR CAL FACILITIES
T MPORARV CONSTRUCTION BU LOINGS
f MPORARY SITE DEVELOPMENT
~~ TOTAL DIRECT COSTS
MATERIAL
10,000
10,000
1.400
2.800
2.300
680
180
2,250
130
30
19,770
•
fUTF August 30, 1972
Pipr 9 OF 12
LABOR
750
750
5,100
1.000
2.100
2,250
240
4,500
520
270
16,730
SUBCONTRACT
-
_
-------
-271
S U
CUSTOMER
. LOCQTI0W
CODE
OlOO
0200
" 0400
B - S y C3 D9 A R V
Environmental Protection Agency ESTHOafE ttD^^O (Task No. 11)
Durham, North Carolina
DESCRIPTION
FIBEO HEflTEaS M @OiLE^S
STaCRS
REACTORS AMD laiMaLS
MATERIAL
p^Yi? August 30, 1972
Pflfip 10 (oil? 12
LA»
SMCMTKAeT
II 1
II i
0500 || TOOERS QH9 INTERNALS |[ fl II
0600 1 HEAT EXCHANGE EOUIOTT
- 0700 1 COOLING TOOERS
fl@00 li VESSELS. TANKS. OEMS & INTERNALS (2)
0300
. IOOC
1100
1200
PUQPS AMD ORIUE^S
BLOWERS AM9 C9D^BESSiHS
ELEVATORS, 5®dUETOBSn DATTEBlAl
(7)
S HANDLIQ6 EflUlP.
msCELLOC3E@US DEOBAaseaiL g®UI!K)IEOT
2500 1! TANKAGE
2@@0
JJMQ
FILTERS, CgWTRI FUSES. SEP» 'E8UIK]|CIT
AGlTATflKS flHi HIUEffi
3000 11 SCRUBBERS 6 EDTBAICDENT SEWafl?§aS
= 3100 5 pACS&BE TiOLS 6 DACHiaE 8W E
Jim__ TiasTitJS. ifENYiiumBCJ. aiQ era
II J51SST coarOOL (I?r®eo8s ®n
fiidfi n 1*^*1 1? ri IT
6,150
II
II
680 ||
| 31,840 II 7,020 || K
11 II
II II
II
II
||
II II
|| ||
II II
HYOGQing, II II II
l»> II II II
- 3400 (1 P0eCUtfE OtilYS li
o y
ODD H PlPJClfi
1400 S SgTOS
"TWlj
" 1600
1700
jjuyi
= 1900
37,990
II
II
7,700
-
|| 251,700 || 232,000 ||
II tl II
IHSTRUdEPTATIdW
£L£C"iIK8£flL
COWCl^TE 193 cjr
STRUCTURAL STEEL 34 ton
f IBEWPFIK1G
mm K Buiifliacs
^ 2200
5,300 II 2,000 II
66,400 Jl 109,300 II
|| 5,690 II 24,030 ||
|| 38,700
SITE SEVELOK3EC3T
IMSBiATIM
2300 || PAIHTIHG £ PRiTECTIUE CBaTIMES
2400 11 FIELD TESTING
2®C8
2YOO
33flO
JMfl
CHEQICALS AK9 eaTAIiygY
PILIilG
FIRE PROTECTION
MISCELLANEOUS FURNITURE m PL
45,900 |l
II 1
II II
)| - || 3,694,000
|f - ||
5,090 11 20,340 ||
In400 Jl 12*600 II
II H
II H
II II
ANT BUILDINGS U H II
S U B- T§ T A L
J700 II QISCELLAdEOUS DIRECT CHARftgS
_Jffl@
J3S8
_iflD JBfjU
^iftl0
STQSjyJ0JISE_ME@WOTS
COMSTRUCTJ9K SULLIES 6 PETW
?®@ILS
TESTIMG OEL0HKS
TFOTRABV ?llr)!Clfi S ELECTBIEflll,
(FACILITIES
412,270
453,870
3,694,000
11 II
II H
J II f
Jl H
TfWIRnRV COOSTRUCTI6N BUILDINGS ' Jl
2t@® ii TEC3P©RflflV SITE BStJELiKlEMf II
- TOTAL DIRECT C
©*£ TT §
v 0 *J
! II
H
H
-------
021-271
GROUP VIII - ENTRAINMENT SEPARATOR RECIRCULATION
Page 73
I SUB-SUMMARY
1
|~ CUSTOMER
J LOCATION
" CODE
* 0100
0200
•s 0400
0500
0600
- 0700
OBOO
0900
- 1000
1100
1200
2500
2600
2900
3000
- 3100
3200
_ 9400
1300
1400
1500
— 1600
1700
1800
- 1900
2000
2100
_2200
• 2300
2400
2600
~" 2foO
.3300
, Ml .
Environmental Protection Agency ESTIMATE MO 41940 (Task No. ILL
Durham, North Carolina
DESCRIPTION
FIRED HEATERS AND 80 HE US
STACKS
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TOWERS
VESSELS. TANKS. DRUMS & INTERNALS
PUMPS AND DRIVERS (5)
BLOWERS AND COMPRESSORS
ELEVATORS. CONVEYORS. MATERIALS HANDLING EQUIP.
MISCELLANEOUS MECHANICAL EQUIPMENT
TANKAGE (1)
FILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS
SCRUBBERS & ENTRAINMENT SEPARATORS
MACHINE TOOLS & MACHINE SHOP EQUIPMENT
HfATiKG. VENTILATION. AIR CONDITIONING.
DUST COMTIOL (Process only)
PACKAGE U»ITS
SUB-TOTAL - MAJOR EQUIPMENT
PIPING
SEWERS
INSIftPMFNTATION
ELECTRICAL
CONCRETE 80 cy
STRUCTURAL STEEL
FIREPROOFING
BUILDINGS
SITE DEVELOPMENT
INSULATION
PAINTING I PROTECTIVE COATINGS
FIELD TESTING
CHEMICALS AND CATALYST
PILING
FIRE PROTECTION
MISCELLANEOUS FURNITURE FOR PLANT BUILDINGS
SUB-TOTAL
3700
-3800
3900
1300
100 1600
2000
2100
MISCELLANEOUS DIRECT CHARGES
STOREHOUSE ACCOUNTS
CONSTRUCTION SUPPLIES 1 PETTY TOOLS
TESTING WELDERS
TEMPORARY P PING I ELECTRICAL FACILITIES
TEMPORARY C INSTRUCT ON BUILDINGS
TEMPORARY S TE DEVELOPMENT
- TOTAL DIRECT COSTS
MATERIAL
30.900
-
30,900
80,200
2,900
3,200
2,660
2,100
-
590
300
122,850
IUTF Auaust 30. 1972
P»CP 11 (IF 12
LABOR
7.000
-
7,000
49,500
1,100
5,300
9,560
2,900
-
2,250
2,700
80,310
SUBCONTRACT
28,500
28,500
28,500
-------
GROUP IX - MAJOR ELECTRICAL EQUIPMENT
Page 74
SUB-SUMMARY
CUSTOMER
- LOCATION
. CODE
0100
0200
0400
0500
0600
" 0700
0800
0900
• 1000
1100
1200
~ 2500
2800
2900
3000
3100
3200
- 3400
••
1300
1400
1500
1600
1700
1800
1900
2000
2100
-2200
2300
2400
-2600
2700
3300
3500
Environmental Protection Agency ESTIMATE NO. 41940 (Task No. 11)
Durham, North Carolina
DESCRIPTION
FIRED HEATERS AND BOILERS
STACKS
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TOWERS
VESSELS. TANKS. DRUMS & INTERNALS
PUMPS AND DRIVERS
BLOWERS AND COMPRESSORS
ELEVATORS. CONVEYORS. MATERIALS HANDLING EQUIP.
MISCELLANEOUS MECHANICAL EQUIPMENT
TANKAGE
FILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS
SCRUBBERS I ENTRAINMENT SEPARATORS
MACRtKE TOOLS & MACHINE SHOP EQUIPMENT
H'ATING. VENTILATION. AIR CONO T ON ING.
OUST CONT OL (Process on y
PACKAGE UNITS
SUB-TO I AL - MAJOR EQUIPMENT
PIPING
SEWERS
INSTRUMENTATION
ELECTRICAL
CONCRETE 130 cy
STRUCTURAL STEEL
FIREPROOF ING
BUILDINGS
SITE DEVELOPMENT
INSULATION
PAINTING 4 PROTECTIVE COATINGS
FIELD TESTING
CHEMICALS AND CATALYST
PILING
FIRE PROTECTION
MISCELLANEOUS FURNITURE FOR PLANT BUILDINGS
SUB-TOTAL
3700 I NISCELLANEpUS DIRECT CHARGES
"3800 I STOREHOUSE ACCOUNTS
3900 1 CONSTRUCTION SUPPLIES & PETTY TOOLS
1300 3 TESTING WELDERS
ring 1600 I TEMPORARY PIPING & ELECTRICAL FACILITIES
2000 | TEMPORARY CONSTRUCT! IN BUILDINGS
2100 • TEMPORARY SITE DEVELOPMENT
~ TOTAL DIRECT COSTS
MATERIAL
-
297,000
3,700
300
301,000
niTr August 30, 1972
PiCF 12 OP 12
LABOR
• -
15,000
13,000
1,200
29,200
SUBCONTRACT
-
_
»
-------
Appendix 2
Annual Operating Cost
-75-
-------
ANNUAL OPERATING COST
WET LIMESTONE SCRUBBING
Client: Environmental Protection Agency
Process: Wet Limestone Scrubbing
Plant Size: 500 MW
Fixed Capital Investment: $20,150,000
Stream Hours: 7,000 Hrs/Yr.
I. Raw Material
A. Limestone
B. Ammonia
II. Utilities
A. Water, Process
B. Electricity
C. Fuel (No. 2 Oil)
III. Operating Labor
A. Direct Labor
B. Supervision
IV. Maintenance
A. Labor and Materials
B. Supplies
V. Overhead
A. Plant
B. Payroll
VI. Fixed Cost
Quantity
31.9 TPH
1,375 Lbs/Day
Quantity
400 gptn
11,300 KW
95.2 MM BTU/Hr.
Unit Cost
4.00 $/T
50.00 $/T
Unit Cost
(2 Men/Shift)
(Depreciation, Interim Replacement,)
(Insurance, Taxes, Cost of Capital )
$0.20/M Gal.
6.75 Mils/KWH
$.80/MM BTU
Rate
4.50 $/Hr.
15% Operating Labor
Rate
4.0% Fixed Investment
15% Labor & Materials
Rate
50% Operating & Maintenance
20% Operating
Rate
18.22% Fixed Invest-
ment
Cost of Capital 8%
Depreciation 15 Years Sinking Fund Method
Insurance .25%
Interim Replacement 0.35%
Taxes 3.16% Federal, 2.33% Local
VII. Total Annual Cost
A. Mills/KWH
Annual Cost
$ 893,200
10,030
Annual Cost
$ 33,600
533,740
533,120
Annual Cost
$ 78,840
11,830
Annual Cost
$ 806,000
120,900
Annual Cost
$ 508,785
18,130
Annual Cost
$3,671,330
$7,219,505
2.06
-76-
-------
WET LIMESTONE SCRUBBING
Allocation of Annual Raw Material
and
Utilities Cost by Groups
Group
1
2
3
4
5
6
7
8
Item
Electricity
Limestone
Water
Electricity
Ammonia
Electricity
Electricity
Fuel Oil
Electricity
-
Electricity
Electricity
Water
Units
31 kw
223,300 tons
9,383 M gal
1,437 kw
200.6 tons
1,863 kw
6,700 kw
666,400 MM Btu
67 kw
-
373 kw
829 kw
158.6 MM gal
$ Per Year
1,463
893,200
1,882
67,900
10,030
87,990
316,470
533,120
3,162
-
17,601
39,154
31,718
Group Cost
$ Per Year
1,463
962,982
98,020
316*470
536,282
-
17,601
70.872
2,003,690
Per Cent
0.1
55.5
5.6
18.3
15.5
-
1.0
_J^O
100.0
NOTE;
Group numbers correspond to groups of process equipment used
in the capital cost estimate.
-77-
-------
Appendix 3
Drawings
Process Flow Diagram - Drawing No. A-202, Sheet 1
Process Flow Diagram - Drawing No. A-202, Sheet 2
Equipment Arrangement - Drawing No. A-601, Sheet 1
Equipment Arrangement - Drawing No. A-601, Sheet 2
Equipment Arrangement - Drawing No. A-601, Sheet 3
Piping Layout - Drawing No. A-801, Sheet 1
Piping Layout - Drawing No. A-801, Sheet 2
Piping Layout - Drawing No. A-801, Sheet 3
-78-
-------
I —
LIMESTONE SLURRY SCRUBBING SYSTEM
FOR NEW 500 MW BOILER
DWG. NO. A-202 SHEET 1 OF 2
-------
noon nn am . KATOIAL BALAKI
OK. ID. A-202 ram 2 of 2
Stream) lo.
tttl
1 Toul bte
2 Toul bte
3 Hater bu
» Solid* bu
3 Solid* Cone.
6 Toam«ratura
7 Deoaity
s vucoeicy t IOOT
9 Fh
10 Wj bu
M
Unite
eu
10* Ib/hi
10? sera
103 Ib/hr
U>3 Ib/hr
«m/«r
°T
103 u>/hr
•Dili
or
Liquid
103 Ib/te
cm
OK
103 Ib/hr
I Solid*
o»
I.G.
cn
n
Ho.
i
2
3
t
3
6
7
1
9
10
1
Co«l
377
•3.2
2
Alb
8U(
14
3
Air to
Air
Huter
4,611
931
0
0
40-80
0
4
Air
to
Boiler
4,023
823
0
0
MO
0
3
Comb. Cu
to
Alt
Beeter
4,333
873
40.8
775
23.0 '
6
All
Heater
Leakage
379
119
0
0
40 - t»
0
8A. 8B
7
Comb. Gu
to
Scrubbing
SyeUB
4,932
991
232
40.8
5.56
300
23.0
«C i 80
Cam*. Cu
• to a
Scrubbing
Train
233
249
60
10.2
5.56
300
6.25
9A, 91
9C 4 90
Slurry
. to •
Vanturl
Scrubber
1,370
4,389
4,150
481
19.0
114 - 127
1.12
10A, 10B
IOC 6 100
Slurrr
from a
Venturl
Scrubber
2,328
4,480
4,060
4M
19.7
114 - 127
1.11
11A, 111
11C t 110
Tot. Slurry
(rom •
Venturl
Scrubber
2,910
5,189
4.4S4
532
19.0
114 - 127
1.12
UA, 121
12C t 120
lacycle
Slurry to
• Venturl
bclrc. Tk.
336
600
344
64
19.0
114 - 127
1.12
UA. Ill
13C 6 130
Slurry O.F.
f torn •
Venturl
Baelr. Tk.
144
293
266
31
19.0
114 - 127
I.B
Strum Ho. 14A, 14B
tec t 140
Title
1 Total bu
2 Toul bu
3 ttaur bu
4 Solid* bu
5 Solid* Cone.
6 Temperature
7 Demlty
8 Vl.co.lty 1 100°T
9 Fh
10 80] bte
Strea
Tltj
1 Total bte
2 Total bte
3 Water bte
4 Solid, bte
5 Solid* Cone.
6 Temperature
7 Denalty
8 Vlacoelty 1 100°P
9 Fh
10 10, bu
Onit*
Gu
lo2 Ib/hr
10, sen
U3 Ib/hr
103 Ib/hr
103 Ib/hr
lao.
Solid
or
Liquid
103 Ib/hr
cn
cn
103 Ib/hr
I Solid.
8.C.
cn
Fh
1
Coax. Gu
from a
Venturl
Ho. Scrubber
1,2*0
241
110
0.9412
0.011
114-117
0
La
fell
Cu
10? Ib/hr
10? sen
10] Ib/ha
103 Ib/hr
cs/scT
OF
103 Ib/hr
a
Solid
or
Liquid
103 Ib/hr
cn
cn
ICJ Ib/hr
Z Solid.
°F
S.G.
CFS
Fh
Ho.
. 1
2
3
10
Stream to.
Tit
1 Toul bu
2 Total bu
3 Water bte .
4 Solid, bu
5 Solid. Cone.
6 Temperature
7 Deualty
8 Vl*co*ltv * 100°F
9 Ph
10 afj bu
la
Delta
Gu
103 Ib/hr
lo3 sen
10? Ib/hr
103 Ib/hr
CB/SCF
OF
10"* Ib/hr
Solid-
or
Liquid
103 Ib/hr
cn
0PM'-
103 Ib/hr
Z Solid.
°T '
S.G.
CFS
Fh
So.
1
2 .
3
4
5
6
7
8
9
10'
6t9
25A, 211
.23C a tS
Comb. Ci
from a
1,315
270
111
1
0.01
200
1.0
39A, 391
39C-* JS
UA, 151
15C 4 130
Slurry
from a
TCA
Scrubber
5, Ml
10,500
10,000
564
10.1
114 — 117
1.06
) 1«
la
la Slurry
r Overflow
656
1,170
1,060
124
i 19.0
114 - 127
1.12
!
.
ID 4
16A, 161
16C 4 160
from a
TCA
belre. Tk.
205
386
370
11
10
1.06
17
Pood
Bolide
Aeeum.
124
110
0
124
100 (40)
40-80
40J
0 4M
17A, 17B
17C 6 170
Tot. Slurry
from a
TCA
bclrc. Tk.
3,878
11,100
10,671
588
10
114 - 127
1.06
5.8 - 6J>
28
Fond
Preelp.
Gain
298
595
595
0
0
40-80
1.
7.
* WB
! 4 400
Emarg'cy Overflow Overflow
Ammonia, from -!.«.'. froa an
to a TCA ToJ lee. Tk. B.S.
bclrc, Tk. Stage 2 Stage 2
1.3 6.360 1.640
13,100 3,170
13,100 3,270
0 0
0 0
IW 114-12-7 1*4 - 127
1.0 1.0
0.6« 0.68
0
0
ISA. 181 19A, 191
18C 4 UD 19C 6 190
Kaeyela Slurry
Slurry to a
U a TCA TCA
bcire. Tk. Scrubber-
318 3,560
600 10,500
572 10,100
32 536
10 10
114 - 127 114 - 127
1.06 1.06
5.8 - 6.0 5.8 - 6.0
29 30 31
Fond
trap,
Loaa
184
368
368
41
Proeua
Bates to
B.S. bc.'Tk.
SUge 2
708
1,420
1,420
40 -
0
0
80
1.0
0.68
Foa
Fond Froo
Seepage Wat
Loae Overt
74 57
148 1,13
148 1,13
40 - 80 40 -
1.0
42
42 42
Overflow
from B.S.
lac. Tank to
SUge 2
6,560 1
13,100 3
13,100 3
0
0
114 - 127 11
1.0
0.68
OA, 20B
OC 6 200
21
..S. Slurry B.S. Waui
to a to
bclrc. Scrubbing
Tank Syetem
23.9 708
32.2 1,420
21.2 1,420
15.9
60
40-80 114
1.61
32
d
eee law
ar Make-up
low Water
2 198
9 396
9 396
3 0
1 0
90 40 - 80
L.O 1.0
7.0
A, 421
C 6 420 43
- 127
1.0
0.68
33
21*. 211
21C 4 21O
E.S. Water
to a TCA
belre.
Tank
177
355
355
0
0
114 - 127
1.0
0.68
34
22A, <2B
22C 6 220
Comb. Cu
froa) an
Enr.
Sapar.
1,280
263
111
1
0.06
114 - 127
1.06
35
23A, 231
23C 6 230
Air
to a
Comb. Gu
tabular
24.6
5.1
0.3
0
0
40-80
0
36
Proeue Slurry
Total Hater Llaaatona U L.S.
Frocua to Tube to Bold
Hater Mill Tuba Hill Tank
770 42 63.7 104
1,540 84 (31.9 TFH) 129
1,540 84 0 84.9
0 0 67.7 63.7
0 0 100 60
40-80 40-80 40-80 40-80
Waah Overflow
Water from E.S.
an B.S. lac. Tank
Stage 2 • Stage 2
,640 708
,270 1,420
,270 1,420
0 0
0 0
1 - 127 40 - 80
1.0 1.0
0.68 0.68
1.0 1.0
7.0 7.0
44
Overflow
from B.S.
to be. Tk.
SUge 1
6,560
13,100
13,100
0
0
114 - 127
1.0
0.68
2.7
44A, 441
44C 6 440
Overflow
from an
E.S.
Suga 1
1,640
3,270
3,270
0
0
114 - 127
1.0
0.68
1.61
43
Tot. 0/flow
from B.S.
be. Tank
SUge 1
7,268
14,420
14,420
0
0
114 - 127
1.0
0.68
24
Oil
to
Scrubbing
Syeum
6.8
16.0
0
0
0
40-80
0.87
2.78
37
Total
Slurry
from L.S.
Bold Tank
178
221
142
106
60
40-80
1.61
46
Total Waah
Water
to B.S.
SUge 1
6,360
13,100
13.106
0
0
114 - 127
1.0
24A, 248
I4C 4 240
Oil to a
Comb.
Gu
Babaaur
4.0
0
0
0
40-80
0.87
2.78
38
Beeyele
Slurry
to L.S.
Bold Tank
282
310
227
170
60
40-80
1.61
46A, 461
46C 4 460
Huh
Water
to an B.S
Stage 1
1,640
3,270
3,270
0
0
114 - 127
1.0
0.64
25
Comb. Cu
from
Scrubbing
Sy.tem
3,260
1.080
444
4
0.06
200
4.28
3*
Emarg'cy
Ammonia
to Scrub*.
Syetam
r.o
22.6
lot
-------
00
PLAN
LIMESTONE SLURRY SCRUBBING SYSTEM
FOR NEW 500 MW BOILER
DWG. NO. A-601 SHEET 1 of 3
-------
00
10
5ECTIQNJ "A-A'
LIMESTONE SLURRY SCRUBBING SYSTEM
FOR NEW 500 MW BOILER
DWG. NO. A-601 SHEET 2 of 3
-------
O'«te.T r«CO COfffttlVTICM
-ttfc*^ fcx«>j>T«JS~
I
00
U)
I
5£CTION
LIMESTONE SLURRY SCRUBBING SYSTEM
FOR NEW 500 MW BOILER
DWG. NO. A-601 SHEET 3 of 3
-------
I
00
*»
I
PL-AN
LIMESTONE SLURRY SCRUBBING SYSTEM
FOR NEW 500 MW BOILER
DWG. NO. A-801 SHEET 1 of 3
-------
00
Ul
SECTION
LIMESTONE SLURRY SCRUBBING SYSTEM
FOR NEW.500 MW BOILER
DWG. NO. A-801 SHEET 2 of 3
-------
I
00
SECTION! '&-&'
LIMBSTONE SLURRY SCBDBBING SYSTEM
FOR NEW 500 MM BOILER
BOG. HO. A-801 SHEET 3 of 3
-------
00
O KCEKTBIC FUft VALVC
CX •*TE VALVC
H) «U>»E VALVe
1^1 CHCCK VALVE
tnj BALL WX.VC
KQ PLUO VALVE
fxi •UTTCOn.Y VALVt
^ ANOLE VALVE
ty ft-WAV VALVE
M LOCK OPEN
M LOCK CLOM9
IS ******
(ft NKIOLI VALVE
Cq PIMCU VALVE
—4 IUMO KAMttE
W0M* VEMT TO AVMOAPMEIE
LIST OP SYMBOLS
JS.|.i&
.. g ..
LOCAL
O4CM1CAL MM.
LJ
OO
LOCAL IfeMEL MOUNTED
MObC «• HATCH
-#- •UOBAATC VUATC
H UM> »UMO A.AMM
CONSCXUtTMN VINT
HLTBI
(T
V^^
- OMCKMTWK MOUCOI pD MWOM4 Wtf *T B^WMltrr » COMTtOL VALVEft)
- IQU1PMOIT PAOA4E (IdMTffUMti
ftEOMDA«V 0» tmt-fTV LH4B
UNt T1»
unuiv
-V
COMMICTION
r«MOTt» HIM owioe it aw-ftiTe.ttOT IMCLUOCD
ABBREVIATIONS
OMt CM TWO L*TT«»»
cewoocnviTv
NTTUOtb)
CUMB4T (CLCCnttCM.)
TMV 0* 'HMK ACWDULK
UUft* CHOIC*
OK VACUUM
•*OIO*CTfVITY
•mo o» raeoutwcY
MULTtVMtUALX
umo FOACTIOM
U*WT PILOT
LMKtf* 040KB
MULTtPIMCTI OM
THI* TULA » M ACCOVDAMCt WITH U&A. 9tm -•%.!, FM«
DMA.
__
LISTOFOPAWIN3S
A-tol POOOC** Fl-OW OI*»»IM
A*«0l PROCrt* PLOW OlA
PIPE LINE DESh5MATk>4
r
MOMWAl MM •«
KMUUTMM Tn
PIPING. MATCglAL. SPECIFICATIOMS
^YM &OL MATgRIA-L.
C8
NL
CARfcOW STSet.
1TAIMLHS VTECU , %0* 00 Sia
PIPIN6 SERVICE DESIGNATIONS
F-0
L.S
SEQVICE
A.MMONI A
fUCt. OIL.
UIV1C«TONC
WATCR
Piping information.
-------
00
00
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C!.&ia [- i«?t—& \~LG>*.
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(I :=== >i!-=^ : I
Limestone slurry scrubbing system for new 500-megawatt boiler.
-------
00
I ' 1 I—y-l ,-otmwoB wMM-unvr
! i ! ! i ; ' ' 4»oiiii>.4oi« at*
hM J±l
- > > > > > > >
© © ©©©©©©©©6 00© o
«; Siiiiili ' i iiiil! 1!
ii ? idiiiiliiiNflililfdiiri!
I !i 10 1 fit! i !i I
i i fi Hi
PHASE. I
Electrical single-line limestone slurry scrubbing system for new 500-megawatt boiler.
-------
BIBLIOGRAPHIC DATA '• Kcport No. 2.
SHEET EPA-R2-73-148a
1. Title and Subtitle
A Process Cost Estimate for Limestone Slurry Scrubbing
of Fl ue Gas , Part I
7. Author(s)
E.L. Calvin
9. Performing Organization Name and Address
Catalytic, Inc.
1515 Mockingbird Lane
Charlotte, North Carolina 28209
12. Sponsoring Organization Name and Address
EPA, Office of Research and Monitoring
NERC/RTP, Control Systems Laboratory
Research Triangle Park, North Carolina 27711
J. Kecipient's Accession No.
5. Report Date
January 1973
6.
8- Performing Organization Kept.
No.
10. Project/Task/Work Unit No.
Task Nn 11
11. Contract/Grant No.
68-02-0241
13. Type of Report & Period
Covered
Final
14.
15. Supplementary Notes
16. Abstracts
a wet limestone scrubbing system for removal of sulfur dioxide from the flue gas of
a new 500-megawatt steam boiler plant, fired with coal containing a 3. 5 percent
sulfur. The estimate covers all equipment from the boiler breeching to the stack.
and includes: limestone storage and processing, slurry scrubbing with stack gas
reheater and accessories, and spent limestone slurry pond disposal and water
recovery. The capital cost for the scrubbing system installed with a new boiler plant
was estimated to be 020.15 million or an incremental cost of $40. 30 per kilowatt of
installed power. The operating cost was estimated to be $7. 20 million per year, or
2.06 mills per kilowatt hour of electricity generated.
17. Key Words and Document Analysis. 17o. Descriptors
Air Pollution
*Desulfurization
Flue Gases
Washing
*Cost Estimates
Capital Costs
Operating Costs
Design
17b. Identifiers/Open-Ended Terms
Air Pollution Control
Stationary Sources
*Wet Limestone Scrubbing
17e. COSATI Field/Group 13B
Limestone
Slurries
Sulfur Dioxide
Coal
Equipment
18. Availability Statement
Unlimited
19. Security Class (This
Report)
UNCLASSIFIED
20. Security Class (This
UNCLASSIFIED
21. No. of Pages
95
22. Price
FORM NTIS-JS (REV. 3-72)
USCOMM-OC I49S2-P72
-------
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Guidelines to Format Standards for Scientific and Technical Reports Prepared by or for die Federal Government,
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------- |