EPA-R2-73-U8b
January 1973 Environmental Protection Technology Series
A Process Cost Estimate
for Limestone Slurry Scrubbing
of Flue Gas
Part II - Detailed Estimate Sheets
Office of Research and Monitoring
U.S. Environmental Protection Agency
Washington, D.C. 20460
-------
EPA-R2-73-148b
A Process Cost Estimate
for Limestone Slurry
Scrubbing of Flue Gas
Part II - Detailed Estimate Sheets
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
-------
SUMMARY
A conceptual design and cost estimate have been prepared for
a wet limestone scrubbing system to operate in conjunction with
the 500 mw steam boiler plant fired with coal that has a concen-
tration of 3.5 per cent sulfur. The wet limestone process is
based upon data developed by TVA, Office of Agricultural and
Chemical Development in the Muscle Shoals Pilot Plant. The de-
sign and cost estimate is for installation with a new boiler plant;
however, the installation for "retrofit" on an existing boiler
plant of similar size would be identical except for the capacity
of induced draft fans.
The capital cost for the plant was estimated to be $20.15 mil-
lion or an incremental cost of $40.30 per kilowatt of installed
power. This capital cost estimate is based upon quotations for
the majority of the equipment and construction labor estimated at
the 1973 level of midwest labor rates. The plant design was per-
formed in sufficient detail to provide take-offs for piping and
other mechanical hardware to provide an accurate basis for the
price quotations. Detailed estimate sheets are included as
Part 2 of the report. Part I of the report gives details of the
design and a summary of capital and operating cost.
Operating cost of the wet limestone scrubbing system was
estimated to be $7.2 million per year, or 2.06 mills per kilo-
watt hour of electricity generated. This operating cost was
calculated using typical unit prices for raw materials and
labor and factors derived from conceptual design. Operating
costs will vary in different locations from differences in
raw material costs, utility costs, and labor rates.
Ill
-------
15018-27IP
SUMMARY SHEET
ESTIMATE/JOB. NO
CUSTOMER
LOCATION .
6>%~01'024-l} DATE
I
MTERIAL
loo
SUBCONTRACTS AND SHOP LABOR
too
M.L RISK INSURANCE, LEML LIABILITY, ETC./ปZS
SPECIAL TAXES. (Salts. Use. ttc. )
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TOTAL MATERIAL, SUBCONTRACTS t SHOP LABOR
coo
FIELD LABOR
>^JsฃiL^ฃ5if!^B_^_i^^____^bm^ff^*i
PAYROLL BURDEN J/.7- /A
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TOTAL FIELD LABOR
OdO
FIELD SUPERVISION
FIELD OFFICE PERSONNEL
FIELD OFFICE EXPENSE
A *
FIELD COST ANALYSIS
ฃ_ฃ
UKDCM.
START-UP OPERATORS
CONSTRUCTION EQUIPMENT AND TOOLS /2'2 * L/)aog &>
TOTAL OTHER FIELD CHARGES
MECHANICAL ENGINEERING
i^
PROCESS ENGINEERING
ESTIMATING AND COST ANALYSIS
gfrฃ
HOME OFFICE TRAVEL EXPENSE
t^B-ToT/l
PURCHASING. EXPEDITING AND SHOP INSPECTION
ACCOUNTING. INDUSTRIAL REL.. GEN. ADM, t CONSTRUCTION
TOTAL HOME OFFICE EXPENSES
000
SUB-TOTAL
n
000
HEAD
ฑ
TOTAL CHARGES
CONTINGENCIES
ooo
ESCALATION
GRAND TOTAL
20
I5o
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RFUARKS
-------
MATERIAL
SHEET
ESTIMATE HO.
CUSTOMER
II -EPA
PAGE
OF
PROTSCTHM
LOCATION
CODE
DESCRIPTION
SIZE
MATERIAL
LABOR
SUBCONTRACT
1
2
3
4
S
6
7
a
9
10
11
12
13
14
IS
18
17
IB
19
20
21
22
23
24
25
28
27
28
29
30
31
32
33
34
35
38
37
7 T
OOQ
ULL
AG
2 & /Q-X x
rry 7^nt<;;
Z5
TOTAL MATERIAL, LABOR AND SUBCONTRACT
f 75" ooo
J F
-------
,ฉ21-27(1
S
I
C3 M A R Y
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LOCATION
an.
COPE
DESCRIPTION
0100
FIRED HEQTERS
0200
BEflCTBRS Qt3B IMTEEilMS
0500
TODERS
HEflT
C06LONG
8353
VESSELS. TOaKS. OBUOS ft IjlTEBOflLX
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i tOC
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FUTEBS.
. EQUIKIEHT
3000
JlPO
SCRUBBERS & EBTBfllCDEOT SEMROTORS
10015 &
EBIHCTOT
J400
. SB ITS
im
&W3
1300
14CC-
1500
1600
CBDCRtTC
JTMCTM8flL STEEL
JUULPlKlOKIEtJT
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2400
MICJTIHE ฃ P89TECTIWE GOATItlGS
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7700
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CBC3SYRUCTI0C3 SU^ilES S
TESTIHC OELBERSf^
-------
021-271
SUB-SUMMARY
CUSTOMER
- LOCATION
, CODE
OiOO
. 0200
0400
0500
0600
0700
0800
0900
* '000
1 : 0?
'233
- 25CJ
:sco
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3100
3200
ซ
' 400
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1300
1400
, I5CO
1630
1700
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1900
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1300
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2700
3300
_ 3500
3700
~ 3800
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2100
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DESCRIPTION
FIRED HEATERS AND BOILERS
STACKS
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TONERS
VESSELS. TANKS. DRUMS & INTERNALS
PUMPS AND DRIVERS (1}
BLOWERS AND COMPRESSORS
ELEVATORS. CONVFYORS. MATERIALS HANDLING EQUIP. (2
MISCELLANEOUS MECHANICAL EQUIPMENT
TANKAGE (/)
FILTERS. CENTRIFUGES. SEP. FOUIPMENT
AGITATORS AND MIXERS
oCfcuaeens & ENT^AINMENT SEPARATORS
MACHItit ;OJLS & MACHINE SHOP EQUIPMENT
HEATING. VENTILATION. AIR CONDITIONING.
3UST CONTR1L (Process only)
pACMCi uirns
SUB-TO, At - MAJOR EQUIPMENT
PIPING
SEWERS
INSTRUMENTATION
ELฃCTR!CAL
CONCiii'F. 2*3 0V
STRUCTURAL STEEL
F1REPROOFING
BUiLDINGS
S',TE DEVELOPMENT
INSULATION
PAIKTINC 6 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 & ELECTR CAL FACILITIES
TEMPORARY CONSTRUCT! II BU LDINGS
TEMPORARY SITE DEVELOPMENT
TOTAL DIRECT COSTS
MATERIAL
fฃ"0
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74,890
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39.200
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3.2^,0
1 30
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7fc,OCO
7^000
76,000
-------
CC1
ESTIMATE DETAIL SHEET
ESTIMATE/JOB NO
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CODE
9
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10
DATE
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46-74
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7
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9
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2
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3
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1
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0
0
0
0
0
0
0
8
0
2
1
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41-74
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CCM>
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8ESC3TOACT
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17-22
23-30
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(100
-------
CC1
ESTIMATE/JOB NO. -t
SEQUENTIAL
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WEIGHT
DESIGN: OF,
PSIG
SHELL: DIAHETER
LENGTH T TO T
THICRNESS
PL SPEC
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TYPE
THICRNESS
SUB TOTAL - 2501
SLABS & PEDESTALS
SADDLES FOR HORIZ. TRS.
CONC. TANK RINGS
SUPPT. SUPERSTRUCTURES
PLATFORBS & LADDERS
FIREPROOFING: TYPE. THR
INSULATION: TYPE. THR
COVER
PAINTING-STRUCT
PAINTING-TANK
. STL.
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5
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17-22
1
1
1
1
1
1
2
2
2
2
7
7
8
8
9
2
2
3
3
0
1
3
0
0
0
0
0
0
0
b
5
6
1
3
A
B
B
B
B
B
B
B
B
9
B
*
*
A
B
C
0
t
F
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9
*
*
*
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*
*
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CODE: 2500
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23-30
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DATE
40-74
QATERIAL
54-00
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-------
CC1
ESTIMATE DETAIL SHEET
ESTIMATE/JOB NO. -ซ
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PIECE*
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FIXER
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BARE PIPE: CARBON
STL
ALLOY
OTHER NATLS.
VALVES: CARBON
STL.
ALLOY
OTHER NATLS.
FLGS. FTGS: CARBON STEEL
ALLOY
OTHER
NATLS.
SPECIALTIES-TRAPS. ETC.
SPRING HANGERS
EXPANSION JOINTS
SHOP FAB'N. - VDR
CARB.
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ALLOY
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17-22
1
3
0
1
ซ
ซ
23-45
LINE DESCRIPTION
17-22
1
1
1
1
1
3
3
3
3
3
0
0
0
0
0
2
3
4
5
6
A
B
C
0
E
F
6
A
B
C
0
E
F
G
A
B
C
0
E
F
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H
1
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A
B
A
B
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TOTAL
CORE: 1300
WRITE IN
23-31
#
%
%
%
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%
%
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%
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FIXED
TYPE
UNIT
TON
TON
TON
TON
TON
TON
TON
NO
NO
NO
NO
NO
NO
NO
UNR
UNR
UNR
UNR
UNR
UNR
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TON
TON
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41-74
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54-10
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ERECT. ALL OTHER:
CARS
. STL
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: ALLOY
MB/TON
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MH.TCN
TESTING 1ELOERS
PI
PING SKETCHES
i TEMP. PIPING
PI
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COAT & *RAP UซOGRD.
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LINE DESCRIPTION
17-22
1
1
1
i
1
1
1
1
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3
3
3
3
3
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7
7
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23-38
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TYPE
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TON
MH
TON
MH
TON
KH
TON
dH
a
PL
EA
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LF
CY
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CY
CY
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NO
LB
LB
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39-45
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46-74
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54-60
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SLABS & PEDESTALS
SADDLES FOR HORIZ. TKS.
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SUPPT. SUPERSTRUCTURES
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CODE: 2500
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23-38
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1900
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FIRED HEATERS AND BOILERS ( 4~]
STACKS
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CC1
ESTIMATE/JOB NO. -H
SEQUENTIAL
PIECE* *
CC11-10
FIHB
*- .. ,.
ROUGH GRADING
FINISH GRADING
BLACK TOP RDS. & PAVING
GRAVEL. SURFACING
RAILROADS
FENCING
EARTH DIKES
DIGGING TEST HOLES
DEEP DELLS
TEHP. RR. ROADS
. FENCES
SITE DORK (OEUOLITIOtl)
SITE DORK SUBCONTRACT
SUB TOTAL - 21
CONCRETE VALVE BOXES
FIREDALL H FOOT 106
FIREDALL D/0 FOOTING
LARGE RATER SEPARATORS
OUTSIDE PAVING
RETAINING DALLS
SIOEDALKS
W
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17-22
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17-22
2
2
2
2
2
2
2
2
2
2
2
1
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7
7
7
7
7
7
7
7
0
0
0
0
0
0
0
0
1
1
5
1
2
2
2
2
2
2
3
2
3
4
5
6
7
8
9
0
1
0
7
1
2
3
4
4
5
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C
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A
A
B
A
A
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*
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CCBE: 2100
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23-30
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1 0700
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DESCRIPTION
FIRED HEATERS AND BOILERS
STACKS
REACTORS AND INTERNALS
T09ERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TOWERS
VESSELS. TANKS. DRUMS & INTERNALS (/)
PUMPS AND DRIVERS
BLOWERS AND COMPRESSORS
ELEVATORS. CONVEYORS. MATERIALS HANOLIN6 EQUIP.
BISCELLANEOUS MECHANICAL EQUIPMENT
TANKAGE
FILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS
SCRUBBERS & ENTRAINMENT SEPARATORS
3100 1 BACHINE TOOLS & MACHINE SHOP EQUIPMENT
2700 1 HEITIRS. VENTILATION. AIR CONDITIONING.
B OUST CONTROL (Process only)
* ,400 | PACKAGE UNITS
1
SUB-TOTAL - MAJOR EQUIPMENT
1300
1400
1500
1600
1700
1800
1900
ปsa
2IB9
- 2700
2300
2400
- 2800
2700
3300
3500
3700
~-aฎ^p
00
1300
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2000
2100
PIPING
SEW RS
INSTRUMENTATION
ELECTRICAL
CONCRETE 20 a Y
STRUCTURAL STEEL
Mซf PROOFING
lUILDINGS
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 K ELEC R CAL FACILITIES
TEMPORARY CONSTRUCTION 1 .DINGS
TEMPORARY SITE DEVELOP* NT
TOTAL DIRECT COSTS
MATERIAL
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2.400
6 tO
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2,2510
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HEIGHT
DBG. NO.
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VENDOR
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INTERNALS
INTERNALS
INTERNALS
INTERNALS
SUB TOTAL - 0801
SLABS-PEDESTALS
SADDLES
SUPPT. SUPERSTRUCTURES
PL
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17-22
1
1
1
1
1
2
2
2
2
7
7
8
8
9
2
2
3
3
0
1
0
0
0
0
0
0
0
5
5
1
3
1
1
1
1
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CODE: 0800
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23-30
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-------
CC1
ESTIMATE/JOB NO. -*
SEQUENTIAL
PIECE*
CC11
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FIXED
.- ป.. .
BARE PIPE: CARBON
STL
ALLOY
OTHER MAILS.
VALVES: CARBON
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OTHER BAILS.
FLGS, FTGS: CARBON STEEL
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SPECIALTIES-TRAPS,
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EXPANSION JOINTS
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17-22
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23-45
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17-22
1
1
1
1
1
3 0
3 0
3 0
3 0
3 0
2
3
4
5
6
A
B
C
D
E
F
G
A
6
C
D
E
F
G
A
B
C
D
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F
G
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1
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A
8
A
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0
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*
*
*
*
*
*
*
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TOTAL
CODE: 1300
WRITE IN
23-3C
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TON
TON
TON
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NO
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NO
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UNR
UNR
UNR
UNR
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39-45
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FIRED HEATERS AND BOILERS
STACKS
REACTORS AND INTERNALS
TOWERS AND INTERNALS
HEAT EXCHANGE EQUIPMENT
COOLING TOWERS
VESSELS. TANKS. DRUMS ft INTERNALS
PUMPS AND DRIVERS
BLOWERS AND COMPRESSORS
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MISCELLANEOUS MECHANICAL EQUIPMENT
TANKAGE
FILTERS. CENTRIFUGES. SEP. EQUIPMENT
AGITATORS AND MIXERS
w SCRUBBERS & ENTRAINMENT SEPARATORS
MACHINE TOOLS & MACHINE SHOP EQUIPMENT
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PACHAS UN!TS
SUB-TOTAL - MAJOR EQUIPMENT
PIPING
SEW:RS
INSTRUMENTATION
ELECTRICAL
CONCRCTl /30 CV
STRUCTURAL STEEL
FIREPROOF ING
BUILDINGS
SITE DEVELOPMENT
INSULATION
PAINTING I PROTECTIVE COATINGS
FIELD TESTING
CHEMICALS AND CATALYST
PILING
FIRE PROTECTION
MISCELLANEOUS FURNITURE FOR PLANT BUILDINGS
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TESTING WELDERS
TEMPORARY PIPING ft ELECTR CAL FACILITIES
TEMPORARY CONSTRUCT ON BU .0 NGS
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-------
BIBLIOGRAPHIC DATA ' RcPฐrt No- - 2'
SHEET EPA-R2-73-148b
4. Title and Subtitle
A Process Cost Estimate for Limestone Slurry Scrubbing
of Flue Gas . Part H -- Detailed Estimate Sheets
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
3. Recipient's Accession No.
5. Report Date
Januarv 1973
6.
8. Performing Organization Rept.
No.
10. Project/Task/Work Unit No.
Task No. 11
11. Contract/Grant No.
68-02-0241
13. Type of Report & Period
Covered
Final
14.
IS. Supplementary Notes
16. Abstracts
JC~ AX V O.J. WJL CliV^ A vฃ/w* ^ vvx.iA^M_A4Ai_* MvซrM.A^v-ปvv,...-inr.v _ ^
design and cost estimate for 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 $20.15 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.
Air Pollution
*Desulfurization
Flue Gases
Washing
*Cost Estimates
Capital Costs
Operating Costs
Design
Limestone
17b. Identifiers/Open-Ended Terms
Air Pollution Control
Stationary Sources
*Wet Limestone Scrubbing
17o. Descriptors
Slurries
Sulfur Dioxide
Coal
Equipment
17c- COSATI Field/Group
13B
18. Availability Statement
Unlimited
19. Security Class (This
Report)
UNCLASSIFIED
20. Security Class (This
Page
UNCLASSIFIED
21. No. of Pages
96
22. Price
FORM NTIS-3S IREV. 1-721
USCOMM-OC I4952-P72
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INSTRUCTIONS FOR COMPLETING FORM NTIS-35 (10-70) (Bibliographic Data Sheet based on COSATI
Guidelines to Format Standards for Scientific and Technical Reports Prepared by or for the Federal Government,
PB-180 600).
1. Report Number. Each individually bound report shall carry a unique alphanumeric designation selected by the performing
organization or provided by the sponsoring organization. Use uppercase letters and Arabic numerals only. Examples
FASEB-NS-87 and FAA-RD-68-09. ซ
2. Leave blank.
3. Recipient's Accession Number. . Reserved for use by each report recipient.
4. Title and Subtitle. Title should indicate clearly and briefly the subject coverage of the report, and be displayed promi-
nently. Set subtitle, if used, in smaller type or otherwise subordinate it to main title. When a report is prepared in more
than one volume, repeat the primary title, add volume number and include subtitle for the specific volume.
5. Report Dote. Fach report shall carry a date indicating at least month and year. Indicate the basis on which it was selected
(e.g., date of issue, date of approval, date of preparation.
6. Performing Organ! zotion Code. Leave blank.
7. Authors). Give name(s) in conventional order (e.g., John R. Doe, or J.Robert Doe). List author's affiliation if it differs
from the performing organization.
8. Performing Organization Report Number. Insert if performing organization wishes to assign this number.
9. Performing Organization Name and Address. Give name, street, city, state, and zip code. List no more than two levels of
an organizational hierarchy. Display the name of the organization exactly as it should appear in Government indexes such
as USCRDR-I.
10. Project/Task/Work Unit Number. Use the project, task and work unit numbers under which the report was prepared.
11. Contract/Grant Number. Insert contract or grant number under which report was prepared.
12. Sponsoring Agency Name and Address. Include zip code.
13. Type of Report and Period Covered. Indicate interim, final, etc., and, if applicable, dates covered.
14. Sponsoring Agency Code. Leave blank.
15. Supplementary Notes. Enter information not included elsewhere but useful, such as: Prepared in cooperation with . . .
Translation of ... Presented at conference of ... To be published in ... Supersedes . . . Supplements
16. Abstract. Include a brief (200 words or less) factual summary of the most significant information contained in the report.
If the report contains a significant bibliography or literature survey, mention it here.
17. Key Words and Document Analysis, (a). Descriptors. Select from the Thesaurus of Engineering and Scientific Terms the
proper authorized terms that identify the major concept of the research and are sufficiently specific and precise to be used
as index entries for cataloging.
(b). Identifiers and Open-Ended Terms. Use identifiers for project names, code names, equipment designators, etc. Use
open-ended terms written in descriptor form for those subjects for which no descriptor exists.
(c). COSATI Field/Group. Field and Group assignments are to be taken from the 1965 COSATI Subject Category List.
Since the majority of documents are multidisciplinary in nature, the primary Field/Group assignment(s) will be the specific
discipline, area of human endeavor, or type of physical object. The applications) will be cross-referenced with secondary
Field/Group assignments that will follow the primary posting(s).
18. Distribution Statement. Denote releasability to the public or limitation for reasons other than security for example "Re-
lease unlimited". Cite any availability to the public, with address and price.
19 & 20. Security Classification. Do not submit classified reports to the National Technical
21. Number of Pages. Insert the total number of pages, including this one and unnumbered pages, but excluding distribution
list, if any.
22. Price. Insert the price set by the National Technical Information Service or the Government Printing Office, if known.
FORM NTI3-33 IREV. 3-72) USCOMM-DC 1ซซS2-P72
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