PARTICULATE EMISSION
CONTROL COSTS FOR
INTERMEDIATE-SIZED
BOILERS
U.S. ENVIRONMENTAL PROTECTION AGENCY
Strategies and Air Standards Division
Economic Analysis Branch
Research Triangle Park,
North Carolina 27711
-------
IGCI
INDUSTRIAL GAS CLEANING INSTITUTE. INC./THE NATIONAL ASSOCIATION OP HAwupAcniREas OF INDUSTRIAL AM POLLUTION CONTROL EQUIPMENT
THE CLEAN AIR PEOPLE
President
ROBERT J. WRIGHT
Fuller Co.
Vice President
FRANK R. CULHANE
Wheelabrator-Frye. Inc.
Secretary-Treasurer
JACK E. MARTIE
Air Correction Divn.. u.O.P.
PARTICULATE EMISSION CONTROL COSTS
BOARD OF DIRECTORS
EUGENE P. STASTNY
Past President FOR
Environmental Elements Corp.
ROBERT W. ARNOLD
INTERMEDIATE-SIZED BOILERS
Carborundum Env'fl. Sys.. Inc.
MICHAEL NEUMANN. JR.
Fisher-Klosterman, Inc.
ROBERT G. HUNTINGTON
American Air Filter Co.
JOSEPH P. KAISER
Gallagher-Kaiser Corp.
WILLIAM W. MOORE
Belco Pollution Control Co.
HARRY J. NOVICK
Research-Cottrell. Inc.
JOSEPH H. POVEY
Matthey Bishop. Inc.
THOMAS V. REINAUER
HAROLPDW.WE,SGERBER Prepared by:
Kirk & Blum Mfg. Co.
Industrial Gas Cleaning Institute
Stamford, Connecticut
CARROLL A. GREATHOUSE
Executive Director
SIDNEY R. OREM
Technical Director
JONATHAN T. DYER
Contract No. 68-02-1473
Task No. 18
Prepared fors
U.S. ENVIRONMENTAL PROTECTION AGENCY
Strategies and Air Standards Division
Economic Analysis Branch
Research Triangle Park,
North Carolina 27711
February 1977
P.O. BOX 1333 • STAMFORD, CONNECTICUT 06904 • TEL. 203/323-3143
-------
TABLE OF CONTENTS
Page
1.0 INTRODUCTION 1-1
2.0 PROCESS DESCRIPTION 2-1
2.1 Mechanical Collectors 2-1
2.2 Fabric Filters 2-3
2.3 Electrostatic Precipitators 2-4
3.0 CONTROL DEVICES 3-1
3.1 Specifications 3-1
3.2 Capital Investment Costs 3-1
3.3 Annualized Operating Costs 3-6
APPENDIX ELECTROSTATIC PRECIPITATOR A-2
SPECIFICATIONS
FABRIC FILTER SPECIFICATIONS A-8
MECHANICAL COLLECTOR SPECIFICATIONS A-15
ii
-------
LIST OF FIGURES
No. Page
2-1 Tubular Centrifugal Collector 2-2
2-2 Fabric Filter Cleaning Mechanisms 2-5
2-3 Typical ESP Arrangement 2-6
3-1 Capital Cost of Electrostatic Precipitators 3-3
3-2 Capital Cost of Fabric Filters 3-4
3-3 Capital Cost of Mechanical Collectors 3-5
3-4 Annualized Operating Costs of Electrostatic 3-8
Precipitators
3-5 Annualized Operating Costs of Fabric Filters ' 3-9
3-6 Annualized Operating Costs For Mechanical 3-10
Collectors
111
-------
LIST OF TABLES
No. Page
3-1 Capital Investment Costs of Control Devices 3-2
3-2 Annualized Operating Costs of Control Devices 3-7
IV
-------
1.0 INTRODUCTION
The purpose of this task was to determine the capital
and annualized operating costs incurred for particulate-
emissions-control systems used on new solid-fuel fired
intermediate-sized boilers. Electrostatic precipitators,
fabric filters, and mechanical collectors were the emission-
control devices evaluated. Boiler size, particle size
distribution, flue gas temperature, and emission control
regulation limits were the variables in these cost esti-
mates .
The scope of the task was limited to a single type of
coal of the following analysis:
Ash 7.5%
Heating value 29.78 megajoules/kg (12,800 Btu/lb)
Sulfur 0.8%
Moisture 5.0%
The sulfur content of this coal will meet New Source Per-
formance Standards.
1-1
-------
Specifications were prepared for the following options:
Boiler size, g
Emission limit, Inlet megajoules/ (10
nanograms/ (lb/ temp., sec. BTU/
Control device joule 10^ Btu) °F or MW hr.)
Mechanical collector 129 (0.3) 600 3 (10.2)
Mechanical collector 129 (0.3) 600 40 (136.5)
Mechanical collector 110 (0.25) 350 73 (249.0)
Electrostatic pre-
cipitator 43 (0.1) 600 15 (51.2)
Electrostatic pre-
cipitator 43 (0.1) 600 45 (153.6)
Electrostatic pre-
cipitator 43 (0.1) 350 73 (249.0)
Fabric filter 4.3 (0.01) 600 3 (10.2)
Fabric filter 4.3 (0.01) 600 25 (85.3)
Fabric filter 4.3 (0.01) 450 55 (187.7)
Fabric filter 4.3 (0.01) 350 73 (249.0)
Prepared specifications are given in the Appendix.
The specifications for each control device were sent to
three IGCI members who manufacture the device. The bidders
furnished quotations of capital investment costs and direct
operating costs for each of the specifications.
The cost data were tabulated and averaged for each
control device. Duct and stack costs were estimated and
added to the capital cost data furnished by IGCI members.
It should be understood that the efficiency data pro-
vided in this study is the normal design value. This value
should be obtained when the collection equipment is in good
operating condition and within the design flow specifica-
tions. There is no assurance, however, that these specifi-
1-2
-------
cations will be in effect 100 percent of the time, due to
unforeseen upsets of process gas flows or conditions. These
upsets include, but are not limited to, changes of process
chemistry or size distribution of suspended particulate
matter, or excessive dust load. Normal, good maintenance
procedures must be employed to meet the continuous high
level efficiency requirements.
1-3
-------
2.0 PROCESS DESCRIPTION
When coal is burned in a boiler, a portion of the ash
produced by combustion is entrained in the flue gas to the
stack. The particulate emissions can be reduced by mechani-
cal collectors, fabric filters, or by electrostatic pre-
cipitators. A brief description of each device is given in
the following sections.
2.1 MECHANICAL COLLECTORS
All types of mechanical collectors utilize the mass or
inertia of particles for their removal from the dust-laden
gas stream. Cyclone and multiple-cyclone collectors are
examples of the type commonly used at industrial boiler
installations. The tubular centrifugal collector (Figure 2-
1) is a cylindrical chamber whose design enables the in-
coming gas stream to form a vortex flow pattern. The dust
particles are thrown by inertia against the collector wall
and fall into a collecting hopper. The vortex action causes
the "cleaned" air to exit through the center of the collector.
Multiple tubular collectors, as the name implies, are a
cluster of small collectors used in a parallel-flow arrange-
ment for better efficiency.
2-1
-------
CLEAN GAS
to
I
to
CLEAN GAS
OUTLET
TUBE
INTER
SPIRAL FLOW
OUTLET
TUBE SHEET
DUST DISCHARGE
TO STORAGE
Cyclone Type
Multi-Tube Type
Figure 2-1. Tubular Centrifugal Collector
-------
Mechanical collectors are most efficient when used to
collect particles with diameters of 10 microns or larger.
Collection efficiency decreases markedly for particle sizes
less than 10 microns because the inertial separating force
is much less. Experience has shown that a well-maintained
mechanical collector can attain an efficiency of 85 to 90
percent for particles over 10 microns; with fly ash particles
efficiencies of 75 to 85 percent per stage is considered
good. Multiple stage collectors are used to obtain removal
efficiencies up to 98 percent.
2.2 FABRIC FILTERS
Particles captured by a fabric filter system are
collected mainly by direct interception and inertial impac-
tion. Fabric selection is important because of the various
parameters to be considered for a particular operation
(e.g., operating temperature, abrasion resistance, acid
resistance, cost); however, the main function of the fabric
is to provide a semirigid filtering medium on which the
initial cake can form. This dust layer then acts as a fine
filter, which is capable of obtaining high collection effi-
ciencies.
Fabric filters are classified according to the method
used for dislodging the built-up dust layer; the methods
include shaking, reverse-flow, reverse-jet, and pulse-jet
2-3
-------
(Figure 2-2). Filter fabrics are classified as woven or
felt. Felt, unlike woven fabric, is a genuine filter medium
and is more efficient in collection of the dust layer; it is
also more expensive than woven fabric.
Fabric filters can attain efficiencies of greater than
99 percent if properly maintained. The efficiency is not
hampered by changes in fly ash properties and boiler loads.
The principal limitation of fabric filters is the inability
of the filter fabric to withstand temperatures above 550°F.
Glass bags or Teflon-coated fabric can be used in this
higher temperature range, but they are costly. Cooling the
flue gas to permit use of less expensive filter media is an
alternative. Normal life expectancy of the fabric is 1 to 2
years depending on ash characteristics, temperature varia-
tions, and the cleaning mechanism.
2.3 ELECTROSTATIC PRECIPITATOR
Another common particulate emission control device
available for industrial boilers is the plate-type electro-
static precipitator (ESP). This type of ESP consists of
alternate parallel banks of discharge electrodes and collect-
ing plates (Figure 2-3). A corona formed on the discharge
electrodes causes gas molecules to form ions. These ionized
gas particles then collide with dust particles (e.g., fly
ash), giving them a charge. The charged particles migrate
2-4
-------
TUBULAR TYPE
SHAKER SYSTEM DUST COLLECTOR
MECHANICAL SHAKER. CONTINUOUS SERVICE
T_A A \ Mr
/
/
_..
>\
/
/
/
V
y
^
/
/
\
ir
1
VUw
/
\
X
/ ~'
1
\
\
>+**•
if
ii
f
h
REVERSE FLOW CLEANING PULSE JET
Figure 2-2. Fabric filter cleaning mechanisms.
2-5
-------
tat
Figure 2-3. Typical ESP arrangement.
-------
toward the oppositely-charged plates, which are periodically
or continuously rapped so the dust can be dislodged and fall
into the collecting hoppers.
\
ESP's can obtain efficiencies greater than 99 percent.
According to the Deutsch-Anderson equation (used most often
for ESP design), the main parameters that affect ESP effi-
ciency are the collecting plate area, particle migration
velocity, and the volume of gas to be treated. The effi-
ciency of an ESP with a given plate area and constant gas
volume can vary widely, depending on the particle migration
velocity, which is a function of fly ash resistivity. The
chemical composition of the ash has a profound effect on fly
ash resistivity, and thus on precipitator performance.
One basic advantage of the precipitator is that its
force is applied only to the particles to be collected,
permitting large volumes of gas to be handled with very low
pressure drop and minimum power requirement.
2-7
-------
3.0 CONTROL DEVICES
3.1 SPECIFICATIONS
The specifications that were developed for each of the
control devices are presented in the Appendix. These spec-
ifications describe the process design conditions under
which the control device will operate; they also furnish de-
tails for construction and for the auxiliary equipment to be
included.
These specifications were sent to the various selected
IGCI members to obtain quotations of capital and direct
operating costs.
3.2 CAPITAL INVESTMENT COSTS
The investment costs for the various particulate con-
trol devices are given in Table 3-1 and are presented graph-
ically in Figures 3-1 through 3-3.
With the exception of the duct and stack costs, all
cost components represent values obtained by computing
averages of costs submitted by IGCI members. The costs for
ductwork and the stack were calculated based upon a common
equipment lay-out arrangement. The duct and stack diameters
were sized for nominal gas velocities, and installed costs
were developed by use of Mean's Cost Data, 1976 Edition.
3-1
-------
Table 3-1. CAPITAL INVESTMENT COSTS OF CONTROL DEVICES FOR INTERMEDIATE-
SIZED COAL-FIRED BOILERS (DEC. 1976)
Control device
Boiler sire, meqaioules/sec . or MW
ClO6 Btu/hr)
Inlet and Outlet Gas Plow
ACFM
op
SCFM
Particulate Loading
Inlet, gr/acf
Inlet, Ib/hr
Outlet, gr/acf
Outlet, Ib/hr
Cleaning Efficiency, %
Equipment Costs
Device
Auxiliary equipment
Total
Installation Costs - Direct
Foundation and supports
Stack*
Ducts3
Piping
Painting
Insulation
Electric
Other
Total
Installation Costs - Indirect
Engineering
Construction and field expenses
Construction fees
Start up
Performance tests
Contingencies
Total
Total Turnkey Cost
Electrostatic Precipitator
15
(51.2)
27,500
600
13,700
0.82
194
0.02
5.1
97.3
$138,750
52,710
191,460
6,750
5,800
25,380
None
1,570
29,410
29,820
60,300
159,030
11,850
21,590
670
5,180
7,020
11,830.
58,140
$408,630
45
(153.6)
83,100
600
41,600
0.82
587
6.02
15.4
97.3
$206,860
75,510
282,370
12,860
9,490
59,150
None
2,030
56,530
33,080
94,970
268,110
13,130
27,500
900
5,180
7,020
18,430
72,160
$622,640
73
(249.0)
115,800
350
75,800
0.96
952
0.025
25
97.3
$248,450
96,360
344,810
15,810
10,950
71,250
None
2,640
66,500
35,050
113,710
315,910
14,720
33,090
1,010
5,180
7,020
22,630
83,650
$744,370
Fabric Filters
3
(10.2)
5,400
600
2,700
0.82
38
0.002
0.1
99.7
$25,690
5,890
31,580
2,180
3,360
3,960
1,240
250
7,510
4,640
5,040
28,180
1,990
1,350
380
830
3,000
770
8,320
$68,080
25
(85.3)
45,960
600
23,000
0.84
330
0.002
0.85
99.7
$122,300
24,390
146,690
8,980
7,310
41,800
2,280
1,300
32,650
9,890
18,680
122,890
8,240
6,430
1,800
2,150
4,500
3,450
26,570
$296,150
55
(187.7)
87,100
450
50,700
0.96
716
0.002
1.9
99.7
$198,770
40,720
239,490
15,420
9,500
59,150
4,010
2,700
55,720
15,610
31,090
193,200
15,310
11,650
3,730
3,550
4,500
7,130
45,870
$478,560
73
(249.0)
115,800
350
75,800
0.96
952
0.0025
2.5
99.7
$262,860
62,740
325,600
19,040
10,950
71,250
4,990
3,500
80,820
18,240
41,900
250,690
19,670
15,150
4,870
4,950
4,500
9,330
58,470
$634,760
Mechanical Collectors
3
(10.2)
5,400
600
2,700
0.46b
21.3
0.07
3.2
85.
$ 6,340
1,950
8,290
1,600
3,360
3,960
None
20
860
200
600
10,600
1,000
4,500
1,500
1,000
2,000
-
10,000
$28,890
40
(136.5)
73,400
600
36,700
2.3
1,447
0.07
43.4
97.
$ 51,050
10,250
61,300
9,000
8,760
53,210
None
120
6,840
8,000
3,900
89,830
2,000
4,500
1,900
1,000
2,000
-
11,400
$162,530
73
(249.0)
115,800
350
75,800
3.0
2,978
0.075
74.4
97.5
$ 88,530
17,150
105,680
13,000
10,950
71,250
None
200
11,370
10,000
5,800
122,570
2,000
6,000
2,400
1,000
2,000
-
13,400
$241,650
I
to
Costs estimated from Mean's Cost Data, 1976 Edition.
Low value based upon a chain grate type boiler.
-------
VO
U)
Q
3
o
a
10"
9
8
7
6
5
10"
LEGEND:
O COLLECTOR
D COLLECTOR PLUS MK. EQPMT.
A TURNKEY COST
t L i
ig* 2 3 4 5 6 7 8 9 10a
GAS FLOW (SCFM)
Figure 3-1„ Capital cost of electrostatic precipitators
used on intermediate-sized boilers.
3-3
-------
10
VO
o
U4
O
cc
3
to
o
o
10"
I I
10J
LEGEND:
O COLLECTOR
D COLLECTOR PLUS AUX. EQPMT.
A TURNKEY COST
L L L
345 1Q 2
GAS FLOW (SCFM)
345
Figure 3-2. Capital cost of fabric filters used on
intermediate-sized boilers.
3-4
-------
10'
VO
ft
o
UJ
a
CO
oc
g
s
CO
o
o
10'
10*
10*
2 345
1 T
i i i
LEGEND:
O COLLECTOR
D COLLECTOR PLUS AUX. EQPMT.
A TURNKEY COST
I I
I i
* 2345 10
GAS FLOW (SCFM)
5
2 345
Figure 3-3. Capital cost of mechanical collectors
used on intermediate-sized boilers.
3-5
-------
3.3 ANNUALIZED OPERATING COSTS
The annual costs for operation of the control devices
are furnished in Table 3-2 and Figures 3-4 through 3-6.
The direct operating costs are predicated upon opera-
tion at a capacity factor of 65 percent. The cost data
shown are the averages of those submitted by IGCI members.
The total operating cost is the sum of direct costs and
indirect costs. The indirect costs consist of overhead and
capitalization charges, which were estimated.
3-6
-------
Table 3-2„ ANWUALIZED OPERATING COSTS OF CONTROL DEVICES FOR INTERMEDIATE-
SIZED COAL-FIRED BOILERS (DEC- 1976)
Basis: Continuous operation at 65 percent of capacity factor.
Control device
Boiler size, mega joules/sec . or MW
(106 Btu/hr)
Inlet and Outlet Gas Flow
ACFM
op
SCFM
Particulate Loading
Inlet, gr/acf
Inlet, Ib/hr
Outlet, gr/acf
Outlet, Ib/hr
Cleaning Efficiency, 8
Direct Operating Costs Unit Cost
Operation:
Operator 510/manhour
Supervision $12/manhour
Total
Maintenance :
Labor $10/manhour
Materials
Total
Replacement parts
Electricity $0.03/kWh
Total Direct Cost
Indirect Costs
Overhead Charges :
Payroll 20% op. labor
Plant 500 lab. 6 mtce.
Total
Capitalization 17% investment
Total Indirect Cost
Total Annual! zed Cost
Electrostatic Precipitator
15
(51.2)
27,500
600
13,700
0.82
194
0.02.
5.1
97.3
$ 1,780
390
2,170
1,295
75
1,370
490
11,170
15,200
430
1,770
2,200
69,470
71,670
$86,870
45
(153.6)
83,100
600
41,600
0.82
587
0.02
15.4
97.3
$ 1,950
390
2,340
2,380
150
2,530
770
24,200
29,840
470
2,440
2,910
105,820
108,730
$138,570
73
(249.0)
115,800
350
75,800
0.96
952
0.025
25
97.3
$ 2,000
390
2,390
2,990
210
3,200
950
32,490
39,030
480
2,800
3,280
126,540
129,820
$168,850
Fabric Filters
3
(10.2)
5,400
600
2,700
0.82
38
0.002
0.1
99.7
$ 4,025
335
4,360
435
265
700
1,790
1,560
8,410
870
2,530
3,400
11,580
14,980
$23,390
25
(85.3)
45,960
600
23,000
0.84
330
0.002
0.85
99.7
$ 6,240
335
6,575
2,650
1,245
3,895
13,930
12,750
37,150
1,320
5,230
6,550
50,350
56,900
$94,050
55
(187.7)
87,100
450
50,700
0.96
716
0.002
1.9
99.7
$ 8,030
335
8,365
3,940
2,385
6,325
23,910
23,700
62,300
1,675
7,345
9,020
81,350
90,370
$152,670
(249..0)
115,800
350
75,8.00
0.96
952
0.0025
2.5
99.7
$ 8,940
350
9,290
5,170
3,030
8,200
32,220
31,200
80,910
1,860
8,750
10,610
107,910
118,520
$199,430
Mechanical Collectors
(10.2)
5,400
600
2,700
0.463
21.3
0.07
3.2
85.
-
-
None
190
None
190
400
650
1,240
None
30
30
4,910
4,940
$ 6,180
40
(136.5)
73,400
600
36,700
2.3
1,447
0.07
43.4
97.
$ 100
30
130
240
None
240
730
16,830
17,930
30
140
170
27,630
27,800
$45,730
73
(249.0)
115,800
350
75, 800
3.0
2,978
0.075
74.4
97.5
$ 200
60
260
260
None
260
730
26,790
28,040
50
260
310
41,080
41,390
$69,430
U)
Low value based upon a chain grate type boiler.
-------
vo
O
a
I I I
o
I I I
LEGEND:
O DIRECT COSTS
A TOTAL COSTS
L t i
45 ICT Z
GAS FLOW (SCFM)
3 4 5
lit
Figure 3-4. Annualized operating costs of electrostatic
precipitators used on intermediate-sized boilers.
3-8
-------
o
LU
a
oo
•f.
o
a
CO
t-
oo
O
o
10
5
10"
5
4
3
10
i i r
' I I I
I 111
L IL
LEGEND:
O DIRECT COSTS
A TOTAL COSTS
i i i i i
10° 2 3 4 5 10^ 2 3 4 5 105 5432
GAS FLOW (SCFM)
Figure 3-5. Annualized operating costs of fabric filters
used on intermediate-sized boilers.
3-9
-------
UD
UJ
o
C£
3
_J
O
O
to
o
o
10'
I I
LEGEND:
O DIRECT COSTS
A TOTAL COSTS
I I
345 10*
GAS FLOW (SCFM)
4 5
10a
Figure 3-6. Annualized operating costs for mechanical
collectors used on intermediate-sized boilers.
3-10
-------
APPENDIX
ELECTROSTATIC PRECIPITATOR SPECIFICATIONS
FABRIC FILTER SPECIFICATIONS
MECHANICAL COLLECTOR SPECIFICATIONS
A-l
-------
Company: IGCI
Project: 68-02-1473
Task No.: 18
Date: November 1976
ELECTROSTATIC PRECIPITATOR SPECIFICATION '
An electrostatic precipitator is to remove solid par-
ticulate matter from the exhaust gas of an intermediate
sized coal-fired boiler. Systems shall be quoted complete,
including the following:
1. Electrostatic precipitator
2. Inlet and outlet plenums
3. Air distribution turning vanes
4. Structural steel for installation of the pre-
cipitator at grade
5. Insulation, 2" thick, to match temperature ser-
vices
6. Induced draft fan with a head equal to the pres-
sure drop across the precipitator selected to
show differential pressure
7. Other necessary auxiliary equipment
8. Electrical installation work.
/ i
Ash handling equipment and controls are not included in this
specification.
Details
1. The material of construction of all parts of the
system shall be mild A-36 steel, 3/16" minimum
thickness.
2. Electrical power at 460v, 3 phase, 60 cycle; and
llOv, 1 phase, 60 cycle is available in sufficient
quantity at the site. Automatic voltage controls
shall be provided so that no access to high vol-
tage equipment is possible without first de-
energizing all fields.
A-2
-------
System Requirements;
1. The attached data sheets outline the system varia-
tions on which quotations will be received, and
provides inlet and outlet flow rates and particu-
late loadings. The gas cleaning device is to
reduce the solids content of the gas to the levels
specified.
2. The coal being fired in the boiler has the follow-
ing analysis?
Sulfur 0.8%
Ash 7=5%
Moisture 500%
Megajoules/Kg 29,78
(Btu/lb 12,800)
3. Size distribution of particles in the inlet gas is
as follows;
Particle Size Percent by weight
Above 100 microns 35
40 to 100 microns 30
20 to 40 microns 14
10 to 20 microns 11
Below 10 microns 10
4. Only spreader stoker type boilers are considered.
A-3
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIPITATORS
FOR INTERMEDIATE
SIZED BOILERS
Data Sheet No.
18-3
Project No. 68-02-1473
Task No. 18
Mega joules/sec .
BOILER SIZE or MW
Inlet and outlet gas flow
ACFM
°F
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
Gas cleaning equipment cost
Cost of auxiliaries
Total equipment cost
Installation costs, direct*
Foundation and supports
Duct work
Stack
Piping
Insulation
Painting
Electrical
Total direct costs
Installation costs, indirect
Engineering
Constr. and field expense
Construction fees
Start-up
Performance test
Contingencies
Total Indirect costs
Turnkey cost
15
27,500
600
13,700
0.82
194
0.02
5.1
97.3%
45
83,100
' 600
41,600
0.82
587
0.02
15.4
97.3%
* Where specified
A-4
-------
ANNUAL OPERATING COST DATA
ELECTROSTATIC PRECIPITATOR
Data Sheet No.
18-3A
Project No. G8-02-147'3
Task No. 18
Megajoule
BOILER SIZE or MW
Inlet & outlet gas flo
ACFM
oF
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
Operating cost item
Direct costs:
Operating labor
Operator
Supervisor
Total
Maintenance
Labor
Materials
Total
Replacement parts
Utilities
Electricity
Total
Total Direct costs
Capital charges
Total annual cost
2S/S6C.
w
Unit cost
$10/manhour
$12/manhour
$10/manhour
$0.03/kWh
15
27,500
600
13,700
0.82
194
0.02
5.1
97.3%
45
83,100
600
'41,600
0.82
587
0.02
15.4
97.3%
Operating costs to be based on annual operation of 8760 hours
per year % 65% capacity factor.
A-5
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIPITATORS
FOR INTERMEDIATE
SIZED BOILERS
Data Sheet No. 18-4
Project No. 68-02-1473
Task No. 18
Mega joules/sec .
BOILER SIZE or MW
Inlet and outlet gas flow
ACFM
°F
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
Gas cleaning equipment cost
Cost of auxiliaries
Total equipment cost
.Installation costs, direct*
Foundation and supports
Duct work
Stack
Piping
Insulation
Painting
Electrical
Total direct costs
Installation costs, indirect
Engineering
Constr. and field expense
Construction fees
Start-up
Performance test
Contingencies
Total Indirect costs
Turnkey cost
73
115,800
350
75,800
0.96
952
0.025
25
97.3%
* Where specified
A-6
-------
ANNUAL OPERATING COST DATA
ELECTROSTATIC PRECIPITATOR
Data Sheet No.
18-4A
Project No. 68-02-147'3
Task No. 18
Megajou]
BOILER SIZE or
Inlet & outlet gas flo
ACFM
oF
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
.es/sec.
MW
w
73
115,800
350
75,800
0.96
952
0.025
25
97.3%
1
Operating cost item
Direct costs:
Operating labor
Operator
Supervisor
Total
Maintenance
Labor
Materials
Total
Replacement parts
Utilities
Electricity
Total
Total Direct costs
Capital charges
Total annual cost
Unit cost
$10/manhour
$12/manhour
$10/manhour
$0. 03/kWh
,
Operating costs to be based on annual operation of 8760 hours
per year @ 65% capacity factor.
A-7
-------
Company: IGCI
Project: 68-02-1473
Task No.: 18
Date: November 1976
FABRIC FILTER SPECIFICATION
i
A fabric filter is to remove solid particulate matter
from the exhaust gas of an intermediate sized coal-fired
boiler. Systems shall be quoted complete, including the
following:
1. Fabric filters
2. Structural steel for installation of the fabric
filter at grade
3. Insulation, 2" thick, to match temperature ser-
vices
4. Air pulse-jet cleaning equipment
5. Slide gates
6. Dust collection hoppers
7. Induced draft fan with a head equal to the pres-
sure drop across the fabric filter installation
selected to show differential pressure.
8. Other necessary auxiliary equipment.
Ash handling equipment is not included in this specifica-
I
tion.
Details:
1. The fabric filter shall be of compartmental con-
struction to allow isolation of a single compart-
ment for cleaning or maintenance.
2. Slide gates shall be provided to isolate com-
partments, and ductwork shall be provided to allow
for a single inlet and a single outlet connection
to and from the fabric filter.
A-8
-------
3. Construction shall allow for vacuum operation of
the fabric filter; the draft fan will be attached
to the fabric filter outlet. The connecting
ductwork will be supplied by others.
4. Housings, slide gates and ductwork shall be of
carbon steel construction. Fabric shall be
selected to match the temperature of the gas
stream.
5. Air pulse jet bag cleaning equipment shall be pro-
vided for system cleaning (compressed air will be
supplied by others). Automatic time cycled con-
trols shall be provided for the air pulse equip-
ment.
A-9
-------
System Requirements;
1. The attached data sheets outline the system varia-
tions on which quotations will be received, and
provides inlet and outlet flow rates and particu-
late loadingso The gas cleaning device is to
reduce the solids content of the gas to the levels
specified.
2. The coal being fired in the boiler has the follow-
ing analysis:
Sulfur 0»8%
Ash 7.5%
Moisture 500%
Megajoules/Kg 29.78
(Btu/lb 12,800)
3. Size distribution of particles in the inlet gas is
as follows:
Particle Size Percent by weight
Above 100 microns 35
40 to 100 microns 30
20 to 40 microns 14
10 to 20 microns 11
Below 10 microns 10
4. Only spreader stoker type boilers are considered.
A-10
-------
CAPITAL COST DATA
FABRIC FILTER
FOR INTERMEDIATE
SIZED BOILERS
Data Sheet No.
18-5
Project No. 68-02-1473
Task No. 18
Mega joules/sec .
BOILER SIZE or MW
Inlet and outlet gas flow
ACFM
op
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
.Outlet, Ib/hr
Cleaning efficiency
Gas cleaning equipment cost
Cost of auxiliaries
Total equipment cost
Installation costs, direct*
Foundation and supports
Duct work
Stack
Piping
Insulation
Painting
Electrical
Total direct costs
Installation costs, indirect
Engineering
Constr. and field expense
Construction fees
Start-up
Performance test
Contingencies
Total Indirect costs
Turnkey cost
3
5400
600
2700
0.82
38
0.002
0.1
99.7%
25
45,900
' 600
23,000
0.84
330
0.002
0.85
99.7%
* Where specified
A-ll
-------
ANNUAL OPERATING COST DATA
FABRIC FILTERS
Data Sheet No.
18-5A
Project No. 68-02-147'3
Task No. 18
Megajou]
BOILER SIZE or MV
Inlet & outlet gas flo
ACFM
op
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
Les/sec.
¥
w
3
5400
600
- 2700
0.82
38
0.002
0.1
99.7%
25
45,900
600 •
23,000
0.84
330
0.002
0.85
99.7%
Operating cost item
Direct costs:
Operating labor
Operator
Supervisor
Total
Maintenance
Labor
Materials
Total
Replacement parts
Utilities
Electricity
Total
Total Direct costs
Capital charges
Total annual cost
Unit cost
$10/manhour
$12/manhour
$10/manhour
$0. 03/kWh
1
Operating costs to be based on annual operation of 8760 hours
per year @ 65% capacity factor.
A-12
-------
CAPITAL COST DATA
FABRIC FILTERS
FOR INTERMEDIATE
SIZED BOILERS
Data Sheet No. 18-6
Project No. 68-02-147*3
Task No. 18
Mega joules/sec .
BOILER SIZE or MW
Inlet and outlet gas flow
ACFM
°F -
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
C-as cleaning equipment cost
Cost of auxiliaries
Total equipment cost
Installation costs, direct*
Foundation and supports
Duct work
Stack
Piping
Insulation
Painting
Electrical
Total direct costs
Installation costs, indirect
Engineering
Constr. and field expense
Construction fees
Start-up
Performance test
Contingencies'
Total Indirect costs
Turnkey cost
55
87,100
450
50,700
0.96
716
0.002
1.9
99.7%
73
115,800
350
75,800
0.96
952
0.0025
2.5
99.7%
* Where specified
A-13
-------
ANNUAL OPERATING COST DATA
FABRIC FILTERS
Data Shoot No.
18-6A
Project No. G8-02-147'3
Task No. 18
Megajou:
BOILER SIZE or MW
Inlet & outlet gas flo
ACFM
op
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
Les/sec.
w
55
87,100
450
50,700
0.96
716
0.002
1.9
99.7%
73
115,800
350
75,800
0.96
952
0.0025
2.5
99.7%
Operating cost item
Direct costs:
Operating labor
Operator
Supervisor
fetal
Maintenance
Labor
Materials
Total .
Replacement parts
Utilities
Electricity
Total
Total Direct costs
Capital charges
Total annual cost
Unit cost
$10/manhour
$12/manhour
$10/manhour
$0. 03/kWh
-
Operating costs to be based on annual operation of 8760 hours
per year @ 65% capacity factor.
A-14
-------
Company: IGCI
Contract No.: 68-02-1473
Task No. 18
Date: November 1976
MECHANICAL COLLECTOR SPECIFICATION
A mechanical collector is to remove solid particulate
matter from the exhaust gas of an intermediate-sized coal
fired boiler. Collector systems shall be quoted complete
including the following items:
1. Tubular centrifugal collector
2. Structural steel framework, as required to support
equipment
3. Insulation, 2" thick, to match temperature ser-
vices
4. Induced draft fan with a head equal to the pressure
drop across the mechanical collectors selected to
show differential pressure.
Duct work and ash collection and handling equipment and
controls are not included in this specification.
System Requirements;
1. The attached data sheets outline the system variations
on which quotations will be made, and provide gas flow
rates and particulate loadings. Solids content of the
gas will be reduced by the collectors to the levels
specified.
2. Coal being fired in the boiler has the following analysis:
Sulfur 0.8% by weight
Ash 7.5%
Moisture 5.0%
Megajoules/Kg 29.78
(Btu/lb 12,800)
A-15
-------
3. Particle size distribution in the inlet gas to the
collectors is as follows:
Percent
Particle Size By Weight
Above 100 microns 44
40 to 100 microns 10
20 to 40 microns 7
10 to 20 microns 9
5 to 10 microns 6
Below 5 microns 24
4. Type collector required: single stage.
5. Type boiler: chain grate.
A-16
-------
CAPITAL COST DATA
MECHANICAL COLLECTOR FOR
INTERMEDIATE SIZED BOILERS
Data Sheet No. 18-1-A
Project No. 68-02-1473
Task No. 18
BOILER SIZE,
Mega joules/sec, or MW
Inlet and outlet gas flow
ACFM
op
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency %
Gas cleaning equipment cost
Cost of auxiliaries
Total equipment cost
Installation costs, direct*
Foundation and supports
Duct work
Stack
Piping
Insulation
Painting
Electrical
Total direct costs
Installation costs, indirect
Engineering
Constr. and field expense
Construction fees
Start-up
Performance test
Contingencies
Total Indirect costs
Turnkey cost
3
5400
600
2700
0.46
21.3
0.07
3.2
85
* Where specified
A-17
-------
ANNUAL OPERATING COST DATA
MECHANICAL COLLECTOR FOR
INTERMEDIATE SIZED BOILERS
Data Sheet No. 18-1-B
Project No. 68-02-147'3
Task No. 18
Boiler size,
Mega joules/sec, or MW
Inlet & outlet gas flc
ACFM
OF
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency %
Operating cost item
Direct costs:
Operating labor
Operator
Supervisor
Total
Maintenance
Labor
Materials
Total
Replacement parts
Utilities
Electricity
Total
Total Direct costs
Capital charges
Total annual cost
w
Unit cost
$10/manhour
$12/manhours
$10/manhour
$0.03/kWh
3
5400
600
2700
0.46
21.3
0.07
3.2
85
Operating costs to be based on annual operation of 8760 hours
per year @65% capacity factor.
A-18
-------
Company: IGCI
Contract No.: 68-02-1473
Task No. 18
Date: November 1976
MECHANICAL COLLECTOR SPECIFICATION
A mechanical collector is to remove solid particulate
matter from the exhaust gas of an intermediate-sized coal
fired boiler. Collector systems shall be quoted complete
including the following items:
1. Tubular centrifugal collector
2. Structural steel framework, as required to support
equipment
3. Insulation, 2" thick, to match temperature ser-
vices
4. Induced draft fan with a head equal to the pressure
drop across the mechanical collectors selected to
show differential pressure.
Duct work and ash collection and handling equipment and
controls are not included in this specification.
System Requirements;
1. The attached data sheets outline the system variations
on which quotations will be made, and provide gas flow
rates and particulate loadings. Solids content of the
gas will be reduced by the collectors to the levels
specified.
2. Coal being fired in the boiler has the following analysis;
Sulfur 0.8% by weight
Ash 7.5%
Moisture 5.0%
Megajoules/Kg 29.78
(Btu/lb 12,800)
A-19
-------
3. Particle size distribution in the inlet gas to the
collectors is as follows:
Percent
Particle Size By Weight
Above 100 microns 35
40 to 100 microns 30
20 to 40 microns 1.4
10 to 20 microns 11
Below 10 microns 10
4. Type collector required: Dual stage.
5. Type boiler: Spreader stoker.
A-20
-------
CAPITAL COST DATA
MECHANICAL COLLECTOR FOR
INTERMEDIATE SIZED BOILERS
Data Sheet No. 18-2-A
Project No. 68-02-1473
Task No. 18
Boiler Size,
Mega joules/sec, or MW
Inlet and outlet gas flow
'ACFM
OF
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency, %
Gas cleaning equipment cost
Cost of auxiliaries
Total equipment cost
Installation costs, direct*
Foundation and supports
Duct work
Stack
Piping
Insulation
Painting
Electrical
Total direct costs
Installation costs, indirect
Engineering
Constr. and field expense
Construction fees
Start-up
Performance test
Contingencies
Total Indirect costs
Turnkey cost
40
73,400
600
* 36,700
2.3
1,447
0.07
43.4
97
•
* Where specified
A-21
-------
ANNUAL OPERATING COST DATA
MECHANICAL COLLECTOR FOR
INTERMEDIATE SIZED BOILERS
18-2-B
Data Sheet No.
Project No. 68-02-147'3
Task No. 18
Boiler Size,
Megajoules/sec. or MW
Inlet & outlet gas flo
ACFM
oF
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr .
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
Operating cost item
Direct costs:
Operating labor
Operator
Supervisor .
Total
Maintenance
Labor
Materials
Total
Replacement parts
Utilities
Electricity
Total
Total Direct costs
Capital charges
Total annual cost
w
Unit cost
$10/manhour
$12/manhours
$10/manhour
$0.03/kWh
40
73,400
600 '
36,700
2.3
1,447
0.07
43.4
97
Operating costs to be based on annual operation of 8760 hours
per year @65% capacity factor.
A-22
-------
CAPITAL COST DATA
MECHANICAL COLLECTOR FOR
INTERMEDIATE SIZED BOILERS
Data Sheet No. 18-3-A
Project No. 68-02-147'3
Task No. 18
Boiler Size,
Mega joules/sec, or MW
Inlet and outlet gas flow
ACFM
op
SCFM
Moisture, Vol. %
Contaminant 'loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency %
Gas cleaning equipment cost
Cost of auxiliaries
Total equipment cost
Installation costs, direct*
Foundation and supports
Duct work
Stack
Piping
Insulation
Painting
Electrical
Total direct costs
Installation costs, indirect
Engineering
Constr. and field expense
. Construction fees
Start-up
Performance test
Contingencies
Total Indirect costs
Turnkey cost
73
115,800
350
75,800
3.0
2,978
0.075
74.4
97.5
* Where specified
A-23
-------
ANNUAL OPERATING COST DATA
MECHANICAL COLLECTOR FOR
INTERMEDIATE SIZED BOILERS
Data Sheet No.
18-3-R
Project No. G8-02-147'3
Task No. 18
Boiler Size,
Mega joules/sec, or MW
Inlet & outlet gas flo
ACFM
OF
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency %
Operating cost item
Direct costs:
Operating labor
Operator
Supervisor
Total
Maintenance
Labor
Materials
Total
Replacement parts
Utilities
Electricity
Total
Total Direct costs
Capital charges
Total annual cost
w
Unit cost
$10/manhour
$12/manhours
$10/manhour
$0.03/kWh
0
73
115,800
350 '
75,800
3.0
2,978
0.075
74.4
97.5
Operating costs to be based on annual operation of 8760 hours.
per year @65% capacity factor.
A-24
-------
B. INSTRUCTIONS FOR SUBMITTING COST DATA
Two forms which are attached have been designed for the
purpose of reporting the cost estimate prepared for each
specification. The forms are titled;
A. Estimated Capital Cost Data
B. Annual Operating Cost Data
These forms will also be used to exhibit, in the final
report for this study, averages of the three cost estimates
for each process and equipment type.. Because your costs
will be averaged with those of other IGCI members, it is
necessary to prepare them in accordance with instructions
given in the following paragraphs.
A. Estimated Capital Cost Data
The upper part of this form should already be filled out for
the particular application when you receive it. This infor-
mation on operating conditions should be identical to that
in the specification and is repeated only for the convenience
of those reading the form.
You should fill in the estimated dollar amounts in the
appropriate spaces on the bottom half of the form. It
should not be necessary to add any information other than
the dollar amounts. If you wish to provide a description of
the equipment proposed, please do so on one or more separate
sheets of paper, and attach it to the form. If any item is
not involved in the equipment you are proposing, please
indicate this by writing "none" in the space rather than
leaving it blank or using a zero.
1. The "gas cleaning device" cost should be reported
just as you would report a flange-to-flange equip-
ment sale to the IGCI. That is, a complete
device including necessary auxiliaries such as
power supplies, mist eliminators, etc. Do NOT
include such items as fans, solids handling equip-
ment, etc., unless these are an integral part of
your gas cleaning device.
A-25
-------
2. "Auxiliaries" are those items of equipment which
are frequently supplied with the gas cleaning
device. There is a purely arbitrary distinction
between those items included here and those in-
cluded in the "Installation" costs. Do NOT include
any of the cost of erecting or installing auxiliaries
in this category.
3. "Installation Cost" should include the field labor
required to complete a turnkey installation as
well as all of the material not in 1. or 2. In
cases where the equipment supplier ordinarily
erects the equipment but does not supply labor for
foundations, etc., it is necessary to include an
estimated cost for these items. General tradework,
including rigging, erection, etc., should be
included in the "Other" category.
The installation should be estimated for a new plant, or one
in which there are no limitations imposed by the arrangement
of existing equipment. Installation labor should be esti-
mated on the basis that the erection will take place in an
area where labor rates are near the U.S. average, and the
distance from your plant is no more than 500 miles. Milwaukee,
Wisconsin is an example of a city with near-average labor rates,
B. Annual Operating Cost Data
Some of the information will be supplied by PEDCo-Environ-
mental such as unit costs for labor and utilities, and
annualized capital charges. You should fill in the usage
figures for the complete abatement system IN THE UNITS
INDICATED BELOW:
Labor hrs/year
Maintenance Materials Dollars/year
Replacement Parts Dollars/year
Electric Power kw-hr/year
PEDCo will average the consumption figures reported, and
convert them to dollar values for inclusion in the final
report, using standard unit prices.
Be sure that the operating factor, indicated on the form in
hours per year, is used for estimating the utility and labor
requirements.
Guidelines for operating Cost Estimates
A-26
-------
The estimates of labor involved for operating and maintaining
air pollution control systems are less likely to be based on
first-hand knowledge than are the estimates of capital cost
for the gas cleaning equipment and system installation. In
order to make comparable and consistent estimates of these
costs, some general rules should be used by all of the
participants in the program. This section describes the
rules which should be followed in making the estimates, and
for describing the estimating basis in the reports prepared
for the EPA.
Three alternative bases may be used for estimating the labor
cost for operation and maintenance of air pollution systems:
1. Direct first-hand knowledge of similar systems.
2. Detailed analysis of incremental labor requirements,
3. Percentage of first cost.
When using this method, it is important to define clearly
the assumptions made with regard to the circumstances of
system operation. Some of these assumptions are indicated
in a general way below:
1. Operating labor.
a. Will the abatement system be operated by the
same crew charged with operation of the pro-
duction equipment? If yes, operator time
should be allocated to the new abatement
system.
b. Are regular logs of operation likely to be
helpful in obtaining best operation of the
abatement equipment?
c. Is additional supervisory time required? If
yes, some supervisor time should be allocated
to the abatement system.
d. Will any special operator skill be required
which would limit the ability of production
equipment operators to serve as abatement
system operators?
2. Maintenance labor.
a. Will maintenance functions be performed
routinely throughout the year, or at annual
or semi-annual equipment maintenance shutdown
A-27
-------
period? !
b. Have routine maintenance and inspection
procedures been recommended?
c. Will there by any special requirements for
labor to purchase or inventory spare'parts?
3. Can there be any labor credit for improvements in
production equipment operation due to the installa-
tion of the abatement system?
A-28
------- |