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 ------- |