EPA-450/3-78-045
February 1977
ELECTROSTATIC
PRECIPITATOR COSTS
FOR LARGE COAL-FIRED
STEAM GENERATORS
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
-------
ELECTROSTATIC PRECIPITATOR COSTS
FOR
LARGE COAL-FIRED STEAM GENERATORS
Prepared by
Industrial Gas Cleaning Institute
Stamford, Connecticut 06904
Contract No. 68-02-1473
Task No. 17
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Strategies and Air Standards Division
Economic Analysis Branch
Research Triangle Park,
North Carolina 27711
February 1977
-------
TABLE OF CONTENTS
Page
1.0 INTRODUCTION 1-1
2.0 PROCESS DESCRIPTION 2-1
3.0 PARTICULATE EMISSION CONTROL 3-1
BY ELECTROSTATIC PRECIPITATOR
3.1 Design Specifications 3-1
3.2 Capital Investment Costs 3-1
3.3 Annualized Operating Costs 3-2
4.0 PROJECTED COMPLIANCE COSTS 4-1
4.1 Method of Projection 4-1
4.2 Investment Costs 4-3
4.3 Annualized Operating Costs 4-6
APPENDIX
Electrostatic Precipitator Specifications A-2
Sample Calculations A-22
11
-------
LIST OF FIGURES
No. Page
2-1 Diagram of Gas Flow For a Cold Side Electro- 2-2
static Precipitator
4-1 Precipitator Investment Costs for Projected 4-4
New Boiler Capacity with Cold Side Location
4-2 Precipitator Investment Costs for Projected 4-5
New Boiler Capacity with Hot Side Location
4-3 Precipitator Annualized Operating Costs for 4-7
Projected New Boiler Capacity with Cold Side
Location
4-4 Precipitator Annualized Operating Costs for 4-8
Projected New Boiler Capacity with Hot Side
Location
111
-------
LIST OF TABLES
No. Page
3-1 Investment Costs for Electrostatic 3-3
Precipitators on 200 MW Utility Boilers
3-2 Investment Costs for Electrostatic 3-4
Precipitators on 700 MW Utility Boilers
3-3 Annualized Operating Costs for Electrostatic 3-5
Precipitators on 200 MW Utility Boilers
3-4 Annualized Operating Costs for Electrostatic 3-6
Precipitators on 700 MW Utility Boilers
4-1 Summary of Coal Utilization for Projected 4-2
New Utility Steam Generators
-------
1.0 INTRODUCTION
The purposes of this task are:
1) To determine the costs for electrostatic precipita-
tors to control particulate emissions from large coal-fired
steam generators, such costs to be a function of different
coal types, boiler sizes, and emission limits;
2) To identify the total costs that will result from
the addition of electrostatic precipitators to the proposed
new generating capacity in the United States, factoring into
these costs coal types, emission limits, and boiler sizes.
The scope is confined to the development of capital and
annualized costs of electrostatic precipitators on boilers
using pulverized coal for fuel. Capital costs include those
for the precipitator, inlet and outlet duct transitions,
foundation and supporting steel, and precipitator erection,
as well as related painting, electrical work, and insula-
tion. Indirect installation costs, which include engineer-
ing, construction, field expenses and fees, start-up, and
contingencies, are to be itemized and added to the direct
costs to yield a turnkey cost.
1-1
-------
Model studies for the precipitator gas distribution
systems are not included since such studies are site spec-
ific.
Costs include the piping and valve components of a fly
ash collection and handling system from the precipitator
hoppers.
Annualized costs are defined as the direct costs of
precipitator operation plus fixed costs for overhead and
capitalization. Fly ash handling costs are excluded, since
utilities operate fly ash and bottom ash handling facilities
as a combined system.
The specifications prepared cover electrostatic pre-
cipitators that treat flue gas resulting from the following
combination of variables:
Boiler size, ESP Emission regulation,
MW Coal type nanograms/joule (Ibs./lO Btu)
200
200
200
200
200
200
200
700
700
700
700
700
700
Best
Best
Worst
Worst
Worst
Worst
Worst
Best
Best
Worst
Worst
Worst
Worst
Cold
Cold
Cold
Cold
Cold
Hot
Hot
Cold
Cold
Cold
Cold
Hot
Hot
43
13
43
22
13
22
13
43
13
43
13
22
13
(0.1)
(0.03)
(0.1)
(0.05)
(0.03)
(0.05)
(0.03)
(0.1)
(0.03)
(0.1)
(0.03)
(0.05)
(0.03)
The specifications were sent to three IGCI members re-
commended by the Engineering Standards Committee as being
1-2
-------
expert in this field of application. Copies of the spec-
ifications are included in the Appendix.
For purposes of comparison, gas volume output from the
two types of coal utilized is taken as the same. In actual
practice, gas volume would differ for a variety of reasons,
primarily the calorific value.
When these quotations were received, they were tabu-
lated and averaged; then estimated installed costs of valving
and piping for an ash handling system were added to this
figure. The cost values so established were used in
conjunction with coal usage data for projected new boilers
to arrive at the costs to be considered in future boiler
construction for compliance with various particulate emis-
sion control regulations.
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, however, no assurance that these specifica-
tions will be in effect 100% of the time, due to unforeseen
upsets in the process gas flows or conditions. These condi-
tions include, but are not limited to, a change in process
chemistry, a change in size distribution of suspended par-
ticulate matter, or an excessive dust load. Normal, good
maintenance procedures must be employed to meet the con-
tinuous high level efficiency requirements.
1-3
-------
2.0 PROCESS DESCRIPTION
A coal-fired utility boiler employing an electrostatic
precipitator for particulate emission control is diagramed
in Figure 2-1. As shown in the figure, air is blown into
the boiler by forced draft fans. To achieve heating econ-
omy, the air is preheated by passage through a steam coil
preheater and then an air heater to recover heat from the
hot exhaust gases. In the boiler, pulverized coal is burned
with the preheated air to generate steam from boiler feed-
water.
Coal combustion produces ash, which is non-combustible
coal residue, and hot gases. While a small amount of the
ash falls to the bottom of the combustion chamber and is
subsequently removed as bottom ash, a considerable amount,
called "fly ash" (70 to 95%) is entrained in the hot gas
stream. The fine particle size of this material makes it
difficult to separate from the combustion gas stream.
An electrostatic precipitator (ESP) is used to remove
this fly ash from the boiler exhaust gases. If it is lo-
cated before the air heater, it is called a "hot side" ESP;
if located after, a "cold side" ESP. Figure 2-1 illustrates
a cold-side ESP.
2-1
-------
h HOT EXHAUST GASES
K>
I
STACK
CLEANED
1 EXHAUST
GAS-,
PRECIPITATOR
INTAKE AIR
Figure 2-1. Diagram of gas flow for a cold side electrostatic precipitator
on a coal-fired utility boiler.
-------
A hot-side or a cold-side precipitator for a particular
boiler installation is selected on an economic basis, de-
pending upon the type of coal burned, the method of firing,
and the level of emissions control required. The chemical
composition of the ash has a profound effect on fly ash
resistivity, and thus on precipitator performance. The type
of fuel has been defined as worst and best for this report.
For this task, pulverized coal firing was specified,
and analyses of a worst and a best coal were set forth
(see specifications in the Appendix) to permit development
of investment and operating costs for three emission control
levels and two boiler sizes.
When boiler exhaust gases pass through the electro-
static precipitator, fly ash particles contained in the gas
become electrically charged and migrate to the electrodes,
where they adhere by electrostatic force. Periodic rapping
of the electrodes causes the accumulated particles to fall
into collecting hoppers located below the precipitators.
The cleaned exhaust gases are sent either to a tall stack
for discharge to the atmosphere or to a flue gas desul-
furization system for removal of sulfur dioxide before being
discharged.
a
Worst coal implies high electrostatic precipitator require-
ments; best coal implies low electrostatic precipitator
requirements.
2-3
-------
When the fly ash particulate matter collected in the
hoppers reaches a specified level, timed cycle operated
valves discharge it to a pneumatic conveying system for
transport to disposal.
2-4
-------
3.0 PARTICULATE EMISSION CONTROL BY
ELECTROSTATIC PRECIPITATOR
3.1 DESIGN SPECIFICATIONS
The design specification and the thirteen variant con-
ditions for electrostatic precipitator operation are pre-
sented in the Appendix.
As shown at the top of each sheet, the percentage of
sulfur in the coal used is either 4 or 0.5 percent. The
higher percentage designates best coal; the lower one indi-
cates worst coal.
The gas temperature indicates the precipitator loca-
tion, 700°F for hot-side and 350°F for cold-side.
The precipitator efficiency and residual particulate
emission values shown are directly correlated to the three
emission control levels considered - 13, 22, and 43 nano-
grams per joule (0.03, 0.05, and 0.1 lb/10 Btu).
3.2 CAPITAL INVESTMENT COSTS
The capital investment required for precipitators
operating under various conditions and particulate emission
control levels is presented in Table 3-1 for 200-MW boilers
and in Table 3-2 for 700-MW boilers.
3-1
-------
The various cost items shown represent the sum of the
precipitator costs and estimated installed costs of piping
and valves for a fly ash handling system. Precipitator
auxiliary equipment typically includes access and supports,
a purge air system, and hopper heaters. Other components of
an ash handling system, such as storage silos, conveying sys-
tems, unloader and controls, are not included. Also, no fans
are included for air movement.
Duct and stack costs are not included in the direct
costs for installation since only flange-to-flange costs of
electrostatic precipitators are being considered.
3.3 ANNUALIZED OPERATING COSTS
Tables 3-3 and 3-4 show the estimated total cost of
operating an electrostatic precipitator, under the various
conditions, on 200- and 700-MW units, respectively. These
costs are predicated upon operation of the precipitators at
65 percent load factor.
The total costs comprise the average of the direct
operating costs submitted by the three IGCI members and the
computed overhead and capitalization charges. Fan operating
costs for air movement or ash conveying are not included.
3-2
-------
Table 3-1. INVESTMENT COSTS FOR ELECTROSTATIC PRECIPITATORS
ON 200 MW UTILITY BOILERS
(December 1976)
Boiler size, MM
Precipitator location
Coal type
Inlet and Outlet Gas Flow
acfm
°F
scfm
Moisture, Vol. %
Particulate Loading
Inlet gr/acf
Inlet Ib/hr
Outlet gr/acf
Outlet Ib/hr
Removal efficiency, %
Emission Control Level,
ng/joule
(lb./106 Btu)
Equipment Costs
Device
Auxiliary equipment
Ash handling equipment
Total
Installation Costs - Direct
Foundation and supports
Insulation
Painting
Electrical
Other
Total
Installation Costs - Indirect
Engineering
Construction ' field expense
Construction fees
St-.nrt.-up
Performance testa
Contingencies
Total
Total turnkey cost
S/kW investment
200
Cold
Best
798,000
350
521,000
10
2.32
15,900
0.03
200
98.7
43
(0.1)
913,100
154,600
35,600
1,103,300
114,300
247,200
5,000
78,600
614,400
1,059,500
126,200
67,600
26,200
10,70"
2G,2"0
48,400
305,300
$2,468,100
12.34
200
Cold
Best
798,000
350
521,000
10
2.32
15,900
0.009
60
99.6
13
(0.03)
1,227,200
171,500
47,500
1,446,200
130,800
296,600
5,000
116,600
778,400
1,327,400
127,700
81,900
27,000
10, flOO
20,001
58,800
332,000
$3,105,«00
15.53
200
Cold
Worst
798,000
350
521,000
10
1.76
12,000
0.03
200
98.3
43
(0.1)
1,361,500
174,700
47,500
1,583,700
134,300
304,400
5,000
103,600
857,500
1,404,800
127,700
89,100
27,000
10,9110
->*,?.an
61,500
342,400
$3,330,900
16.65
200
Cold
Worst
798,000
350
521,000
10
1.76
12,000
0.015
100
99.2
22
(0.05)
1,828,900
191,900
62,500
2,083,300
157,400
397,700
5,600
156,300
1,120,000
1,837,000
129,600
109,300
28,000
11,100
.-••i.SOO
74,100
377,900
$4,298,200
21.49
200
Cold
Worst
798,000
350
521,000
10
1.76
12,000
0.009
60
99.4
13
(0.03)
2,046,100
207,600
75,600
2,329,300
173,000
436,600
5,600
181,600
1,281,900
2,078,700
131,200
127,700
28.900
11,100
25,800
87.800
413,100
$4,321,100
24.11
200
Hot
Worst
985,000
700
450,000
10
1.43
12,000
0.012
100
99.2
22
(0.05)
1,546,100
190,200
47,500
1,783,800
151,900
388,700
5,300
133,300
949,200
1,628,400
127,700
89,600
27,000
11,100
75, ROO
64,600
345,800
$3,758,000
18.79
200
Hot
Worst
985,000
700
450,000
10
1.43
12,000
0.007
60
99.5
13
(0.03)
1,837,000
196,000
62,500
2,095,500
166,600
424,700
5,600
205,300
1,144,200
1,946,400
129,600
107,000
20,000
12,300
25,800
76,000
378,700
$4,420,600
22.10
Ul
I
u»
-------
Table 3-2. INVESTMENT COSTS FOR ELECTROSTATIC PRECIPITATORS
ON 700 MW UTILITY BOILERS
(December 1976)
U)
I
Boiler Size, MW
Precipitator Location
Coal Type
Inlet and Outlet Gas Flow
acfm
op
scfm
Moisture, Vol. t
Particulate Loading
Inlet gr/acf
Inlet Ib/hr
Outlet gr/acf
Outlet Ib/hr
Removal efficiency, %
Emission Control Level
ng/joule
(lb/10* Btu)
Equipment Costs
Device
Auxiliary equipment
Ash handling equipment
Total
Installation Costs - Direct
Foundation and supports
Insulation
Painting
Electrical
Other
Total
Installation Costs - Indirect
Engineering
Construction and field expense
Construction fees
Start-up
Performance Tests
Contingencies
Total
Total Turnkey Cost
SAW Investment
700
Cold
Best
2,790,000
350
1,825,000
10
2.32
55,600
0.03
700
98.7
43
(0.1)
3,103,700
469,900
122,400
3,696,000
376,800
847,800
9,400
285,600
1,987,800
3,507,400
181,500
278,000
63,200
28,200
56,000
176,700
783,600
$7,987,000
11.41
700
Cold
Best
2,790,000
350
1,825,000
10
2.32
55,600
0.009
210
99.6
13
(0.03)
3,958,300
526,000
167,000
4,651,300
423,700
988,600
10,600
460,900
2,487,200
4,371,000
187,300
328,800
66,600
32,000
56,000
207,700
878,400
$9,900,700
14.14
700
Cold
Worst
2,790,000
350
1,825,000
10
1.76
42,200
0.03
700
98.3
43
(0.1)
4,652,300
543,200
167,000
5,362,500
370,300
1,033,700
9,400
430,900
2,705,100
4,549,400
187,300
336,300
66,600
28,600
56,000
206,700
881,500
$10,793,400
15.42
700
Cold
Worst
2,790,000
350
1,825,000
10
1.76
42,200
0.009
210
99.5
13
(0.03)
6,833,900
634,200
256,200
7,7*4, JOO
577,400
1,357,700
13,100
646,300
4,028,000
6,622,500
198,700
449,000
72,300
35,800
56,000
217,700
1,029,500
$15,376,300
21.97
700
Hot
Worst
3,450,000
700
1,580,000
10
1.43
42,200
0.012
350
99.2
22
(0,05)
4,895,000
571,700
167,000
5,633,700
430,400
1,206,600
7,200
520,600
2,934,200
5,099,000
187,300
340,600
66,600
32,100
56,000
218,100
900,700
$11,633,400
16.62
700
Hot
Worst
3,450,000
700
1,580,000
10
1.43
42,200
0.007
210
99.5
13
(0.03)
6,007,300
609,400
212,700
6,t)29,4UO
500,500
1,372,000
7,200
664,600
3,574,900
6,119,200
193,100
199,900
69,500
36,300
56,000
267,100
1,021,900
$13,970,500
19.96
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Table 3-3. ANNUALIZED OPERATING COSTS FOR
ELECTROSTATIC PRECIPITATORS ON 200 MW UTILITY BOILERS
(December 1976)
Basis: 8,760 operating hours per year at 65% capacity factor
•oiler Siie. MM
?recipitator Locetion
Coal Type
Inlet and Outlet Gaa Flow
»cf»
•p
ecfa>
Hoiatura
Particulate Loadlnq
Inlat gr/acf
Inlat Ib/hr
Out at qr/acf
Outlet Ib/hr
Reaoval efficiency, *
gauaaion Control Level
noV Joule
(Ib./I0( Itul
Operating. Colt Item unit coat
Direct Coata
Operating Labor
Operator $10/«an-hr
Supenilioa $l2/a>an-hr
Total
Halntenance
Labor $10/»an-hr
Mkteriali
Total
•epiacawnt Parta
otilltlea
Electricity S0.03/ktrh
Total Direct Coeta
Indirect Coeta
Overhead Charoe*
Payroll 20* oper. lab.
Plant 50* lab. I Mint.
Total
Capitalisation Charaea 17* of inveat-
•ent
Total Indirect Colt*
Total Annual lied Coat
Mllla/kHh Operating Coat
200
Cold
Beat
791,000
350
521,000
10
2.32
15,900
0.03
200
91.7
43
(0.1)
7.420
2.520
9.940
9,120
2,300
12,110
5,950
104,410
132,490
1.990
11.030
13,020
419,510
$432, (00
$5(5,090
0.32
200
Cold
Beat
791,000
350
521,000
10
2.32
15,900
0.009
(0
99. (
13
(0.03)
9,130
2,520
11. (50
10.910
3.070
14,050
7.500
123,330
15(,530
2,330
12,1(0
15,190
527,950
$543,140
$(99. (70
0.40
200
Cold
Uorat
791,000
350
521,000
10
12,000
0.03
200
91.3
43
(0.1)
(.570
2,520
9,090
11.420
3,3(0
14.710
9,000
111,310
151,110
1,120
11,930
13,750
566.250
$510.000
$731,110
0.42
200
Cold
Uorat
791,000
350
521,000
10
1.76
12,000
0.015
100
99.2
22
(0.05)
7,420
2,520
9,940
12,730
4,230
14.960
12.500
151,130
191,230
1,990
13.450
15,440
7 30, (90
$744,130
$937.3(0
0.54
200
Cold
Horat
791.000
350
521,000
10
1.76
12,000
0.009
(0
99.5
13
(0.03)
1,210
2,520
10,100
14,030
5,110
19.140
13,500
111,400
231,140
2.1(0
14,970
17,130
119,590
$ 836,720
$1,0(8,5(0
0.61
200
Hot
Horat
915.000
700
450,000
10
1.43
12.000
0.012
100
99.2
22
10.05)
9,130
2.520
11. (50
11,150
3,110
14.330
9,500
1(1,150
204 , 330
2.330
12.990
15.320
(31.1(0
$(54.110
$151.510
0.49
200
Hot
Horat
915.000
700
450,000
10
1.43
12,000
0.007
(0
99.5
13
10.03)
10.140
2.520
13,3(0
11,750
3.590
15.341
11,000
21 2, (90
753,290
2, (10
14.35*
17,030
751,500
$ 7(1, SJO
$1,020,920
0.51
3-5
-------
Table 3-4. ANNUALIZED OPERATING COSTS FOR ELECTROSTATIC
PRECIPITATORS ON 700 MW UTILITY BOILERS
(December 1976)
Basis: 8,760 operating hours per year at 65% capacity factor
•oiler 51l«, MW
Precipitator Location
Co«l Typ«
Inlet and Outlet CM Flov
acfM
•r
Kim
Moisture, Vol.<
Particulate Loading
Inlet gr/«cf
Inlet Ib/hr
Outlet gr/acf
Outlet Ib/hr
Kesjoval efficiency. 1
Emission Control Level
ng/Joule
db./10' Ito)
Operating Cost Itsai unit cost
Direct Costs
Operating Labor
Operator 110/nan-hr
Supervision S12/Han-hr
Total
Maintenance
Labor $10/man-hr
Hater ials
Total
Replacement Parts
Dtllities
Electricity «0.03/kwh
Tct.il Direct Costs
Indirect Costs
Overhead Char9es
Payroll >0t oper. lab.
Plant SOI lab. t maint.
Total
Capitalisation Cnaroes 17% capital
investment
Total Indirect Coets
Total Annualized Cost
Nllls/kWh Operating Cost
700
Cold
lest
2,790,000
350
1,125,000
10
2.32
55,600
0.03
700
•1.7
43
(0.1)
16,270
3,480
19.750
31,050
• ,250
39,300
17,500
313,710
3»0,2(0
3.950
29,530
33,410
1,357.770
11.391,250
tl. 711, 510
0.29
700
Cold
Best
2,790,000
350
1,125,000
10
2.32
55,600
0.009
210
99. C
13
(0.03)
21,400
3.410
24. (SO
33.0«0
9, COO
42. MO
25.000
394,3(0
411,920
4,910
33,710
31,760
1, (13. 120
$1,721,880
»2. 201, 100
0.36
700
Cold
•erst
2,790,000
350
1,125,000
10
1.76
42,200
0.03
700
98.3
43
(0.1)
13,700
3,480
17,180
34,590
10, (20
45,210
33,500
216,050
181,940
3.430
31.200
34,130
1, (34,180
$1,869,510
$2,251, (50
0.37
700
Cold
Worst
2,790,000
350
1.125,000
10
1.76
42,200
0.009
210
99.5
13
(0.03)
18.830
3,480
22,310
43,710
17,300
60,710
47.000
537,390
((7,410
4,4(0
41.510
45,970
2. (13. 970
$2,659,940
S3, 327. 350
0.54
700
Hot
Worst
3,450,000
700
1,580,000
10
1.43
42,200
0.012
350
99.2
22
(0.05)
22,150
3,780
25,930
34,740
10.213
44,950
11,500
447, MO
590,240
5,190
35,440
40, (30
1,977, (80
$2,018,310
(2, (08, 550
0.43
700
Hot
Worst
3,450,000
700
1,580,000
10
1.43
42,200
0.007
210
99.5
13
(0.03)
27,280
3,780
31.0(0
38,140
12,950
51.7*0
37,000
(33,730
753,510
(,210
41,430
47. (40
2.374.990
$2, 422. (30
$3,176.210
0.52
3-6
-------
4.0 PROJECTED COMPLIANCE COSTS
4.1 METHOD OF PROJECTION
Data from the Federal Energy Administration and PEDCo
files were used to project new boiler installations in the
United States through the year 1985. These data were tabu-
lated according to the size of the boilers and the type of
coal to be used.a A summary is given in Table 4-1.
The investment and operating costs generated in Section
3 for 200- and 700-MW boiler precipitators were then used to
compute investment and operating costs, weighted according
to the proportion of the best and worst coal projected for
use in boilers of these sizes. (See the sample calculations
given in the Appendix.) Such weighted values were computed
for each of the three emission-control levels considered and
also for hot- and cold-side precipitator operation when using
the worst coal, and for cold-side precipitators only for
best coal use.
aln the absence of other data, geographic location and coal
heating value were employed to determine the type coal used
at projected new installations. "Worst" coal was assumed for
all locations west of the Mississippi River and those east
of the Mississippi having coal heating values less than
10,000 or more than 12,500 Btu/lb. "Best" coal was assumed
to be that used by plants east of the Mississippi River
when the coal heating value ranged from 10,000 to 12,500
Btu/lb.
4-1
-------
Table 4-1. SUMMARY OF COAL UTILIZATION FOR PROJECTED NEW
UTILITY STEAM GENERATORS
Boiler size
range
MW
More than 500
301 to 500
100 to 300
Less than 100
Totals
Beat Coal Use
Capacity In
size range
MW
35,264
13,916
4,976
821
54,979
Percentage in
size range
43.29
40.91
62.33
60.10
44.05
Worst Coal Use
Capacity In
size range
MW
46,187
20,100
3,008
545
69,840
Percentage in
size range
56.71
59.09
37.67
39.90
55.95
Total capacity in
size range
MW
81,451
34,016
7,986
1,366
124,819
Percent of total
projected
capacity
65.26
27.25
6.40
1.09
100.00
Cumulative
percentage of
total
capacity
65.26
92.51
98.91
100.00
I
to
Source of data for projection:
(1) "Trends in Power Plant Capacity and Utilization", Federal Energy Administration, December 1976.
(2) PEDCo data for FGD Installations in the United States, December 1976.
-------
Where cost data from Section 3 were incomplete, partic-
ularly at the 22 ng/joule (0.05 lb/10 Btu) emission level,
interpolation was required to compute weighted values.
4.2 PROJECTED INVESTMENT COSTS
The projected precipitator investment costs for com-
pliance with the various particulate emission control levels
with cold- and hot-side precipitators are presented in
Figures 4-1 and 4-2, respectively. These graphs were
prepared by plotting weighted investment values in $/kW
versus the percentage of new 200- and 700-MW boilers pro-
jected.
4-3
-------
19
18-
17
16
8
u
£ 15
14
IS
!•! 13
11-
I I 1 I I I
i, -^ HUSSION LIMIT.
I I
l i i
10 20 30 40 SO 60 70 80 90 100
PERCENT OF PROJECTED NEK MILER CAPACITY
Figure 4-1. Cold side precipitator investment costs
for projected new boiler capacity.
4-4
-------
18-
I i i I i 1 I i
17-
16-
** 14-
o
o
12
11
10
i i i
10 20 30 40 50 60 70 80 90 100
PERCENT Of PROJECTED NEU BOILER CAPACITY
Figure 4-2. Hot side precipitator investment costs
for projected new boiler capacity.
4-5
-------
4.3 PROJECTED ANNUALIZED OPERATING COSTS
The annualized operating costs projected for electro-
static precipitator use at various particulate emission
levels are shown in Figures 4-3 and 4-4 for cold- and hot-
side locations, respectively. The figures were derived from
plots of weighted operating costs in mills per kWh versus
the percentage of new 200- and 700-MW boilers projected.
4-6
-------
0.48
0.46
0.44
LU
U
0.42
~ 0.40
0.38
Q.
O
0.36
0.34
0.32
T I I I I
0 10 20 30 40 50 60 70 80 90 100
PERCENT OF MWWECTED NEW BOILER CAPACITY
Figure 4-3. Cold side precipitator annualized operating
costs for projected new boiler capacity.
4-7
-------
0.48
0.44
0.36
0.32
0.28
0.24
0.20
j I
j I
10 20 30 40 50 60 70 80 90 100
PERCENT OF PROJECTED NEW BOILER CAPACITY
Figure 4-4. Hot side precipitator annualized operating
costs for projected new boiler capacity.
4-8
-------
APPENDIX A
ELECTROSTATIC PRECIPITATOR SPECIFICATIONS
SAMPLE CALCULATIONS
A-l
-------
Company: IGCI
Project: 68-02-1473
Task No.: 17
Date:
ELECTROSTATIC PRECIPITATOR SPECIFICATION FOR LARGE
COAL-FIRED STEAM GENERATORS
An electrostatic precipitator is to remove solids from
the exhaust gas of a large coal-fired steam generator.
Systems shall be quoted complete, including the following:
1. Electrostatic precipitator
2. Inlet plenum
3. Outlet plenum
4. Air distribution turning vanes
5. Structural steel for installation of the pre-
cipitator at grade
6. Insulation including weatherproof lagging to match
temperature to be 2" thick on 350° services and 4"
thick on 700° services
7. Other necessary auxiliary equipment
8. Electrical installation work.
Draft fans and ash handling equipment and controls are not
included in this specification.
Details
1. The precipitator is to continuously reduce the
solids content of the gas to the levels specified
on the attached data sheets.
2. The precipitator shall be a single-stage plate-
type unit with inlet face velocity not to exceed
5.5 FPS for 700°F services, and not to exceed 4.5
FPS for 350°F services.
3. The material of construction of all parts of the
system shall be mild steel A-36, minimum 3/16"
thickness.
A-2
-------
4. 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 for each field. A safety inter-
lock system shall be provided so tha-t no access to
high voltage equipment is possible without first
de-energizing all fields.
5. A heated, pressurized penthouse design shall be
employed.
6. Thirteen system variations are specified on the
attached data sheets. Each is specified for use
with either of two grades of coal. Coal analyses
are:
Best Worst
Sulfur, % 4.0 0.5
Moisture, % 15.0 28.1
Ash, % 10.0 5.9
Ash Compounds
Sodium - low
Iron - low
Calcium - high
Heat value
Mega joules/kg 24.89 19.36
(Btu/lb) (10,700) (8,322)
7. A model study for the precipitator gas distribu-
tion system will not be required.
A-3
-------
CAPITAL COST.DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILERS SIZE)
Data Sheet No. 17-1
Project No. 68-02-147*3
Task No. 17
Equipment Classification
Coal Sulfur Content
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
•»
202
4.0%
798,000
350
521,000
10
2.32
15,900
0.009
60
99.6%
* Where specified
A-4
-------
ANNUAL OPERATING COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILER SIZE)
17-1A
Data Sheet No.
Project No. 68-02-147'3
Task No. 17
EQUIPMENT CLASSIFICATI
COAL SULFUR CONTENT
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
ON
w
202
4.0%
798,000
350
521,000
10
2.32
15, 900
0.009
60
99.6%
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, all systems, to be based on annual operation
of 8760 hours per year @ 65% capacity factor.
A-5
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILER SIZE)
Dat-i Sheet No. 17-2
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATION
COAL SULFUR CONTENT
204
0.5%
In lot 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
798,000
350
521,000
10
1.76
12,000
0.015
100
99.2%
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
Con tingencies
Total Indirect costs
Turnkey cost
* Where specified
-------
ANNUAL OPERATING COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILER SIZE)
Data Shoot No. 17-2A
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATI
COAL SULFUR CONTENT
Inlet & outlet gas flo
ACFM
°F
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
DN
//
Unit cost
$10/manhour
$12/manhour
$10/manhour
$0.03/kWh
204
0.5%
798,000
350
521,000
10
1.76
12,000
0.015
100
99.2%
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIP1TATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILER SIZE)
Dat.i Sheet No.
17-3
Project No. 68-02-147"3
Task No. 17
EQUIPMENT CLASSIFICATION
COAL SULFUR CONTENT
Inlet and outlet gas flow
ACFM
op
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, qr/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
205
0.5%
798,000
350
521,000
10
1.76
12,000
0.009
60
99.5%
* Where specified
-------
ANNUAL OPERATING COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILER SIZE)
Data Sheet No.
17-3A
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATI
COAL SULFUR CONTENT
Inlet & outlet gas flo
ACFM
°F
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
3N
w
Unit cost
$10/manhour
$12/manhour
$10/manhour
$8.03/kWh
205
0.5%
798,000
350
521,000
10
1.76
12,000
0.009
60
99.5%
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILER SIZE)
Data Sheet No.
17-4
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATION
COAL SULFUR CONTENT
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
207
0.5%
985,000
700
450,000
10
1.43
12,000
0.012
100
99.2%
208
0.5%
985,000
700
450,000
10
1.43
12,000
0.007
60
99.5%
* Where specified
-------
ANNUAL OPERATING COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILER SIZE)
Data Sheet No.
17-4A
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATI
COAL SULFUR CONTENT
Inlet & outlet gas flo
ACFM
°F
SCFM
Moisture, Vol. I
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
DN
tt
Unit cost
$10/manhour
$12/manhour
$10/manhour
?0.03/kWh
207
0.5%
985,000
700
450,000
10
1.43
12,000
0.012
100
99.2%
208
0.5%
985,000
700
450,000
10
1.43
12,000
0.007
60
99.5%
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(700 MW BOILER SIZE)
Data Sheet No. 17-5
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATION
COAL SULFUR CONTENT
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 co;;t:
701
4.0%
2,790,000
350
1,825,000
10
2.32
55,600
0.03
700
98.7%
702
4.0%
2,790,000
350
1,825,000
10
2.32
55,600
0.009
210
99.6%
1
* Where specified
A-12
-------
ANNUAL OIM.'KAVINC; COST DATA
ELECTROSTATIC PREC 1 PITA'J'ORS
FOR LARCH COAL-FIRED STEAM
GENERATORS
(700 MW BOILER SIZE)
Data Sheet No.
17-5A
Project No. 60-02-1473
Task No. 17
EQUIPMENT CLASSIFICATI
COAL SULFUR CONTENT
Inlet & outlet gas flo
ACFM
°F
SCFM
Me; i r, Lure, Vo.l . I
Contaminant load.incj
Inlet, cjr/ACF
Inlet, Ib/hr
Outlet, yr/ACF
Outlet, Ib/hr
Cleaning efficiency
ON
.V
701
4.0%
2,790,000
350
1,825,000
10
2.32
55,600
0.03
700
98.7%
702
4.0%
2,790,0
3
1,825,0
2.
55,6
0.0
2
99.
10
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
SlO/manhour
$12/manhour
$10/manhour
?0.03/kWh
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(700 MW BOILER SIZE)
Data Shoot No. 17-7
Project No. 68-02-147'3
Task No. 17
EQUIPMENT CLASSIFICATION
COAL SULFUR CONTENT
Inlet and outlet gas flow
ACFM
Op
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, yr/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- ii)>
Performance test
Contingencies
Total Indirect costs
Turnkey cost
705
0.5%
2,790,000
350
1,825,000
10
1.76
42,200
0.009
210
99.5%
* Where
-------
ANNUAL OIMJKATINC COST DATA
L'LLCTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(700 MW BOILER SIZE)
Dnta Sheet No.
17-7A
Project No. 68-02-l<17'3
Task No. 17
EQUIPMENT CLASSIFICATI
COAL. SULFUR CONTENT
Inlet (, outlet gas flo
ACFM
°F
.SCFM
Mu i uturo, Vo.l . I
Con tain i riant ] CKul.i.iKj
In Let, (jr/ACF
Inlet, Ib/lir
Outlet, cjr/ACF
Outlet, Ib/hr
Cleaning efficiency
Operating cost item
Direct costs:
Operating labor
Operator
Supervisor
To Lai
Maintenance
Labor
Ma terials
Total
Replacement parts
Utilities
Electricity
Total
Total Direct costs
Capital charges
Total annual cost
ON
*/
Unit cost
$10/manhour
$12/manhour
$10/manhour
$0.03/kWh
705
0.5%
2,790,000
350
1,825,000
10
1.76
42,200
0.009
210
99.5%
i
A-15
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(700 MW BOILER SIZE)
17-8
Data Sheet No.
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATION
COAL SULFUR CONTENT
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
Con tingenc ies
Total Indirect costs
Turnkey cost
707
0.5%
3,450,000
700
1,580,000
10
1.43
42,200
0.012
350
99.2%
708
0.5%
3,450,000
700
1,580,000
10
1.43
42,200
0.007
210
99.5%
1
* Where specified
-------
ANNUM, OPERATING COST DATA
ELECTROSTATIC PREC LPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(700 MW BOILER SIZE)
Data Sheet No. 17-8A
Project No. 68-02-1-173
Task No. 17
EQUIPMENT CLASSIFICATI
COAL SULFUR CONTENT
Inlet & outlet gus flo
ACFM
OF
SCFM
Moi sture, Vo] . ?,
Con ta]iun
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILER SIZE)
Data Sheet No. 17-9
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATION
COAL SULFUR CONTENT
I M lot
-------
ANNUAL OPERATING COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
(200 MW BOILER SIZE)
17-9A
Data Sheet No.
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATI
COAL SULFUR CONTENT
Inlet s, outlet gas flo
ACFM
Of
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
ON
w
201
4.0%
798,000
350
521,000
10
2.32
15,900
0.03
200
98.7%
203
0.5%
798,000
350
521,000
10
1.76
12,000
0.03
200
98. 3%
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
$O.Q3/kWh
Operating costs, all systems, to be based on annual operation
of 8760 hours per year 065% factor.
A-19
-------
CAPITAL COST DATA
ELECTROSTATIC PRECIPITATORS
FOR LARGE COAL-FIRED STEAM
GENERATORS
[700 MW BOILER SIZE)
Data Sheet No. 17-10
Project No. 68-02-1473
Task No. 17
EQUIPMENT CLASSIFICATION
COAL SULFUR CONTENT
Inlet ami 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 coat
703
0.5%
2,790,000
350
1,825,000
10
1.76
42,200
0.03
700
98.3%
* Wliert; !;p
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i, oi'KKATiru; COST DATA
I'.'.KCTKOSTAT I C l'KI;:C I I' 1 TATORS
1'UU l.AKCJi' COAL-i'lRKD STKAM
n.it.a .r;hont do.
17-10A
1'iojoct Uo. GO-G2-1-173
Tusk Uo. 17
(700 MW UOILKU SIZE)
EQUIPMENT CLASSIFICATION
COAL SULFUR CONTENT ,
703
O.S'l
In ! <•: t f. uuL let ija:; L
AC KM
°l-'
SCI'M
Mo i :; t ur- •, Vo I .
Con Liiin i nan L J oaJ i nij
i n 1 cL , ij r/ACF
inlet, ib/hr
On I: Jot, ij r/ACF
Outlet, Ib/hr
Clunnimj offiL-ic-ncy
2,790,000
350
1,825,000
10
1.76
42,200
0.03
700
98. 3%
Opera t j mj cost i tout
D i root cos t:; :
Opera t:.i ncj labor
a tor
Supervisor
Total
Un 11 cos t
1 0/innnhour
> 1 2/manhour
Mi j n teiuiiice
Labor
Ma torj a Is
HO/manhour
Tot a 1
Replacement parts
Utilities
1-Jl eel r ic i ty
$0.03/kWh
'I'ol.al
Tota1 D i rect costs
Capital charges
Total annual co:;
Operating costs, all systems, to be based on annual operation
of 8760 hours per year @65% factor.
A-21
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SAMPLE CALCULATIONS TO DETERMINE
WEIGHTED INVESTMENT AND OPERATING COSTS
I. BASIS FOR COMPUTATIONS:
a) 43 ng/joule emission control level
b) Use of cold side electrostatic precipitators for
both best and worst coal.
II. WEIGHTED INVESTMENT COSTS
a) At 200 MW level
Per Table 3-1, the unit costs are
For Best Coal: $12.34/kW
For Worst Coal: $16.65/kW
Per Table 4-1,
For 100 to 300 MW range, it is projected that
the coal mix to be used is 62.33% Best Coal
and 37.67% Worst Coal.
Wtd. Inv. = (Best Amt.)(Unit cost) +
(Worst Amt.) (Unit cost)
Substituting values in this equation,
Wtd. Inv. = (0.6233) ($12.34/kW) + (0. 3767) ($16.65/kW)
= 7.69 + 6.27
= $13.96/kW
b) At 700 MW level
Per Table 3-2, the unit costs are
For Best Coal: $11.41/kW
For Worst Coal: $15.42/kW
Per Table 4-1, it is projected that for >500 MW
the coal mix to be used is 43.29% Best Coal and
56.71% Worst Coal.
A-22
-------
Wtd. Inv. = (Best Amt.)(Unit cost) +
(Worst Amt.) (Unit cost)
Substituting values in this equation,
Wtd. Inv. Cost = (0.4329)($11.41/kW) +
(0.5671)($15.42/kW)
= 4.94 + 8.74
= $13.68/kW
III. WEIGHTED OPERATING COSTS
a) At 200 MW level
Per Table 3-3, the unit costs are
For Best Coal: 0.32 mills/kWh
For Worst Coal: 0.42 mills/kWh
Per Table 4-1, for 100 to 300 MW range, it is
projected that the coal mix to be used is 62.33%
Best Coal and 37.67% Worst Coal.
Wtd. Op. Cost = (Best Amt.)(Unit cost) +
(Worst Amt.) (Unit cost)
Substituting values in the equation,
Wtd. Op. Cost = (0.6233)(0.32 mills/kWh) +
(0.3767) (0.42 mills/kWh)
= 0.20 + 0.16
=0.36 mills/kWh
b) At 700 MW level
Per Table 3-4, the units costs are
For Best Coal: 0.29 mills/kWh
For Worst Coal: 0.37 mills/kWh
Per Table 4-1, for >500 MW range, it is projected
that the coal mix to be used is 43.29% Best Coal
and 56.71% Worst Coal
Wtd. Op. Cost = (Best Amt.)(Unit cost) +
(Worst Amt.) (Unit cost)
Substituting values in the equation,
Wtd. Op. Cost = (0.4329) (0.29) + (0.5671) (0.37)
= 0.126 + 0.210
= 0.336 mills/kWh
A-23
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TECHNICAL REPORT DATA
/Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-450/3-78-045
4 TITLE ANDSUBTlTLE
Electrostatic Precipitator Costs for Large Coal-Fired
Steam Generators
7. AUTHOR(S)
Donald J. Loudin
3. RE,CIPIENT'S ACCESSION NO.
5. REPORT DATE
February 1977
6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Industrial Gas Cleaning Institute
700 N. Fairfax Street, Suite 304
Alexandria, Virginia 22314
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-1473, Task 17
12. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
Capital and annualized costs for electrostatic precipitators for use on large
coal-fired steam generators are estimated for a variety of conditions:
a. Boiler sizes of 200 and 700 megawatts
b. Hot and cold side units
c. Emission standards of 13, 22, and 43 nanograms per joule (0.03, 0.05,
and 0.10 Lbs particulate per million Btus)
d. Low and high resistivity coal
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b. IDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Air Pollution
Cost Estimates
Dust Control
Electrostatic Precipitators
Air Pollution Control
Stationary Sources
Coal-fired Boilers
Emission Standards
13B
18. DISTRIBUTION STATEMENT
Unlimited
19 SECURITY CLASS (This Reportj
Unclassified
21. NO. OF PAGES
49
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 222O-1 (>-73)
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