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


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  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

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                      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

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                       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

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                       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

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                      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

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     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

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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

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                  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

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                                           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.

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     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

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     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

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            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

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     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

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              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»

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             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

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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
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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 
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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

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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

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          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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