EPA-450/ 3- 78-046
August 1977
        FABRIC FILTER 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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         FABRIC FILTER COSTS

FOR LARGE COAL-FIRED STEAM GENERATORS
             Prepared By

  Industrial Gas Cleaning Institute
    Stamford, Connecticut  06904
       Contract No. 68-02-2532
             Task No.  5
            Prepared For

U.S. Environmental Protection Agency
Strategies and Air Standards Division
      Economic Analysis Branch
       Research Triangle Park
        North Carolina  27711
             August 1977

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                          CONTENTS






                                                       Page




1.0  INTRODUCTION                                       1-1




2.0  PROCESS DESCRIPTION                                2-1




3.0  PARTICULATE EMISSION CONTROL BY FABRIC FILTER      3-1




     3.1  Specifications                                3-1




     3.2  Investment                                    3-1




     3.3  Annualized Costs                              3-1




APPENDIX  FABRIC FILTER SPECIFICATIONS                  A-2

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                       LIST OF FIGURES
No.                                                    Page

2-1  Typical Fabric Filter Arrangement                  2-3

3-1  Capital Cost of Fabric Filters                     3-3
     Used on Large-Sized Boilers

3-2  Annualized Costs of Fabric Filters                 3-5
     Used on Large-Sized Boilers
                              11

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                       LIST OF TABLES
No.                                                    Page

3-1  Capital Cost Data for Fabric Filters               3-2
     Used on Large-Sized Boilers

3-2  Annual Operating Cost Data for Fabric              3-4
     Filters Used on Large-Sized Boilers
                              111

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                      1. 0  INTRODUCTION






     The purpose of this task is to determine the costs of



fabric filters to control particulate emissions from large



coal-fired steam generators.  These costs are to be a func-



tion of boiler size only.  The emission limit (0.01 gr/acf)



and coal specification are assumed to be identical for each



application.  The scope of this report is limited to the



development of capital and annualized costs of fabric filters



on boilers firing pulverized coal.  Investment costs cover



the fabric filters, inlet and outlet duct transitions, foun-



dations and support steel, equipment erection, painting, and



electrical work.  A turnkey cost will be determined by add-



ing these direct costs to the indirect installation costs,



which include engineering, construction, field expenses and



fees, startup, and contingencies.



     The above costs include the piping and valve components



of a fly ash collection and handling system from the fabric



filter hoppers to a common collection point.



     Annualized costs are defined as the direct costs of



fabric filter operation plus fixed costs for overhead and
                            1-1

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capitalization.  The cost of fly ash disposal is excluded,



because some utilities have adequate space for on-site



disposal.




     The specifications (see Appendix)  cover fabric filters



that treat flue gas under conditions involving the following



combination of variables.
Boiler size,
MW
200
500
700
Emission regulation,
gr/acf
0.01
0.01
0.01
lb/10b Btu
0.033
0.033
0.033
The specifications were sent to three IGCI members recom-



mended by the Engineering Standards Committee as experts in



this field of application.



     The quotations received were tabulated and averaged.



Estimated installed costs of valving and piping for an ash



handling system were added to this average figure.



     The efficiency data provided in this study represents



the maximum performance that can be guaranteed by the equip-



ment suppliers.  These values will be obtained when the



collection equipment is in good condition and operating



within design flow specifications.  This does not mean that



these efficiencies will be achieved all of the time.  Un-



foreseen upsets in process gas flows or conditions such as



a change in process chemistry or an excessive dust loading will
                            1-2

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affect performance.   Good maintenance procedures are necessary



to maintain high-level efficiency.
                            1-3

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                  2.0  PROCESS DESCRIPTION






     Figure 2-1 depicts a coal-fired utility boiler equipped



with a fabric filter for particulate emission control.  Air



is blown into the boiler by forced-draft fans, and induced



draft fans are used to pull the cleaned flue gas through the



fabric filter to make up for pressure drop through the



filter and to operate the boiler in a balanced-draft condition.



As an economy measure, air passes through a heat exchanger



designed to recover heat from the hot exhaust gases.  In the



boiler, pulverized coal burned with the preheated air generates



steam from boiler feed water.



     Coal combustion produces ash (a noncombustible coal



residue) and hot gases.  Although a small amount of the ash



falls to the bottom of the combustion chamber and is sub-



sequently removed as bottom ash, 70 to 95 percent of it is



entrained (as fly ash) in the hot gas stream.  Because this



material is of such fine particle size, it is difficult to



separate from the combustion gas stream.  A fabric filter



may be used to remove this fly ash from the boiler exhaust



gases.



     Fabric filters are selected for particular boiler



installations on an economic basis,  which depends on the
                             2-1

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type of fabric used, method of cleaning, and the air-to-



cloth ratio.  The chemical composition of the fly ash affects



filter performance somewhat, mostly through corrosive problems,



Acid condensation can cause corrosion within the filter;



however, this occurs only when the gas stream is lowered



below 300°F.



     As boiler exhaust gases pass through the fabric filter,



fly ash particules contained in the gas are collected pri-



marily by direct interception and inertial impaction.



Periodic cleaning of the fabric (by mechanical shake and/or



reverse air) causes the accumulated particles to fall into



collecting hoppers beneath the filter compartments.  The



cleaned exhaust gases are sent through an induced-draft fan



to a stack and are ultimately discharged to the atmosphere.



     When the fly ash collected in the hoppers reaches a



specified level, valves discharge it to a pneumatic conveying



system for transport to a disposal area.  Sometimes the hop-



per disposal process is timer-actuated rather than controlled



by a level indicator.
                             2-2

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I
U)
                                          FLY ASH
                                          COLLECTION
                                          HOPPER
                      Figure  2-1.   Typical fabric  filter arrangement.

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     3.0  PARTICULATE EMISSION CONTROL BY FABRIC FILTER






3.1  DESIGN SPECIFICATION



     The design specifications for fabric filter operation



on three boiler sizes are presented in the Appendix.  The



fabric filter efficiency and residual particulate emission



values shown are directly correlated with the emission con-



trol level considered-0.01 gr/acf, or 0.033 Ib/MM Btu.



3.2  CAPITAL INVESTMENT COSTS



     Table 3-1 presents the capital investment required for



fabric filters to achieve the particulate emission control



level when operating under design conditions.



     The various cost items shown represent the sum of the



fabric filter costs and installed costs of piping and valves



for a fly ash handling system.  Fabric filter auxiliary



equipment typically includes access and supports.  Ash



handling auxiliary components (storage silos, unloaders,



controls, etc.) are not included.



     Duct and stack costs are not included in the direct



costs of installation because only flange-to-flange costs of



the fabric filters are considered.



3.3  ANNUALIZED OPERATING COSTS



     Table 3-2 shows the estimated total costs of operating
                             3-1

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CAPITAL COST  DATA
FABRIC FILTER
FOR LARGE SIZED  BOILERS
Do
     Sheet No.  I of 2
Project No. 68-02-2532
Task No.      5
BOILER SIZE Megajoules/sec
or MW
Inlet & 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
Installed ash handling equipment

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
200
798,000
350
520,000
10
1.46
9,970
0.01
70
99.3
1,884,800

376,000

2,260,800
732,200
99,700
By
By
17,400
528,000
41,000
159,800

1,578,100
459,700
180,600
396,300
265,900
17,800
12,300

70,900
1,403,500
5,242,000
500
1,993,000
350
1,305,000
10
1.46
24,930
0.01
175
99.3
4,077,000

1,038,000

5,115,000
1,309,500
221,200
Others
Others
41,800
1,196,000
91,100
378,000

3,237,600
914,900
303,900
788,900
592,700
32,700
15,800

157,300
2,806,200
11,158,800
700
2,790,000
350
1,826,000
10
1.46
34,900
0.01
245
99.3
5,605,100

1,267,000

6,872,100
1,838,100
292,900


58,100
1,630,000
121,200
628,700

4,569,000
1,269,200
382,700
1,099,200
817,000
41,00-0
17,200

212,100
3,838,400
15,279,500
* Where specified

  Table  3-1.   CAPITAL COST DATA FOR FABRIC FILTERS USED ON
                      LARGE-SIZED BOILERS
                            3-2

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   10"
                                              I      I    I   I
    5


    4



    3




    2
oc.
•f.
t—
oo
o
   10'
    5


    4
                                               OEQUIPMENT COST

                                               A TURNKEY  COST
   10C
J	I
2345        10°

               GAS FLOW (SCFM)
345
                                                                    10'
        Figure 3-1.
        Capital  cost of fabric filters  used

        on large-sized boilers.
                                  3-3

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ANNUAL OPERATING COST DATA
 FABRIC FILTERS
Data Sheet No.
2 of 2
                                        Project No.  68-02-2532

                                        Task No.      5
Mega joules/sec.
BOILER SIZE or MW
Inlet & outlet gas flow
ACFM
OF
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACf
Outlet, Ib/hr
Cleaning efficiency
Operating cost item Unit cost
Direct costs:
Operating labor
Operator $10/manhour
Supervisor $12/manhour
Total
Maintenance
Labor $10/manhour
Materials
Total
Replacement parts
Utilities
Electricity $0.03/kWh
Pressure drop across collector
Flange to flange AP, maximum
, minimum
Total
Total direct costs
Capital charges
Total annual cost
200
798,000
350
522,000
10
1.46
9,970
0.01
70.0
99.3



20,900
6,000
26,900

14,500
1,900
16,400
57,200

243,000
6-8, "W.G.
5-5 1/2

343,500
891,100
1,234,600
500
1,993,000
350
1,305,000
10
1.46
24,930
0.01
175.0
99.3



23,200
6,400
29,600

27,900
3,500
31,400
119,500

571,900
6-8
5-5 1/2

752,400
1,897,000
2,649,400
700
2,790,000
350
1,824,000
10
1.46
34,900
0.01
245.0
99.3



25,900
7,000
32,900

37,100
4,200
41,300
160,800

786,000
6-8
5-5 1/2

1,021,000
2,597,500
3,618,500
Operating costs to be based on annual operation of 8760 hours
per year @ 65% capacity factor.

  Table 3-2.   ANNUAL OPERATING COST DATA FOR FABRIC FILTERS
                 USED ON LARGE-SIZED BOILERS
                            3-4

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   10'
                                                        I   I
    5


    4



    3





P  2
oo
§


1/1
I—
00   I-

8   5


    4




    3
                                                O DIRECT COSTS

                                                A TOTAL COSTS
                        J	I
              I
I	I
 45        10°


    GAS  FLOW (SCFM)
                                                                   10'
         Figure  3-2.
Annualized costs of  fabric filters

used on  large-sized  boilers.
                                 3-5

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a fabric filter under the specified conditions on 200-, 500-



and 700-MW units, respectively.  These costs are predicated



upon operation of the fabric filters at 65 percent capacity



(load) factor.



     The total costs represent the average of the direct



operating costs submitted by the three IGCI members and the



computed overhead and capitalization charges.  Fan operation



(both induced-draft and reverse-air) for air movement is



included.  Utility costs of ash conveying are not included.
                               3-6

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          APPENDIX




FABRIC FILTER SPECIFICATIONS
            A-l

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                         APPENDIX A

              1.0  FABRIC FILTER SPECIFICATIONS


     A fabric filter is to remove solid particulate matter

from the exhaust flue gas of a large pulverized coal-fired

boiler.  The system shall be quoted complete, including the

following:

     1.   Fabric filter

     2.   Structural steel for installation of the fabric
          filter with at least 5 feet clearance under ash
          discharge

     3.   Insulation, 2" thick

     4.   Reverse air cleaning, including reverse air fan

     5.   Slide gates

     6.   Dust collection hoppers

     7.   Other necessary auxiliary equipment including
          cleaning cycle sequence timers.

Ash handling equipment and controls are not included in

these specifications.



Details:

     1.   The fabric filter shall be of compartmental
          construction to allow isolation of a single
          compartment for cleaning and maintenance.

     2.   Pneumatic or electric remote control gate valves
          shall be provided to isolate modules, and ductwork
          shall be provided to allow for a single inlet and
          a single outlet connection to and from the fabric
          filter.
                            A-2

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          Construction shall allow for suction operation of
          the fabric filters; the induced draft fan will be
          attached to the fabric filter outlet.  The con-
          necting ductwork will be supplied by others.

          Housings, valves and ductwork shall be of carbon
          steel construction.  Fabric shall be fiberglass.
System Requirements
          The attached data sheets outline the system
          variations on which quotations will be received,
          and provides inlet and outlet flow rates and
          particulate loadings.   The gas cleaning device is
          to reduce the solids content of the gas to the
          levels specified.

          The coal being fired in the boilers has the
          following analysis:

          0    Sulfur              0.5%

               Ash                 5.9%

          0    Moisture           28.1%

          0    Heat value         19.36  Joules/nanogram
                                  8,322  (Btu/lb)

          Size distribution of particles in the inlet gas is
          as follows:

          Particle size                 Percent by weight*

          Above 100 microns                     10

          40 to 100 microns                     15

          20 to 40 microns                      15

          10 to 20 microns                      20

          Below 10 microns                      40
* From Fine Particulate Emission Inventory and Control
  Survey, by the Midwest Research Institute, January 1974.
                             A-3

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CAPITAL COr.T DATA
FABRIC FLLTF.R
FOR  LARGE
SIZED BOILERS
Data Short No.	_
Project No.   68-02-2532

Task no.         5
BOILER SIZE Mega joules/sec.
or MW
Inlet and outlet gas flow
ACFM
CF
SCFM
Moisture , Vol . %
Contaminant loading
Inlet, qr/ACF
Inlet, ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleanina efficiency
Gas cleaning equipment cost
Cost of auxiliaries


Total equipment cost
Installation costs, direct*
Foundation and supports
Duct v.1 o r k
Stack
Piping
Insulation
Pa inting
Electrical

Total direct costs
Installation costs, indirect
Engineering
Constr. and field expense
Construction fees
Start-up
Performance test

Contingencies
Tcta] Indirect costs
Turnkey cost
200
798,000
350
520,000
10
1.46
9,970
0.01
70
99.3

























500
1,993,000
350
1,305,000
10
1.46
24,930
0. 01
175
99. 3




















..




700
2,790,000
350
1,826,000
10
1.46
34,900
0.01
245
99.3

























* U'here spec i f icd
                                   A-4

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ANNUAL OPERATING COST DATA
FABRIC FILTERS
Data Shed No.	

Project No.   68-02-2532

Task No.      5
Mega joules/ sec .
BOILER SIZE or MW
Inlet & outlet gas flow
ACFM
Op
SCFM
Moisture, Vol. %
Contaminant loading
Inlet, gr/ACF
Inlet, Ib/hr
Outlet, gr/ACF
Outlet, Ib/hr
Cleaning efficiency
Operating cost item Unit cost
Direct costs:
Operating labor
Operator $10/manhour
Supervisor $12/manhour
Total
Maintenance
Labor $10/manhour
Materials
Total
Replacement parts
Utilities
Electricity $0.03/kWh
Pressure drop across collectc
Flange to flange AP, maximum
, rnimimum
Total
Total direct costs
Capital charges
Total annual cost
200
798,000
350
522,000
10
1.46
9,970
0.01
70.0
99.3













3r




500
1,993,000
350
1,305,000
10
1.46
24,930
0.01
175.0
99. 3


















700
2,790,000
350
1,824,000
10
1.46
34,900
0.01
245.0
99.3


















Operating costs to be based on annual operation of 8760 hours
per year @ 65% capacity factor.
                              A-5

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TECHNICAL REPORT DATA
(Please read Imumeiions on the reverse before completing!
1 REPORT NO. |2
EPA-450/3-78-046 |
4.
7.
9.
12
15
16
17
a.
TITLE A\DSUBTITLE
Fabric Filter Costs for Large Coal-Fired
Steam Generators
AUTHOR(S)
John Bruck, N.D. Noe
PERFORMING ORGANIZATION NAME AND ADDRESS
Industrial Gas Cleaning Institute
700 N. Fairfax Street, Suite 304
Alexandria, Virginia 22314
. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standar
Research Triangle Park, North Carolina 277
. SUPPLEMENTARY NOTES
3. RECIPIENT'S ACCESSIOONO.
5. REPORT DATE
August 1977

6. PERFORMING ORGANIZATION CODE
8. PERFORMING ORGANIZATION REPORT NO.
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-2532, Task 5
13. TYPE OF REPORT AND PERIOD COVERED
Final
Je 14. SPONSORING AGENCY CODE
11


. ABSTRACT
Capital and annual ized costs are provided by vendors for fabric filters used for
particulate emission control of large coal-fired steam generators. Generator sizes
of 200, 500, and 700 megawatts are considered at an emission level of 14.3 nanograms
per joule (0.033 Ibs/million Btu) both equipment and turnkey costs are provided.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Air Pollution
Cost Estimates
Dust Control
19
ClSTPIBUTION STATEMENT
Unl imited
b. IDENTIFIERS/OPEN ENDEDTERMS
Air Pollution Control
Stationary Sources
Coal-Fired Boilers
Fabric Filters
Emission Standards
19. SECURITY CLASS (This Report)
Unclassified
20. SECURITY CLASS /This page/
Unclassified
c. COSATI Field/Group
13B
21. NO. OF PAGES
21
22. PRICE
EPA Form 2220-1 (9-73)

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