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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