EPA 450/5-80-007
CAPITAL AND OPERATING COSTS
FOR INDUSTRIAL BOILERS
Prepared by
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-3074
Work Assignment No. 7
?N 3400-G
EPA Project Officer
John M. Pratapas
Economic Analysis Branch
Office of Air Quality Planning ar.d Standards
Research Triangle Park, North Carolina 27711
Prepared for
U.S. Environmental Protection Agency
Office of Air Quality, Planning and Standards
Rerearch Triangle Park, North Carolina 27711
June, 1979
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This report was furnished to the U.S. Environmental Protec-
tion Agency by PEDCo Environmental, Inc., Cincinnati, Ohio, in
fulfillment of Contract No. 68-02-3074, Work Assignment No. 7.
The contents of this report are reproduced herein as received
from the contractor. The opinions, findings, and conclusions
expressed are those of the author and not necessarily those of
the Environmental Protection Agency.
11
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TABLE OF CONTENTS
Page
Disclaimer ii
List of Figures iv
List of Tables v
Acknowledgment viii
1.0 Introduction 1
2.0 Specific Boilers and Characteristics 3
Boiler Configuration 24
Design Heat Input Rate 24
Fuel Analysis 24
Fuel Consumption 26
Excess Air Usage 26
Flue Gas Characteristics 30
Load Factor 31
Utility Requirements 32
Manpower Requirements 32
Bottom Ash Disposal Requirement 33
References for Section 2 34
3.0 Cost Estimates for New Boilers 35
Cost Estimating Procedure 35
Cost Estimates 48
References for Section 3 56
4.0 Equations for Boiler Costs 57
Methodology 57
Appendix A A~l
Appendix B B~l
Appendix C c~l
iii
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LIST OF FIGURES
No.
1 Equipment Costs of Water-Tube Boilers (With Fans and
Ducts) Firing Eastern Low-Sulfur Coal Versus Heat
Input 70
2 Equipment Costs of Package, Fire-Tube Boilers (With
Fans and Ducts) Firing Residual Oil, Distillate Oil
or Natural Gas Versus Heat Input 71
3 Equipment Costs of Dual-Fuel, Water-Tube Boilers
(With Fans and Ducts) Firing Residual Oil/Natural
Gas or Distillate Oil/Natural Gas Versus Heat Input 72
4 Total Turnkey Costs of Coal-Fired, Package, Underfeed-
Stoker Boilers Firing Eastern High-Sulfur Coal or
Subbituminous Coal Versus Heat Input 73
5 Total Turnkey Costs of Coal-Fired, Field-Erected
Boilers Firing Eastern High Sulfur Coal or Subbi-
tuminous Coal Versus Heat Input 74
6 Total Turnkey Costs of Package, Fire-Tube Boilers
Firing Residual Oil, Distillate Oil, or Natural Gas
Versus Heat Input 75
7 Total Turnkey Costs of Dual-Fuel, Package Boilers
Firing Residual Oil/Natural Gas or Distillate Oil/
Natural Gas Versus Heat Input 76
8 Total Turnkey Costs of Dual-fuel, Field-Erected
Boilers Firing Residual Oil/Natural Gas or Distillate
Oil/Natural Gas Versus Heat Input 77
9 Operating and Maintenance Costs (Less Fuel Costs) for
Various Boilers Versus Equivalent Hours Operated Per
Year at Maximum Capacity 78
10 Operating and Maintenance Costs (Less Fuel Costs) for
Various Boilers Versus Equivalent Hours Operated Per
Year at Maximum Capacity 79
11 Operating and Maintenance Costs (Less Fuel Costs) for
Various Boilers Versus Equivalent Hours Operated Per
Year at Maximum Capacity 80
iv
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LIST OF TABLES
Number Page
1 List of Boilers Costed for Development of
Cost Equations 4
2 Design Parameters for Coal-Fired, Package,
Water-Tube, Underfeed-Stoker Boilers 6
3 Design Parameters for Coal-Fired, Package,
Water-Tube^ Underfeed-Stoker Boilers 7
4 Design Parameters for Coal-Fired, Package,
Water-Tube, Underfeed-Stoker Boilers 8
5 Design Parameters for Coal-Fired, Field-Erected,
Water-Tube, Spreader-Stoker Boilers 9
6 Design Parameters for Coal-Fired, Field-Erected,
Water-Tube, Spreader-Stoker Boilers 10
7 Design Parameters for Coal-Fired, Field-Erected,
Water-Tube, Spreader-Stoker Boilers 11
8 Design Parameters for Field-Erected, Water-Tube,
Pulverized-Coal-Fired Boilers 12
9 Design Parameters for Field-Erected, Water-Tube,
Pulverized-Coal-Fired Boilers 13
10 Design Parameters for Field-Erected, Water-Tube,
Pulverized-Coal-Fired Boilers 14
11 Design Parameters for Package, Fire-Tube
Boilers Firing Residual Oil 15
12 Design Parameters for Package, Fire-Tube
Boilers Firing Distillate Oil 16
13 Design Parameters for Package, Fire-Tube
Boilers Firing Natural Gas 17
14 Design Parameters for Package, Water-Tube
Boilers Firing Residual Oil 18
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LIST OF TABLES (continued)
Number Page
15 Design Parameters for Package, Water-Tube
Boilers Firing Distillate Oil 19
16 Design Parameters for Package, Water-Tube
Boilers Firing Natural Gas 20
17 Design Parameters for Field-Erected,
Water-Tube Boilers Firing Residual Oil 21
18 Design Parameters for Field-Erected,
Water-Tube Boilers Firing Distillate Oil 22
19 Design Parameters for Field-Erected,
Water-Tube Boilers Firing Natural Gas 23
20 Ultimate Analyses of Fuels Selected for the
Boilers 25
21 Typical Amounts of Excess Air Supplied to
Fuel-Burning Equipment 27
22 Basic Equipment and Installation Items Included
in a New Boiler Facility 39
23 Sources of Cost Data for Equipment and
Installation Items Included in Boiler Plants 40
24 Typical Values for Indirect Capital Costs 42
25 Annual Unit Costs for Operation and
Maintenance 43
26 Direct Annual Operation and Maintenance Cost
Items Associated with Boilers 45
27 Methods Used to Estimate Direct Annual Costs 46
28 Estimated Capital and Annualized Costs of
Package, Waters-Tube, Underfeed-Stoker Boilers
Firing Coal 49
29 Estimated Capital and Annualized Costs of
Field-Erected, Water-Tube, Spreader-Stoker
Boilers Firing Coal 50
VI
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LIST OF TABLES (continued)
Number Page
30 Estimated Capital and Annualized Costs of
Field-Erected, Water-Tube/ Pulverized-Coal-
Fired Boilers 51
31 Estimated Capital and Annualized Costs of
Package, Fire-Tube Boilers 52
32 Estimated Capital and Annualized Costs of Dual-
Fuel, Water-Tube Boilers Firing Residual
Oil/Natural Gas 54
33 Estimated Capital and Annualized Costs of Dual-
Fuel, Water-Tube Boilers Firing Distillate
Oil/Natural Gas 55
34 Format for Presentation of Capital Costs of
Industrial Boilers 59
35 Format for Presentation of Annualized Costs
of Industrial Boilers 61
36 Cost Equations for Package, Water-Tube,
Underfeed-Stoker Boilers 63
37 Cost Equations for Field-Erected, Water-Tube,
Spreader-Stoker Boilers 64
38 Cost Equations for Field-Erected, Water-Tube,
Pulverized-Coal-Fired Boilers 66
39 Cost Equations for Package, Fire-Tube Boilers 67
40 Cost Equations for Water-Tube, Dual-Fuel
Boilers Firing Residual Oil/Natural Gas 68
41 Cost Equations for Water-Tube, Dual-Fuel
Boilers Firing Distillate Oil/Natural Gas 69
vii
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ACKNOWLEDGEMENT
This report was prepared for the Office of Air Quality,
Planning and Standards of the U.S. Environmental Protection
Agency. The EPA Project Officer was John M. Pratapas. PEDCo
appreciates his direction and assistance.
The PEDCo Project Director was Mr. William F. Kemner. Mr.
Larry L. Gibbs was Project Manager. Principal authors were
Messrs. Gibbs, John P. Abraham, Duane S. Forste, N. David Noe,
and Harry T. Kimball.
vzn
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1.0 INTRODUCTION
The purpose of this study is to develop general equations to
relate the costs of various types of boilers to parameters such
as fuel type, fuel analysis, operating hours, and input capacity.
The equations are to represent a cross section of fuel types
including several ranks of coal, distillate oil, residual oil,
and natural gas, and a cross section of boiler types including
fire-tube, package water-tube, field-erected water-tube, stoker
coal-fired, and pulverized coal-fired.
These equations will be used by the Office of Air Quality,
Planning and Standards (OAQPS) as input to a computer model to be
used in evaluating the economic impacts of various alternative
regulatory scenarios as applied to new industrial boilers.
The specific equations to be developed were for distillate
oil-fired fire-tube, residual oil-fired fire-tube, natural gas-
fired fire-tube, stoker coal-fired package water-tube, residual
oil/natural gas-fired package water-tube, distillate oil/natural
gas-fired package water-tube, stoker coal-fired field-erected
water-tube, pulverized coal-fired field-erected water-tube,
residual oil/natural gas-fired field-erected water-tube, and
distillate oil/natural gas-fired field-erected water-tube. To
develop these equations, 51 specific boiler/fuel combinations
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were costed. In addition, costs for 8 other boiler/fuel combina-
tions developed previously under Contract No. 68-02-2603, Task 19
were used in development of the equations. This report summarizes
the equations for the 10 major boiler/fuel combinations and
presents detailed costs for the 59 specific boilers used in
developing these equations.
In Section 2 are presented the characteristics of the spe-
cific boiler types, fuels, and sizes for which costs were pre-
pared. Section 3 presents the detailed costs for 59 boilers and
the methodology used to obtain costs. Section 4 presents the
equations describing boiler costs and the methodology for obtain-
ing these equations. Appendices A, B, and C present the detailed
cost tables for the 59 boilers.
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2.0 SPECIFIC BOILERS AND CHARACTERISTICS
The boilers were selected jointly by PEDCo and OAQPS for
detailed costing to cover the size range and fuel types of boilers
typically found in industrial use. A minimum number of boilers
were chosen that would still provide a good basis for development
of boiler cost equations. The boilers selected for detailed
costing are listed in Table 1.
Operational and design parameters had to be specified for
the selected boilers before the costs could be estimated. The
following key operating and design parameters are required for
each boiler:
0 Boiler configuration
0 Design heat input rate
0 Fuel analysis
0 Fuel consumption
0 Excess air usage
0 Flue gas characteristics
0 Load factor
The values determined for these operating and design param-
eters (Tables 2 through 19) are based on published data and
practical knowledge of good boiler operating paractices. The
methodology used to determine these values is described below.
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TABLE 1. LIST OF BOILERS COSTED FOR DEVELOPMENT OF COST EQUATIONS
Boiler type
Package water- tube, underfeed stoker
Package water-tube , underfeed stoker
Package water-tube, underfeed stoker
Package water- tube, underfeed stoker
Package water-tube, underfeed stoker
Package water- tube, underfeed stoker
Package water- tube, underfeed stoker
Package water-tube, underfeed stoker
Package water-tube, underfeed stoker
Package water-tube, underfeed stoker
Package water-tube, underfeed stoker
Package water-tube, underfeed stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube spreader stoker
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Heat input,
106 Btu/h
15
15
15
15
30
30
30
30
60
60
60
60
75
75
75
75
150
150
150
150
200
200
200
200
200
200
200
200
400
400
400
400
Steam generating
Capacity, 103 lb/h
12.0
12.0
12.0
12.0
24.0
24.0
24.0
24.0
48.0
48.0
48.0
48.0
60.0
60.0
60.0
60.0
120.0
120.0
120.0
120.0
160.0
160.0
160.0
160.0
160.0
160.0
160.0
160.0
320.0
320.0
320.0
320.0
Fuel
Eastern high-sulfur coal
Eastern low-sulfur coal
Subbituminous coal
Eastern medium-sulfur coal
Eastern high-sulfur coal
Eastern low-sulfur coal
Subbituminous coal
Eastern medium-sulfur coal
Eastern high-sulfur coal
Eastern low-sulfur coal
Subbituminous coal
Eastern medium-sulfur coal
Eastern high-sulfur coal
Eastern low-sulfur coal
Subbituminous coal
Eastern medium-sulfur coal
Eastern high-sulfur coal
Eastern low-sulfur coal
Subbituminous coal
Eastern medium-sulfur coal
Eastern high-sulfur coal
Eastern low-sulfur coal
Subbituminous coal
Eastern medium-sulfur coal
Eastern high-sulfur coal
Eastern low-sulfur coal
Subbituminous coal
Eastern medium-sulfur coal
Eastern high-sulfur coal
Eastern low-sulfur coal
Subbituminous coal
Eastern medium-sulfur coal
(continued)
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TABLE 1. (continued)
Boiler -type
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Field-erected water-tube pulverized
Package fire-tube
Package fire-tube
Package fire-tube
Package fire-tube
Package fire-tube
Package fire- tube
Package fire-tube
Package fire-tube
Package fire-tube
Package water-tube
Package water-tube
Package water-tube
Package water-tube
Field-erected water-tube
Field-erected water-tube
Field-erected water-tube
Package water-tube
Package water-tube
Package water- tube
Package water-tube
Field-erected water-tube
Field-erected water-tube
Field-erected water-tube
Heat input,
106 Btu/h
700
700
700
700
5
5
5
15
15
15
29
29
29
30
60
100
150
200
400
700
30
60
100
150
200
400
700
Steam generating
Capacity, 103 lb/h
560.0
560.0
560.0
560.0
4.0
4.0
4.0
12.0
12.0
12.0
23.2
23.2
23.2
24.0
48.0
80.0
120.0
160.0
320.0
560.0
24.0
48.0
80.0
120.0
160.0
320.0
560.0
•Fuel
Eastern high-sulfur coal
Eastern low-sulfur coal
Subbituminous coal
Eastern medium-sulfur coal
Distillate oil
Natural gas
Residual oil
Distillate oil
Natural gas
Residual oil
Distillate oil
Natural gas
Residual oil
Residual oil/natural gas
Residual oil/natural gas
Residual oil/natural gas
Residual oil/natural gas
Residual oil/natural gas
Residual oil/natural gas
Residual oil/natural gas
Distillate oil/natural gas
Distillate oil/natural gas
Distillate oil/natural gas
Distillate oil/natural gas
Distillate oil/natural gas
Distillate oil/natural gas
Distillate oil/natural gas
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TASLI: 2. rrsiGN PARAMETERS For. COAL-FIRED, PACKAGE,
WATEr.-TUDE, UNDERFEED-STOKER BOILERS
Thermal input, MW (10° Btu/h)
fuel
Fuel rate, kg/a
(tona/h)
Analysis
% aulfur
% ash
Heating value, kJ/kg
(Btu/lb)
Exceas air, %
Flue gas flow rate, m /a
(acfm)
Flue gaa temperature, °K (°F)
Load factor, %
Utility requirementa
Electricity, kw
Process water, liters/a (gpm)
Manpower requirementa
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
4.4 (IS)
Eastern high-
sulfur coal
4.4 (15)
4.4 (15)
Eastern low- Subbituminous
sulfur coal coal'
4.4 (15)
Eastern medium-
sulfur coal
0.16
(0.64)
3.5
10.6
27,447
(11,800)
50
3.04
(6450)
478 (400)
60
190
0.30 (4.8)
5
2
2
0.14
(0.54)
0.9
6.9
32,099
(13,800)
50
2.88
(6100)
450 (350)
60
162
0.30 (4.8)
5
2
2
0.20
(0.78)
0.6
5.4
22,330
(9,600)
50
2.95
(6250)
450 (350)
60
233
0.30 (4.8)
5
2
2
0.14
(0.57)
2.3
13.2
30,703
(13,200)
50
2.98
(6325)
450 (350)
60
169
0.30 (4.8)
5
2
2
46.16 (0.05)
25.35 (0.03) 28.66 (0.03) 51.19 (0.06)
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TABLE 3. DESIGN PARAMETERS FOR COAL-FIRED, PACKAGE,
WATER-TUBE, UNDERFEED-STOKER BOILERS
Thermal input, MH (10° Btu/h)
Fuel
Fuel rate, kg/s (ton/h)
Analysis
% sulfur
% ash
Heating value, kJ/kg
(Btu/lb)
Excess air, %
Flue gas flow rate, m /s (acfm)
if
Flue gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kW
Process water,liters/3 (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
8.8 (30)
Eastern high-
sulfur coal
0.32 (1.27)
3.5
10.6
27,447
(11,800)
50
6.09 (12,900)
478 (400)
60
296
0.61 (9.6)
90.71 (0.10)
8.8 (30)
Eastern low-
sulfur coal
8.8 (30)
8.8 (30)
Subbituminoua Eastern medium-
coal sulfur coal
0.27 (1.09)
0.9
6.9
32,099
(13,800)
50
5.76 (12,200)
450 (350)
60
253
0.61 (9.6)
6
2
2
0.39 (1.56)
0.6
5.4
22,330
(9600)
50
5.90 (12,500)
450 (350)
60
364
0.61 (9.6)
6
2
2
0.28 (1.13)
\ 2'3
30,703
(13,200)
50
5.97 (12.650)
450 (350)
60
264
0.61 (9.6)
6
2
2
54.43 (0.06) 54.43 (0.06) 99.78 (0.11)
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TABLE 4. DESIGN PARAMETERS FOR COAL-FIRED, PACKAGE,
WATER-TUBE, UNDERFEED-STOKER BOILERS
oo
Thermal input, MW (10° Btu/h)
Fuel
Fuel rate, kg/s
(tons/h)
Analysis
t sulfur
% ash
Heating value, kJ/kg
(Btu/lb)
Excess air, I
Flue gas flow rate, m /s
(acfm)
Flue gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kw
Process water, liters/s (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
17.6 (60)
17.6 (60)
17.6 (60)
17.6 (60)
Eastern high- Eastern low-
sulfur coal sulfur coal
Subbituminous Eastern medium-
coal sulfur coal
0.64
(2.54)
3.5
10.6
27,447
(11,800)
50
12. IB
(25,800)
478 (400)
60
392
1.21 (19.2)
7
4
4
0.55
(2.18)
0.9
6.9
32,099
(13,800)
50
11.52
(24,400)
450 (350)
60
335
1.21 (19.2)
7
4
4
0.76
(3.12)
0.6
5.4
22,330
(9,600)
50
11.80
(25,000)
450 (350)
60
482
1.21 (19.2)
7
4
4
0.57
(2.25)
2.3
13.2
30,703
(13,200)
50
11.94
(25,300)
450 (350)
60
350
1.21 (19.2)
7
4
4
181.42 (0.20) 99.78 (0.11) 117.92 (0.13) 199.56 (0.22)
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TABLE 5. DESIGN PARAMETERS FOR COAL-FIRED, FIELD-ERECTED,
WATER-TUBE, SPREADER-STOKER BOILERS
vo
Thermal input, MH (10 Btu/h)
4
Fuel
Fuel rate, kg/s (ton/h)
Analysis
% sulfur
% ash
Heating value, kJ/kg
(Btu/lb)
Excess air, t
Flue gas flow rate, m /a
(acfm)
Flue gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liters/s (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
22.0 (75)
22.0 (75)
22.0 (75)
22.0 (75)
Eastern high-
sulfur coal
0.80 (3.18)
3.5
10.6
27,447
(11,800)
50
15.24
(32,300)
478 (400)
60
425
1.52 (24.0)
8
4
4
Eastern low-
sulfur coal
0.69 (2.72)
0.9
6.9
32,099
(13,800)
50
14.21
(30,100)
450 (350)
60
363
1.52 (24.0)
8
4
4
Subbituminous
coal
0.99 (3.91)
0.6
5.4
22,330
(9600)
50
14.82
(31,400)
450 (350)
60
523
1.52 (24.0)
8
4
4
Eastern med
sulfur coal
0.72 (2.82)
2.3
13.2
30,703
(13,200)
50
14.73
(31.200)
450 (350)
60
379
1.52 (24.0)
8
4
4
107.03 (0.12)
59.59 (0.07) 67.04 (0.07) 118.19 (0.13)
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TABLE 6. DESIGN PARAMETERS FOR COAL-FIRED, FIELD-ERECTED,
WATER-TUBE, SPREADER-STOKER BOILERS
Thermal input, MVf (10° Btu/h)
Fuel
Fuel rate, kg/a (ton/h)
Analysis
% aulfur
% ash
Heating value, kJ/kg
(Btu/lb)
Exceaa air, t
Flue gas flow rate, m /s
(acfm)
Flue gas temperature, °K (°P)
Load factor, %
Utility requirements
Electricity, kW
Process water, liter a/a (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
44.0 (ISO)
44.0 (150)
44.0 (150)
44.0 (150)
Eastern high-
sulfur coal
1.60 (6.36)
3.5
10.6
27.447
(11,800)
50
30.58
(64,800)
478 (400)
60
628
3.03 (48.0)
12
4
4
Eastern low-
sulfur coal
1.38 (5.44)
0.9
6.9
32,099
(13,800)
50
28.69
(60,800)
450 (350)
60
537
3.03 (48.0V
12
4
4
Subbituminous
coal
1.98 (7.82)
0.6
5.4
22,330
(9600)
SO/
29.64
(62,800)
450 (350)
60
773
3.03 (48.0)
12
4
4
Eastern med
sulfur coal
1.43 (5.63)
2.3
13.2
30,703
(13,200)
50
29.72
(63,000)
450 (350)
60
561
3.03 (48.0)
12
4
4
Bottom ash disposal requirement,
kg/h (ton/h)
217.70 (0.24)
117.92 (0.13) 136.07 (0.15) 235.85 (0.26)
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TABLE 7. DESIGN PARAMETERS FOR COAL-FIRED, FIELD-ERECTED,
WATER-TUBE, SPREADER-STOKER BOILERS
Thermal input. MW (10 Btu/h)
Fuel
Fuel rate, kg/s
(tons/h)
Analysis
% sulfur
% ash
Heating value, kJ/kg
(Btu/lb)
Excess air, %
Flue gas flow rate, m /s
(acfm)
Flue gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liters/s (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
58.6 (200)
58.6 (200)
58.6 (200)
58.6 (200)
Eastern high- Eastern low-
sulfur coal sulfur coal
Subbituminous Eastern medium-
coal sulfur coal
2.13
(8.48)
3.5
10.6
27,447
(11,800)
50
40.77
(86,400)
478 (400)
60
813
4.04 (64.0)
16
4
6
1.84
(7.25)
0.9
6.9
32,099
(13,800)
50
38.27
(81,100)
450 (350)
60
695
4.04 (64.0)
16
4
6
2.64
(10.43)
0.6
5.4
22,330
(9,600)
50
39.52
(83,700)
450 (350)
60
1001
4.04 (64.0)
16
4
6
1.91
(7.51)
2.3
13.2
30,703
(13,200)
50
39.65
(84,000)
450 (350)
60
726
4.04 (64.0)
16
4
6
281.20 (0.31) 163.28 (0.18) 181.42 (0.20) 317.49 (0.35)
-------
TABLE 8. DESIGN PARAMETERS FOR FIELD-ERECTED, WATER-TUBE,
PULVERIZED-COAL-FIRED BOILERS
Thermal input, MW (10 Btu/h)
Fuel
Fuel rate, kg/a (ton/h)
Analysis
t sulfur
t ash
Heating value, kJ/kg
(Btu/lb)
Excess air, %
Plue gas flow rate, m /s
(acfm)
Flue gas temperature, °K (°F)
Load factor, t
Utility requirements
Electricity, kw
Process water, liters/s (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
58.6 (200)
58.6 (200)
58.6 (200)
58.6 (200)
eastern high-
sulfur coal
2.13 (8.48)
3.5
10.6
27,447
(11,800)
30
35.30
(74,800)
478 (400)
60
2052
4.04 (64.0)
16
4
6
Eastern low-
sulfur coal
1.84 (7.25)
0.9
6.9
32,099
(13,800)
30
33.32
(70,600)
450 (350)
60
1754
4.04 (64.0)
16
4
6
Subbituminous
coal
2.64 (10.43)
0.6
5.4
22,330
(9600)
30
34.55
(73,200)
450 (350)
60
2526
4.04 (64.0)
16
4
6
Eastern med
sulfur coal
1.91 (7.51)
2.3
13.2
30,703
(13,200)
30
34.62
(73,400)
450 (350)
60
1831
4.04 (64.0)
16
4
6
163.28 (0.18) 90.71 (0.10) 99.78 (0.11) 181.42 (0.20)
-------
TABLE 9. DESIGN PARAMETERS FOR FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILERS
Thermal input, MW (10° Btu/h)
Fuel
Fuel rate, kg/s (ton/h)
Analysis
% sulfur
« ash
Heating value, kJ/kg
(Btu/lb)
Excess air, «
Flue gas flow rate, m /s
(acfm)
Flue gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liters/s (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
117.2 (400)
117.2 (400)
117.2 (400)
117.2 (400)
Eastern high-
sulfur coal
4.27 (16.95)
3.5
10.6
27,447
(11,800)
30
70.63
(149,600)
478 (400)
60
4142
8.08 (128.0)
28
6
12
Eastern low-
sulfur coal
3.65 (14.49)
0.9
6.9
32,099
(13,800)
30
66.80
(141,500)
450 (350)
60
3540
8.08 (128.0)
28
6
12
Subbituminous
coal
5.25 (20.83)
0.6
5.4
22,330
(9600)
30
68.89
(146,000)
450 (350)
60
5097
8.08 (128.0)
28
6
12
Eastern medii
sulfur coal
3.82 (15.14)
2.3
13.2
30,703
(13,200)
30
71.35
(151,200)
478 (400)
60
3695
8.08 (128.0)
28
6
12
326.56 (0.36)
181.42 (0.20) 199.56 (0.22) 362.84 (0.40)
-------
TABLE 10. DESIGN PARAMETERS FOR FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILERS
Thermal Input, MW (10 Btu/h)
Fuel
Fuel rate, kg/8
(tons/h)
Analysis
% sulfur
% ash
Heating value, kJ/kg
(Btu/lb)
Excess air, %
Flue gas flow rate, m /s
(acfro)
Flue gas temperature, °K (*F)
Load factor, \
Utility requirements
Electricity, kW
Process water, liters/s (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
205.1 (700)
205.1 (700)
Eastern high- Eastern low-
sulfur coal sulfur coal
205.1 (700)
Subbituminous
coal
205.1 (700)
Eastern medium-
sulfur coal
7.47
(29.66)
3.5
10.6
27,447
(11,800)
30
123.55
(261,800)
478 (400)
60
7249
14.14 (224.0)
38
6
16
6.39
(25.36)
0.9
6.9
32,099
(13,800)
30
116.62
(247,100)
450 (350)
60
6195
14.14 (224.0)
38
6
16
9.19
(36.46)
0.6
5.4
22,330
(9,600)
30
120.93
(256,200)
450 (350)
60
8920
14.14 (224.0)
38
6
16
6.68
(26.52)
2.3
13.2
30,703
(13,200)
30
121.17
(256,900)
450 (350)
60
6466
14.14 (22
38
6
16
570.43 (0.63) 317.49 (0.35) 357.22 (0.39) 635.14 (0.70)
-------
TABLE 11.
DESIGN PARAMETERS FOR PACKAGE, FIRE-TUBE
BOILERS FIRING RESIDUAL OIL
Thermal input, MW (10 Btu/h)
Fuel
Fuel rate, m /h
(gal/h)
Analysis
% sulfur
% ash 3
Heating value, MJ/m
(Btu/gal)
Excess air, %
Flue gas flow rate, m /s
(acfm)
Flue gas temperature, "K (°F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liter/s (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement
kg/h (tons/h)
1.5 (5)
Residual oil
0.13
(33.4)
3.0
0.1
41,714
(149,800)
15
0.75
(1,600)
478 (400)
45
59
0.10 (1.6)
4
0.5
4.4 (15)
Residual oil
0.38
(100.1)
3.0
0.1
41,714
(149,800)
15
2.21
(4,700)
478 (400)
45
114
0.30 (4.8)
4
2
1
8.5 (29)
Residual oil
0.73
(193.6)
3.0
0.1
41,714
(149,800)
15
4.28
(9,100)
478 (400)
45
236
0.60 (9.5)
4
2
1
Negligible
Negligible
Negligible
-------
TABLE 12. DESIGN PARAMETERS FOR PACKAGE, FIRE-TUBE
BOILERS FIRING DISTILLATE OIL
<3\
Thermal input, MW (10° Btu/h)
Fuel
Fuel rate, m3/h (gal/h)
Analysis
% sulfur
% ash ,
Heating value, MJ/m (Btu/gal)
Excess air, \
Flue gas flow rate, m /s (acfm)
Flue gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kW
Process water, llter/s (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
1.5 (5)
Distillate oil
0.14 (36.0)
0.5
Trace
38,712 (139,000)
4.4 (15)
Distillate oil
0.41 (107.9) .
0.5
Trace
38,712 (139,000)
8.5 (29)
Distillate oil
0.79 (208.6)
0.5
Trace
38,712 (139,000)
15
0.81 (1700)
450 (350)
45
59
0.10 (1.6)
4
.5
15
2.36 (5000)
450 (350)
45
114
0.30 (4.8)
4
2
1
15
4.45
450
45
236
0.60
4
2
1
(9700)
(350)
(9.5)
Negligible
Negligible
Negligible
-------
TABLE 13. DESIGN PARAMETERS FOR PACKAGE, FIRE-TUBE
BOILERS FIRING NATURAL GAS
Thermal input, MW (10 Btu/h)
Fuel
Fuel rate, m3/s (ft3/h)
Analysis
% sulfur
% ash , ,
Heating value, kJ/m (Btu/ft )
Excess air, %
Flue gas flow rate, m /s (acfm)
Flue gas temperature, °K (*F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liter/a (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
1.5 (5)
Natural gas
0.04 (5000)
Trace
Trace
37,218 (1000)
15
0.81 (1700)
450 (350)
45
59
0.10 (1.6)
4
.5
4.4 (15)
Natural gas
0.12 (15,000)
Trace
Trace
37,218 (1000)
15
2.45 (5200)
450 (350)
45
114
0.30 (4.8)
4
2
1
8.5 (29)
Natural gas
0.23 (29,000)
Trace
Trace
37,218 (1000)
15
4.74 (10,100)
450 (350)
45
236
0.60 (9.5)
4
2
1
Negligible
Negligible
Negligible
-------
TABLE 14.
DESIGN PARAMETERS FOR PACKAGE, WATER-TUBE
BOILERS FIRING RESIDUAL OIL
o>
Thermal input , MW (10° Btu/h)
Fuel
Fuel rate, m /h
(gal/h)
Analysis
« sulfur
% ash ,
Heating value, MJ/m
(Btu/gal)
Excess air, %
Flue gas flow rate, m /s
(acfm)
Flue gas temperature, °K (*F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liter/s (gptn)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
8.8 (30)
Residual oil
17.6 (60)
Residual oil
29.3 (100)
Residual oil
44.0 (ISO)
Residual oil
0.76
(200.3)
3.0
0.1
41,714
(149,800)
15
4.62
(9800)
478 (400)
55
236
0.61 (9.6)
4
2
1
1.52
(400.5)
3.0
0.1
41,714
(149.800)
15
9.25
(19,600)
478 (400)
55
265
1.21 (19.2)
4
2
2
2.53
(667.6)
3.0
0.1
41,714
(149,800)
15
15.43
(32,700)
478 (400)
55
316
2.02 (32.0)
6
2
2
3.79
(1001.3)
3.0
0.1
41,714
(149,800)
15
23.12
(49,000)
478 (400)
55
379
3.03 (48.0)
8
2
2
Negligible
Negligible
Negligible
Negligible
-------
TABLE 15.
DESIGN PARAMETERS FOR PACKAGE, WATER-TUBE
BOILERS FIRING DISTILLATE OIL
vo
Thermal input, HH (10° Btu/h) 8.8 (30) • 17.6 (60) 29.3 (100) 44.0 (150)
Fuel
Fuel rate, m /h
(gal/h)
Analysis
% sulfur
% ash ,
Heating value, MJ/m
(Btu/gal)
Excess air, %
Flue gas flow rate, m /s
(acfm)
Flue gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liters/a (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h) Negligible Negligible Negligible Negligible
Distillate
oil
0.82
(215.8)
0.5
Trace
38,712
(139.000)
15
4.36
(9.240)
450 (350)
55
236
0.61 (9.6)
4
2
1
Distillate
oil
1.63
(431.7)
0.5
Trace
38,712
(139.000)
15
8.73
(18,500)
450 (350)
55
265
1.21 (19.2)
4
2
2
Distillate
oil
2.72
(719.4)
0.5
Trace
38,712
(139,000)
15
14.53
(30,800)
450 (350)
55
316
2.02 (32.0)
6
2
2
Distillate
oil
4.09
(1080.0)
0.5
Trace
38.712
(139.000)
15
21.78
(46,200)
450 (350)
55
379
3.03 (48.0)
8
2
2
-------
TABLE 16.
DESIGN PARAMETERS FOR PACKAGE, WATER-TUBE
BOILERS FIRING NATURAL GAS
K>
O
Thermal input, MW (10° Btu/h)
Fuel
Fuel rate, m /s
(ft3/h)
Analysis
% aulfur
% ash 3
Heating value, kJ/m 1
(Btu/Ct )
Excess air, %
Flue gas Clow rate, m /s
(acfm)
Flu* gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liters/s (gpm)
Manpower requirements
Direct- labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
8.B (30)
Natural gas
0.24
(30,000)
Trace
Trace
37,218
(1000)
IS
4.43
(9,380)
450 (350)
55
236
0.61 (9.6)
4
2
1
17.6 (60)
Natural gas
0.47
(60,000)
Trace
Trace
37,218
(1000)
15
8.87
(18,800)
450 (350)
55
265
1.21 (19.2)
4
2
2
29.3 (100)
Natural gas
0.79
(100,000)
Trace
Trace
37,218
(1000)
15
14.77
(31,300)
450 (350)
55
316
2.02 (32.0)
6
2
2
44.0 (150)
Natural gas
1.18
(150,000)
Trace
Trace
37,218
(1000)
15
22.15
(46,900)
450 (350)
55
379
3.03 (48.0)
8
2
2
Bottom ash disposal requirement,
kg/h (ton/h) Negligible Negligible Negligible Negligibli
-------
TABLE 17.
DESIGN PARAMETERS FOR FIELD-ERECTED, WATER-TUBE
BOILERS FIRING RESIDUAL OIL
Thermal input, MW (10° Btu/h)
Fuel
Fuel rate, m /h
(gal/h)
Analysis
% sulfur
% ash ,
Heating value, MJ/m
(Btu/gal)
Excess air, %
Flue gas flow rate, m /s
(acfm)
Flue gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liters/a (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h)
58.6 (200)
Residual oil
117.2 (400)
Residual oil
205.1 (700)
Residual oil
5.05
(1335.1)
3.0
0.1
41,714
(149,800)
15
30.87
(65,400)
478 (400)
55
569
4.04 (64.0)
10
3
3
10.11
(2670.2)
3.0
0.1
41,714
(149,800)
15
61.73
(130,800)
478 (400)
55
885
8.08 (128.0)
18
4
4
17.69
(4672.9)
3.0
0.1
41.714
(149,800)
15
108.03
(228,900)
478 (400)
55
1453
14.14 (224.0)
23
4
7
Negligible
Negligible
Negligible
-------
TABLE 18.
DESIGN PARAMETERS FOR FIELD-ERECTED, WATER-TUBE
BOILERS FIRING DISTILLATE OIL
10
K>
Thermal input, MH (10 Btu/h) 58.6 (200) 117.2 (400) 205.1 (700)
Fuel
Fuel rate, n»3/h
(gal/h)
Analysis
% sulfur
% ash ,
Heating value, MJ/m
(Btu/gal)
Excess air, %
Plue gas flow rate, m /s
(acfm)
riue gas temperature, °K (*F)
Load factor, %
Utility requirements
Electricity, kW
Process water, liters/s (gpm)
Manpower requirements
Direct labor, man-yr
Supervision, man-yr
Maintenance labor, man-yr
Bottom ash disposal requirement,
kg/h (ton/h) Negligible Negligible Negligible
Distillate
oil
5.45
(1438. 8)
0.5
Trace
38,712
(139,000)
15
29.07
(61,600)
450 (350)
55
569
4.04 (64.0)
10
3
3
Distillate
oil
10.89
(2877.7)
0.5
Trace
38,712
(139,000)
IS
58.14
(123,200)
450 (350)
55
885
8.08 (128.0)
18
4
4
Distillate
oil
19.06
(5036.0)
0.5
Trace
38,712
(139,000)
15
101.76
(215,600)
450 (350)
55
1453
14.14 (224.0)
23
4
7
-------
TABLE 19.
DESIGN PARAMETERS FOR FIELD-ERECTED, WATER-TUBE
BOILERS FIRING NATURAL GAS
to
U)
Thermal input, MH (10 Btu/h)
Fuel
Fuel rate, m3/s
(ftVh)
Analysis
% sulfur
% ash 2
Heating value, kJ/m ,
(Btu/ftJ)
Excess air, %
Flue gas flow rate, m /•
(acfm)
Flue gas temperature, °K (°F)
Load factor, %
Utility requirements
Electricity, kw
Process water, liters/a (gpm)
Manpower requirements
Direct labor, man-yr
.Supervision, man-yr
Maintenance labor, man-yr
58.6 (200)
Natural gas
15.7
(200,000)
Trace
Trace
37,218
(1000)
15
29.50
(62,500)
450 (350)
55
569
4.04 (64.0)
10
3
3
117.2 (400)
Natural gas
3.15
(400,000)
Trace
Trace
37,218
(1000)
15
59.04
(125,100)
450 (350)
55
885
8.08 (128.0)
18
4
4
205.1 (700)
Natural gas
5.51
(700,000)
Trace
Trace
37,218
(1000)
15
103.31
(218,900)
450 (350)
55
1453
14.14 (224.0)
23
4
7
Bottom ash disposal requirement,
kg/h (ton/h) Negligible Negligible Negligible
-------
BOILER CONFIGURATION
Boiler configuration was specified as an initial step in the
selection of representative boilers.
DESIGN HEAT INPUT RATE
This rate is based on the available capacities of the boil-
ers within the selected configurations. The selection of the
capacity range reflects the most common capacities within a par-
ticular boiler configuration.
FUEL ANALYSIS
Fuel type for each boiler was chosen as part of the initial
selection process. The fuel analyses presented in Table 20 for
natural gas, distillate oil, and residual oil were determined
from data about "average" fuels presented by Babcock & Wilcox
(1972). The Babcock & Wilcox analysis of Birmingham natural gas
was selected as average. The values selected for distillate oil
represent No. 2 fuel oil; they were selected from the middle of
the ranges presented, except for sulfur content, which was
selected from the upper part of the range for evaluation of a
distillate oil with a relatively high sulfur content. The
analysis for the residual oil was selected from the ranges of
values given for No. 6 fuel oil; again, all values were taken
from the middle of the ranges except the sulfur value, which
comes from the upper part of the range so that a high-sulfur
residual oil can be evaluated.
24
-------
TABLE 20. ULTIMATE ANALYSES OF FUELS SELECTED FOR THE BOILERS*
-------
Four coal analyses were used to represent the major coal-
producing areas and classes of coals available in the United
States. Data from Babcock & Wilcox (1972) served as the basis for
the analyses of eastern high-sulfur, high-ash, bituminous coal;
eastern low-sulfur, low-ash, low-moisture, bituminous coal; and
western low-^sulfur, low-ash, high-moisture, subbituminous coal.
Versar, Inc. provided the analysis of eastern medium-sulfur, high-
ash, low-moisture bituminous coal.
FUEL CONSUMPTION
Given the heat input rate specified for each selected boiler
in Table 1, fuel consumption was calculated by dividing the heat
input rate by the heating value of the fuel used. For example,
if a package, water-tube, underfeed stoker with a heat input rate
of 8.8 MW thermal (30 x 106 Btu/h) fires eastern coal at 27,447
kJ/kg, the amount of fuel required is equal to 8800 kJ/s T
27,447 kJ/kg, or 0.32 kg/s.
Because input capacities are specified, it is not necessary
to consider the efficiencies of boiler heat transfer or fuel
burning.
EXCESS AIR USAGE
The amount of excess air selected for each boiler type is
based on practical knowledge of good boiler operating practices.
Table 21 presents ranges (percentages by weight) of excess air
common to different boiler types. A value for each boiler was
26
-------
TABLE 21.
TYPICAL AMOUNTS OF EXCESS AIR SUPPLIED
TO FUEL-BURNING EQUIPMENTS
Fuel
Type of burners
Excess air,
% by weight
Pulverized coal
Coal
Fuel oil
Natural gas
Partially water-cooled
for dry-ash-removal
Spreader stoker
Chain-grate and
traveling-grate stokers
Underfeed stoker
Multifuel and flat-flame
Multifuel
15-40
30-60
15-50
20-50
10-20
7-15
Babcock & Wilcox, 1963.
27'
-------
selected out of this range, based upon previous experience and
data on boiler operating characteristics.
A mass balance was then performed to obtain the amount of
excess air. The combustion air was assumed to have a temperature
of 27°C (80°F), a relative humidity of 60 percent, and a pressure
of 101 kPa (14.7 psi). The amount of air required for complete
combustion of the fuel was calculated on a molal basis from the
ultimate analysis of the fuel and the emission rates of the vari-
ous flue gas constituents.
An example of the procedure is shown below using the pack-
age, water-tube, underfeed-stoker boiler with a heat input of 8.8
MW thermal (30 x 106 Btu/h).
The molal configuration for each of the gaseous constituents
of the flue gas (determined by emission factors) is calculated by
dividing the mass rate by the molecular weight of the constitu-
ent. The results for the example boiler are shown below:
Constituent moles/h
Carbon monoxide (CO) 0.09
Hydrocarbons (as CH4) 0.07
Sulfur dioxide (SO2) 2.80
Nitrogen oxides (as NO2) 0.23
The molal rate of each component is then calculated using
the fuel mass rate per hour and the ultimate analysis of the
fuel. The results for the example boiler are tabulated below:
28
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Mass rate/
Fuel constituent kg/h (Ib/h) Molal rate
Carbon (C) 12.44 (1646) 137.1
Hydrogen (H2) 0.85 (113) 56.1
Sulfur (S) 0.68 (90) 2.8
Oxygen (O2) 1.26 (167) 5.2
Nitrogen (N2) 0.25 (33) 1.2
Water (H20) 1.69 (223) 12.4
The remaining flue gas constituents (C02, H20, N2) are cal-
culated by molal balance by subtracting the calculated moles of
emissions (U.S. EPA, 1975) from the moles of equivalent components
in the fuel. For example, the CO and CH. represent part of the
carbon from the fuel. Assuming the remaining carbon is oxidized
to CO2/ the molal quantity of C02 is 137.17 moles of carbon minus
0.09 moles of CO minus 0.07 moles of CH4 or 137.01 moles of CO2.
The results of similar analyses for the other flue gas constit-
uents of the example boiler are as follows:
Constituent Molal quantity
C02 137.0
H20 68.5
N2 1'1
To calculate the stoichiometric oxygen required, each flue
gas constituent is examined in terms of equivalent oxygen con-
tent. The following is a presentation of data for the example
boiler.
29
-------
Flue gas Moles Moles of ©2 Moles of
constituent per hour per mole constituent per hour
CO 2
CO
CH4
SO,
H20
N0x (as N02)
N?
137.0
0.09
0.07
2.80
68.5
0.23
1.1
1.0
0.5
0.0
1.0
0.5
1
0.0
137.0
0.4
0.0
2.8
34.2
0.23
0.0
Total 174.27
Of the 174.3 moles of O2 required, the O2 in the coal sup-
plies 5.2 moles and the H.O in the coal supplies 6.2 moles.
Therefore the theoretical requirement from the combustion air is
162.9 moles of 02. The excess air for this boiler is 50 percent
of stoichiometric. Therefore the total oxygen required is 1.5
times the theoretical requirement, or 244.4 moles. It was
assumed that the combustion air is 21 percent oxygen and 79
percent nitrogen. Therefore the N2 required is 919 moles. The
weight of dry air supplied is then 15,256 kg/h (33,564 Ib/h). At
the previously assumed combustion air conditions, 6.0212 mole of
water is contained in the wet air per mole of dry air (24 moles
of H2O total). The total wet combustion air supplied is then
15,453 kg/h (33,996 Ib/h).
FLUE GAS CHARACTERISTICS
The volume of the exit flue gas is dependent upon its compo-
sition, the amount of excess air, and the exit temperature. The
30
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total moles of the various flue gas constituents was determined
for each boiler in the excess air calculations. At standard
conditions, the volume of a mole of gas is 10.2 m (359 ft ),
assuming ideal behavior. Therefore the volume of the flue gas at
standard conditions can be calculated.
The actual volume of the flue gas must be calculated at the
flue gas temperature. Assumed temperatures of the exit flue gas
from each boiler were based on typical temperatures from previous
boiler studies. The calculated volumes of flue gas were then
adjusted from standard conditions to the actual temperature. It
was assumed that the flue gas pressure is constant at 101 kPa
(14.7 psi) .
For example, for a package, water tube, under feed-stoker
boiler with a heat input of 8.8 MW thermal (30 x 10 Btu/h) ,
total dry flue gas was calculated to be 1135.9 moles. On a wet
basis, flue gas was calculated to be 1228.4 moles. At the assumed
exhaust temperature of 478°K (400°F) the flue gas volume is:
•a
1228.4 moles/h x 10.2 in /mole x
21,938 m3/h (775,204 ft3/h)
2730
21,938 m3/h * 3600 s/h =6.09 m3/s (12,900 ft3/min)
LOAD FACTOR
Assumed load factors for the boilers were based on ranges of
load factors for industrial boilers. Battelle (Locklin, et al.,
1974) estimated load factors in industrial/ commercial boilers to
range from 30 to 80 percent. Selection of values from the range
31
-------
for each representative boiler was based on previous boiler
studies and data on typical load factors. The load factors are
believed to be representative of new industrial boilers supplying
process steam.
UTILITY REQUIREMENTS
A boiler facility requires electricity to operate a variety
of equipment. The equipment items include fans, controls,
pulverizers or stokers, feeders, crushers, conveyors, pumps,
compressors, lights, heating equipment, air conditioning, and
instrumentation. For each boiler facility an estimate was made
of the electrical requirements for these equipment items based on
boiler plants of similar size.
Also a boiler requires make-up water to replace that lost in
the steam-condensation cycle. For each of the boilers it was
assumed that 20 percent of the total water requirement is lost in
every condensate cycle.
MANPOWER REQUIREMENTS
The labor required to operate a boiler facility consists of
operating labor, supervision, and maintenance labor. The labor
requirement is based upon the number of men required to operate
the boiler on a continuous (24 hour) basis. The plant is assumed
to operate on a three shift basis with each man working the
equivalent of 2190 hours per year. The estimates of manpower
requirements reflect a conservative case with state laws that
32
-------
require an operator at all times for a boiler facility taken into
account. A less conservative approach could reduce these labor
requirements to some extent and in cases of multiple boilers at a
single site, the requirement would be significantly reduced.
BOTTOM ASH DISPOSAL REQUIREMENT
For coal-fired boilers the bottom ash disposal requirement
is calculated based upon the fly ash emission factors presented
in AP-42 (U.S. EPA, 1977). For each type of boiler, the percent
bottom ash is as follows:
Coal-firing mechanism Percent bottom ash
Pulverizer 20
Spreader stoker 35
Overfeed stoker 35
Chain grate stoker 75
Underfeed stoker 75
Other stokers 75
The hourly rate of bottom ash is calculated as follows :
% bom ash
Bottom ash (tons/h) = Coal feed (tons/h) x
For example, for the 8 . 8 MW thermal (30 x 10 Btu/h) package
water-tube underfeed stoker boiler firing eastern high-sulfur
coal the bottom ash rate is :
Bottom ash = (1.27 ton/h)(10.6 * 100) (75 T 100)
=0.10 ton/h
33
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REFERENCES FOR SECTION 2
Babcock & Wilcox. 1963. Steam - Its Generation and Use, Thirty-
seventh Edition. New York City.
Babcock & Wilcox. 1972. Useful Tables for Engineers and Steam
Users, Twelfth Edition. New York City-
Locklin, D.W., H.H. Krause, A.A. Putnam, E.L. Kropp, W.T. Reid,
and M.A. Duffy. 1974. Design Trends and Operating Problems
in Combustion Modification of Industrial Boilers. EPA
R-802402, Battelle-Columbus Laboratories, Columbus, Ohio.
U.S. EPA. 1977. Compilation of Air Pollutant Emission Factors,
AP-42, Third Edition.
34
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3.0 COST ESTIMATES FOR NEW BOILERS
Estimates were developed for the cost of new installations
of the boilers described in Section 2. An outline of the pro-
cedures used in developing the costs is followed by the cost
estimates.
COST ESTIMATING PROCEDURE
Cost of a boiler facility includes the costs of basic equip-
ment, the costs of installation, and the costs of operating and
maintaining the boiler. A capital cost estimate is developed by
the following steps:
0 Define the battery limits of the facility.
0 Develop a list of equipment required.
0 Obtain prices for each equipment item.
0 Calculate installation costs.
0 Calculate indirect capital costs.
Costs are all-inclusive, accounting for the material and
labor needed to complete an operational boiler plant. The esti-
mates were prepared from a detailed equipment summary. Estimates
of erection costs are based on experience and on actual cost of
erection at similar plants.
Battery limits of the facility extend from the fuel-receiving
equipment to the ash disposal site, inclusively. Excluded are
35
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steam and condensate piping beyond the boiler building and
pollution control equipment. Costs of ducting and the stack are
included.
Based on guidelines presented by H.K. Ferguson (Coffin,
1978), an equipment list was developed for each boiler. The
major equipment items are described below.
Water enters the system through a treatment process—for
this study a standard Zeolite softening system. The makeup water
is then fed to a deaerator, which has a 15-minute holding capacity
at full flow. The return condensate is piped to the condensate
return tank. It is assumed that 20 percent makeup is required.
The overflow storage tank for the condensate return tank is sized
to hold the condensate generated in 1 hour at full load capacity.
A continuous-blowdown flash tank and drain heat recovery
system recover all available heat from both the flash steam and
the drains.
Two boiler feed pumps are provided, 100 percent capacity
each. Automatic recirculation shutoff is not included. A fixed
minimum-flow bypass orifice is used for simplicity.
Each oil-fired boiler has 100 percent Maximum Capacity
Rating (MCR) oil-burning capability and includes a storage tank
and transfer pump facility. In the plant, a pump and heater set
are provided, consisting of two pumps (100 percent capacity) for
firing of No. 6 oil. Capacity of the storage tank provides
approximately 7 days firing at MCR.
36
-------
Coal is stored in the plant in overhead bunkers supported by
the building steel. Coal is loaded into the bunkers by a con-
veying system designed to fill the bunkers completely during an
8-hour shift. Bunker capacity is sufficient to operate the plant
for 24 hours at full load.
The conveying system includes the under-track hopper, which
supplies a coal silo with 10 days' storage; a -bucket elevator or
belt conveyor, depending on building height (100 ft maximum for a
bucket elevator); and an over-bunker tripper conveyor to load
each bunker section. A crusher included with the hopper allows
some sizing of the coal feed.
The stoker-fired plants include an under-bunker conveyor,
tripper mechanism, and a nonsegregating conical distributor to
the stoker hopper.
The pulverized-coal-fired plant includes gravimetric feeders
to the pulverizers.
Ash handling systems of the pneumatic type (dry) transport
fly ash and bottom ash to a temporary storage silo for later
removal by truck. The bottom ash handling equipment includes a
clinker breaker.
Except for the pulverized-coal-fired boiler, which requires
an air heater to dry the coal sufficiently, all boilers are
equipped with economizers.
Controls are provided to regulate combustion, feedwater, and
flame safety. The pulverized-coal-fired boiler also has an
electronic pulverizer control system for safe and reliable start-
ing of the pulverizers.
37
-------
The building, constructed of insulated steel, includes a
small office area and employees' washroom. No provision is made
for an enclosed control room for the operators; rather, the
boiler control panels are free-standing in front of the boiler
firing aisle. Lighting, ventilation, ladders, gratings, and
painting are included.
A 1 to 2 acre parcel of land is allocated to each of the
boilers. Table 22 lists the basic equipment and installation
items included in' the capital cost estimates. Table 23 lists the
sources of data used in estimating capital costs. Costs were
obtained for the low-sulfur bituminous coal; costs were then
apportioned to the subbituminous, medium-sulfur, and high-sulfur
bituminous coals by use of factors obtained from boiler manu-
facturers. Indirect capital costs were estimated as a percentage
of the installed equipment costs. Table 24 lists the percentages
used for each item.
The costs are based on a Greenfield boiler installation with
no pollution control equipment, located in the Midwest. Regional
cost factors may be used to estimate costs in areas other than
the Midwest. The costs were adjusted to June 30, 1978.
Annual operating and maintenance costs are based on require-
ments for labor, materials, and utilities as cited by manufac-
turers of boilers and auxiliary equipment and presented in Section
2, together with the unit costs specified for the Midwest in
Table 25.
38
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TABLE 22. BASIC EQUIPMENT AND INSTALLATION ITEMS INCLUDED
IN A NEW BOILER FACILITY
Equipment:
Boiler (with fans and ducts)
Stack
Instrumentation
Pulverizers or Stoker system
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel oil system
Installation:
Foundations and supports
Piping
Insulation
Painting
Electrical
Building
39
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TABLE 23. SOURCES OF COST DATA FOR EQUIPMENT AND INSTALLATION
ITEMS INCLUDED IN BOILER PLANTS
Equipment item
Sources of cost data
Boiler (with fans and ducts)
Stacks
Instrumentation
Pulverizers or stoker system
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
(continued)
Babcock & Wilcox Co.
Combustion Engineering, Inc.
Cleaver-Brooks Division of
Aqua-Chem
Erie City Energy Division of Zurn
E. Keeler Co.
Airtek
Rust Engineering
Richardson Cost Estimating Manual
Aedes Associates, Inc.
Babcock & Wilcox Co.
Combustion Engineering, Inc.
Cleaver-Brooks Division of
Aqua-Chem
Erie City Energy Division of Zurn
E. Keeler Co.
Babcock & Wilcox Co.
Combustion Engineering, Inc.
Cleaver-Brooks Division of
Aqua-Chem
Erie City Energy Division of Zurn
E. Keller Co.
Jeffrey Manufacturing Co.
Babcock & Wilcox Co.
Combustion Engineering, Inc.
Cleaver-Brooks Division of
Aqua-Chem
Erie City Energy Division of Zurn
E. Keeler Co.
Pennsylvania Crusher Co.
Richardson Cost Estimating Manual
Chicago Heater Co.
Cochrane Environmental Systems
Richardson Cost Esimating Manual
Ingersoil-Rand
Richardson Cost Estimating Manual3
Richardson Cost Estimating Manual
40
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TABLE 23. (continued)
Equipment items
Sources of cost data
Condensate system
Water treatment system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel oil system
Foundations and supports
Piping
Insulation
Painting
Electrical
Building
Richardson Cost Estimating Manual3
Crane Cochran Zeolite
Calgon Corp.
Milton Roy Co.
Richardson Cost Estimating Manual3
Ingersoil-Rand
Richardson Cost Estimating Manual
Jeffrey Manufacturing Co.
Caterpillar Co.
Richardson Cost Estimating Manual
Allen-Sherman-Hoff, Inc.
United Conveyor
Richardson Cost Estimating Manual3
Aedes Associates, Inc.
Coen Co.
Aedes Associates, Inc.
Aedes Associates, Inc.
Aedes Associates, Inc.
Aedes Associates, Inc.
Aedes Associates, Inc.
Aedes Associates, Inc.
Aedes Associates, Inc.
Richardson, 1978.
41
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Table 24. TYPICAL VALUES3 FOR INDIRECT CAPITAL COSTS
Cost item
Range of values
Engineering
Construction and field
expenses
Contractor's fee
Shakedown
Performance test
Contingency
Working capital
8 to 20 percent of installed cost.
High value for small projects; low
value for large projects.
Recommend 10 percent
7 to 20 percent of installed cost.
Recommend 10 percent
10 to 15 percent of installed cost,
Recommend 10 percent
1 to 6 percent of installed cost.
Recommend 2 percent
Minimum value of $2000.
10 to 30 percent of total direct
and indirect costs dependent upon
accuracy of estimate.
Recommend 20 percent
15 to 35 percent of the total
annual operation and maintenance
costs.
Recommend 25 percent
Devitt, 1979.
42
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TABLE 25. ANNUAL UNIT COSTS FOR OPERATION AND MAINTENANCE
(June 1978 dollars)
Cost factors
Direct labor, $/man-hour
Supervision, $/man-hour
Maintenance labor, $ /man-hour
Electricity, mills/kWh
3
Process water, $/10 gal
Coal, $/106 Btu
Eastern high-sulfur
Eastern medium-sulfur
Eastern low- sulfur
Subbituminous
No. 2 fuel oil, $/106 Btu
No. 6 fuel oil, $/106 Btu
Natural gas, $/106 Btu
Bottom ash disposal, $/ton
Recommended value
12.02a
15.63b
14.63a
25.80°
0.15d
0.74e
0.95f
1.166
0.42e
3.00g
2.2lg
1.95h
40. OO1
Engineering News-Record, June 29, 1978, pp. 52-52. Average for
Chicago, Cincinnati, Cleveland, Detroit, and St. Louis.
Estimated at 30 percent over direct labor rate.
EEI members publication for June, 1978. Average for Boston,
Chicago, Indianapolis, Houston, San Francisco, and Los Angeles.
Peters, M.S., and K.D. Timmerhaus. Plant Design and Economics
for Chemical Engineers, 2nd Edition. McGraw-Hill Book Co. New
York 1968. p. 772. Adjusted to 1978 prices using Nelson
Refinery Operating Cost Indexes for Chemicals. July 1978.
Coal Outlook, July 18, 1978. Spot market prices.
Average of prices for high- and low-sulfur coal.
Electrical Week, May issues, 1978. Spot market prices.
-•
Gas Facts, 1977. American Gas Association. Average U.S. price.
Based on $2/ton-mile and disposal site 20 miles from plant.
43
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Table 26 lists the elements of annual operating and main-
tenance costs; Table 27 indicates the methods used in developing
the costs; the boiler parameter tables (Tables 2 through 19) show
the manpower requirements on which the labor costs are based.
The cost of disposing of bottom ash from a coal-fired boiler
is based on a 32-km (20-mi) one-way haul to ultimate disposal in
an environmentally sound landfill. The bottom ash is assumed to
be wetted to 20 percent moisture and hauled in covered trucks.
The disposal cost components include truck loading, washing the
loaded trucks, truck transportation, road cleaning and repair,
truck unloading, washing the unloaded trucks, and landfill fees,
including treatment. The ash disposal operation is conducted by
an outside contracting firm rather than the company itself. The
waste disposal cost is estimated at $44/Mg ($40/ton). This is a
conservative estimate of the average cost for a typical industrial
boiler with a heat input of about 30 MW thermal (100 x 106 Btu/h).
Although the waste disposal cost can vary greatly depending upon
the haul distance and the method of disposal, this conservative
estimate reflects good environmental practice.
Another component of operating cost is overhead, which
represents a business expense that is not charged directly to a
particular part of the process but is allocated to it. Overhead
costs include administrative, safety, engineering, legal, and
medical services; payroll expenses including PICA; employee
benefits; and public relations. Overhead costs are usually
44
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TABLE 26. DIRECT ANNUAL OPERATION AND MAINTENANCE COST ITEMS
ASSOCIATED WITH BOILERS
Operational labor
Supervision
Maintenance labor
Replacement parts
Electricity
Process water
Fuel
Waste disposal
Chemicals
45
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TABLE 27. METHODS USED TO ESTIMATE DIRECT ANNUAL COSTS
Cost item
Operational labor
Supervision
Maintenance labor
Replacement parts
Electricity
Oil or gas-fired boilers
Stoker units
Pulverized-coal-fired units
Process water
Fuel
Haste disposal
Chemicals
Method of obtaining cost
Multiply manpower requirements from
parameter tables by rate given in
Table 25.
Multiply manpower requirements from
parameter tables by rate given in
Table 25.
Multiply manpower requirements from
parameter tables by rate given in
Table 25.
Aedes Associates, Inc. determined
percentages of total equipment cost
based on actual jobs (8 to 21%).
Based on major equipment and light-
ing loads.
59 to 1453 kW
162 to 1001 kW
1754 to 6920 kW
Multiply kW by operating hours to
obtain annual kWh. Multiply annual
kWh by electric rate given in Table
25.
Requirement calculated assuming 80
percent return of condensate (20%
make-up). Multiply annual usage by
water rate given in Table 25.
Fuel requirement calculated based
on design heat input multiplied by
hours per year operated based on
load factors given in Tables 2 to
19. Multiply annual fuel require-
ment by appropriate rate from Table
25.
Requirement calculated from total
ash in fuel minus the quantity
emitted as fly ash. Multiply the
annual quantity of wash by an
average cost of $40/ton for dis-
posal in an environmentally sound
landfill 20 miles from the plant
site.
Requirement calculated assuming
constant water quality and 80 per-
cent return of condensate (20%
Bake-up). Multiply amount of
chemicals used by average costs
obtained from chemical suppliers.
46
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presented as payroll overhead and plant overhead. Following are
the values used for each:
Payroll overhead = 30 percent of operating labor
Plant overhead = 26 percent of labor and materials.
The capital investment in a boiler is generally translated
into annual capital charges. These charges, along with the
annual operating costs, represent the total annualized cost of a
boiler.
EPA classifies annual capital-related charges for cost
purposes under the following components: general and administra-
tive costs, taxes, insurance; a capital-recovery factor, which
represents a levelized principal and interest payment; and
interest on working capital. The first three components are set
at a total of 4 percent of depreciable investment. The capital-
recovery factor was determined at 10 percent interest over the
life of a facility.
Capital recovery factors are based on the following boiler
life expectancies:
Expected life,
Boiler type years
Package Scotch fire-tube 20
Package water-tube 30
Field-erected water-tube 45
From these values for boiler life and the assumed interest rate
of 10 percent, the capital recovery factors calculated for each
boiler type are 'as follows:
47
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Capital recovery
Boiler type factor, %
Package Scotch fire-tube 11.75
Package water-tube 10.61
Field-erected water-tube 10.14
COST ESTIMATES
Costs are estimated for all 59 of the typical boilers iden-
tified in Section 2. The basic boiler costs were obtained as
verbal or written -quotations from various boiler manufacturers
including Babcock and Wilcox; Cleaver Brooks; Zurn Industries,
Inc.; Erie City; and Combustion Engineering. Capital cost esti-
mates for auxiliary equipment (e.g., water treatment systems) are
based on quotations obtained from manufacturers in related projects,
The estimated costs are summarized in Table 28 for the
package water-tube underfeed-stoker boilers firing the four
different coal types. Detailed cost breakdowns for each of these
boilers are presented in Appendix A.
The estimated costs are summarized for field-erected water-
tube spreader-stoker boilers firing the four coal types in Table
29. The detailed costs are presented in Appendix A.
Table 30 summarizes the estimated costs of field-erected
water-tube, pulverized-coal-fired boilers. Detailed cost break-
downs are presented in Appendix A.
The estimated costs for package fire-tube boilers are sum-
marized in Table 31 with the detailed costs presented in Appendix
B.
48
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TABLE 28. ESTIMATED CAPITAL AND ANNUALIZED COSTS OF PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILERS FIRING COAL
»
Size,
MM (10* BtU/h)
4.4 (15)
4.4 (IS)
4.4 (15)
4.4 (IS)
8.8 (30)
8.8 (30)
8.8 (30)
8.8 (30)
17.6 (60)
17.6 (60)
17.6 (60)
17.6 (60)
Coal
Eastern high-sulfur
Eastern low-sulfur
Subbituminous
Eastern medium-sulfur
Eastern high-sulfur
Eastern low-sulfur
Subbltuninous
Eastern medium- sulfur
Eastern high-sulfur
Eastern low-sulfur
Subbituminous
Eastern medium-sulfur
Capital costs
Grand total. $
1,245,000
1,094,600
1,487,300
1,133,200
1,891,300
1,665,200
2,257,100
1,723,000
3,021,800
2,670,700
3,594,100
2,758,100
Annual! zed costs
Direct cost
plus overhead
leas fuel, $
469.900
453,300
485,100
462,800
565,800
538,700
587,100
554,000
847,000
802,000
873,400
832.000
Fuel
Coats, $
58,300
91,500
33,100
74,900
116,700
182.900
66,200
149,800
233,400
365,800
132,500
299,600
Capital
charges, $
176,900
154,700
212,500
160,500
269,800
236,300
323,600
244,900
431,100
378,600
515,600
391,900
Total, $
705.100
699,500
730,700
698,200
952.300
957.900
976,900
448,700
1,511,500
1,546.400
1,521.500
1,523,500
Parameter
table No.
2
2
2
2
3
3
3
3
4
4
4
4
Cost
table
A-l. A-2
A-3, A-4
A-5, A-6
A-7, A-i
A-9. A-10
A-ll, A-12
A-l 3, A-14
A-15, A-16
A-17, A-l>
A-19, A- 20
A-21, A-22
A-23. A-24
vo
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TABLE 29. ESTIMATED CAPITAL AND ANNUALIZED COSTS OF FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILERS FIRING COAL
Slie,
MH (106 BtU/h)
22.0 (75)
22.0 (75)
22.0 (75)
22.0 (75)
44.0 (ISO)
44.0 (150)
44.0 (150)
44.0 (150)
58.6 (200)
58.6 (200)
58.6 (200)
58. t (200)
Coal
Eastern high-sulfur
Eastern low-sulfur
Subbltumlnous
eastern medium-sulfur
Eastern high-sulfur
Eastern low-sulfur
Subbitumlnous
Eastern medium-sulfur
Eastern high-sulfur
Eastern low-sulfur
Subbltuminous
Eastern medium-sulfur
Capital costs
Grand total, $
4.587,700
4.064.200
5,440,700
4,192.200
8.784,200
7,804,100
10,395,800
8.041,900
10,510,200
9,355,200
12,411,400
9.637,500
Annual lied coats
Direct cost
(jlus overhead
less fuel, $
898, BOO
858,500
935,600
878,800
1,265,700
1,187,300
1,334.300
1,229,000
1,641,000
1,541.900
1,731,700
1,596,200
Fuel
Costs. $
291,700
457,300
165,600
374,500
583,400
914,500
331,100
749,000
777,900
1,219,400
441,500
998,600
Capital'
charges, $
638,300
563,100
760,000
581,700
1,225,900
1,084.500
1.455,700
1,119,500
1,465,000
1,298,000
1,736,500
1,339,700
Total. $
1,828,800
1,178,900
1,861.200
1,835,000
3,075,000
3,186,300
3.121,100
3,097,500
3,883,900
4,059,300
3,909,700
3.934,500
Parameter
table No.
5
5
5
5
•
C
6
C
7
7
7
7
Cost
table
A-25, A-26
A- 27, A-28
A-29, A-30
A-31, A-32
A-33, A-34
A- 35, A- 36
A-37. A-38
A-39, A-40
A-41. A-42
A-43, A-44
A-45, A-46
A-47, A-4B
UI
o
-------
TABLE 30. ESTIMATED CAPITAL AND ANNUALIZED COSTS OF FIELD-ERECTED, WATER-TUBE,
PULVERIZED-COAL-FIRED BOILERS
Size,
MM (106 Btu/h)
58.6 (200)
SB. 6 (200)
58.6 (200)
58.6 (200)
117.2 (400)
117.2 (400)
117.2 (400)
117.2 (400)
205.1 (700)
205.1 (700)
205.1 (700)
205.1 (700)
Coal
Eastern high-sulfur
Eastern low-sulfur
Subbltumlnous
Eastern medium-sulfur
Eastern high-sulfur
Eastern low-sulfur
Subbituninous
Eastern medium-sulfur
Eastern high-sulfur
Eastern low-sulfur
Subbitumlnous
Eastern medium-sulfur
Capital costs
Grand total, S
12.202,400
10,823,200
14,468,400
11.161,500
22,638,000
20,094,000
26,836,600
20,707,300
36,490.200
32.369.200
43,060,300
33,302,400
Annual lied coat*
Direct cost
plus overhead
less fuel, $
1', 766,900
1.656.200
1,901,500
1,701,400
3,068,300
2,878,200
3.288,800
2,960,700
4,200,000
3,912.500
4,509,900
4,044,300
Fuel
Coats. $
777.900
1,219,400
441,500
998.600
1,555,800
2,438,800
883,000
1,997,000
2,722,600
4,267,900
1,545,300
3.495,200
Capital
charges, $
1.702,900
1,504,400
2,025,600
1,554,100
3,159,500
2,792,500
3,758,200
2.883,000
5,096,800
4,500,900
6,035,000
4,639,500
Total, $
4,247,700
4,380.000
4,368,600
4,254,100
7.783,600
8,109,500
7,930,000
7,840,700
12,019.400
12,681,300
12,090,200
12,179,000
Parameter
table No.
8
8
8
8
9
9
9
9
10
10
10
10
Cost
table
A-49. A-50
A-51, A-52
A-53, A- 54
A-S5, A-56
A-57, A-58
A-59, A-60
A-61. A-62
A-63. A-64
A-CS, A-66
A-67. A-68
A-69, A-70
A-71. A-72
-------
TABLE 31. ESTIMATED CAPITAL AND ANNUALIZED COSTS OF PACKAGE, FIRE-TUBE BOILERS
Site
MM (106 Btu/h)
1.5 (5)
4.4 (IS)
8.5 (29)
1.5 (5)
4.4 (15)
• .5 (29)
1.5 (5)
4.4 (15)
8. 5 (29)
Fuel
Residual oil
Residual oil
Residual oil
Distillate oil
Distillate oil
Distillate oil
Natural gas
Natural gas
Natural gas
Capital costs
grand total, $
243,700
404,200
602,500
241. BOO
404,800
610,900
236,600
389,300
580,900
Annua 11 zed costs
Direct cost
plus
overhead
leas fuel, $
201,300
322,400
347,800
201,300
322,400
347,800
201,300
322,400
347,800
Fuel
cost, $
43.600
130,700
252,600
59,100
177.400
343,000
38,400
115,300
222,900
Capital
charges, $
35,500
58,100
87,200
34,900
57,600
87,300
34,400
56,000
84,300
Total. $
280,400
511,200
687,600
295,300
557,400
778,100
274,100
493,700
655,000
Paraneter
table No.
11
11
11
12
12
12
13
13
13
Cost
table
B-l, 8-2
B-3, B-4
B-5, B-6
B-7, B-8
B-9, B-10
B-ll, B-12
B-13, B-ll
B-l 5, B-K
B-l 7. B-B
in
NJ
-------
Estimated costs of dual-fuel water-tube boilers firing
residual oil/natural gas are summarized in Table 32 with detailed
costs presented in Appendix C. Table 33 summarizes the estimated
costs of dual-fuel water-tube boilers firing distillate oil/natural
gas. Detailed costs are presented in Appendix C.
53
-------
TABLE 32. ESTIMATED CAPITAL AND ANNUALIZED COSTS OF DUAL-FUEL, WATER-TUBE
BOILERS FIRING RESIDUAL OIL/NATURAL GAS
Boiler type
Package
Package
Package
Package
Field-erected
Field-erected
Field-erected
Size, HH
(10* Btu/h)
8.8 (30)
17.6 (60)
29.3 (100)
44.0 (ISO)
58.6 (200)
117.2 (400)
205.1 (700)
Capital
cost*
Grand
total, $
(oil/gas)
802, 900/
793,500
1.230.500/
1,211,700
1.734,000/
1,702,700
2.276.600/
2,229,600
7.412.000/
7,349,300
13,225,9007
13,100,600
21,331,4007
21,112,200
Annual ii«d coat*
Direct coat
plus overhead
leaa fuel, $
(oil/gas)
359,400
420,200
520,800
625,900
868,100
1,393,700
1,898,300
Fuel
Coat a, f
(oil/gaa)
319,4007
281,900
638.9007
563,700
1,064,8007
939,500
1,597,2007
1,409,300
2,129.6007
1,879.000
4,259,1007
3,758,000
7,453,4007
6,576,600
Capital
chargea, $
(oil/gaa)
110,3007
109,300
168,5007
166,600
236,3007
233,200
308,6007
303,900
1,019,1007
1.012,900
1.815,3007
1,802.800
2.924,3007
2,902,400
Total, 9
(oil/gaa)
789,1007
750,600
1,227,6007
1,150,500
1,821,9007
1,693,500
2.531,7007
2,339,100
4,016,8007
3.760,000
7,468,1007
6,954,500
12,276,0007
11,377,300
Parameter
tablea
(oil/gaa)
14/16
14/16
14/16
14/16
17/1$
17/19
17/1>
Coat
tables
C-l, C-2
C-3, C-4
C-5, C-6
C-7, C-l
C-9, C-10
C-ll, C-12
C-13, C-14
in
•u
-------
TABLE 33. ESTIMATED CAPITAL AND ANNUALIZED COSTS OF DUAL-FUEL, WATER-TUBE
BOILERS FIRING DISTILLATE OIL/NATURAL GAS
Boiler type
Package
Package
Package
Package
Field-erected
Field-erected
Field-erected
Site, HH
(106 Btu/h)
8.8 (30)
17.6 (60)
29.3 (100)
44.0 (ISO)
58.6 (200)
117.2 (400)
205.1 (700)
Capital
coat a
Grand
total, $
(oil/gaa)
817, 200/
779,300
1,26 7, OOO/
1,191,100
1.806.500/
1,680,000
2,393,9007
2.204,200
7.483.5007
7,230,500
13.379.900/
12,874,000
21.609.400/
20,724,100
Annual lied coata
Direct coat
plua overhead
leae fuel, $
(oil/gaa)
359,400
420.200
520,800
625,900
868,100
1.393,700
1,898,300
Fuel
Coata, |
(oil/gaa)
433, 600/
281,900
867. 200/
563.700
1,443,4007
939,500
2.16B.100/
1,409.300
2,890,800/
1,879,000
5,781,600/
3,758,800
10, 117, BOO/
6,576,600
Capital
charges, $
(oil/gaa)
111, OOO/
107,200
171, 200/
163,600
242,6007
229.900
319,2007
300,200
1,021,3007
996.000
1.821.300/
1,770,700
2.935.900/
2,847,400
Total, *
(oil/gaa)
904. OOO/
748,500
1.458.600/
1,147,500
2,208,800/
1,690,200
3.113.200/
2,335,400
4,780,2007
3,743,100
8,996,6007
6,922,400
14, 952, OOO/
11,322,300
Parameter
tablea
(oil/gaa)
15/16
15/16
15/16
15/16
11/19
18/19
18/19
Coat
tablea
C-15, C-16
C-17, C-H
C-19, C-20
C-21, C-22
C-23, C-24
C-25. C-26
C-27, C-28
Ul
-------
REFERENCES FOR SECTION 3
Coffin, B.D. 1978. Costing Examples of Industrial Applications,
coal-fired Boiler Plants. H.K. Ferguson Co., Cleveland,
Ohio.
Richardson Engineering Services, Inc. 1978. Process Plant Con-
struction Estimating and Engineering Standards. Solana
Beach, California.
Devitt, T., P. Spaite, and L. Gibbs. 1979. The Population and
Characteristics of Industrial/Commercial Boilers. PEDCo
Environmental, Inc., Cincinnati, Ohio.
56
-------
4.0 EQUATIONS FOR BOILER COSTS
In order to obtain costs for use by OAQPS in the overall
economic evaluation of various regulatory options on new boiler
installations, it was necessary to develop relationships between
boiler capacity, fuel, and costs. In this task, equations were
developed to describe the costs of package fire-tube boilers
firing a variety of fuels, package water-tube boilers firing
a variety of fuels, and field-erected water-tube boilers also
firing a variety of fuels. The following sections present the
methodology used in deriving these equations and the results of
the analysis.
METHODOLOGY
The basic steps involved in deriving new boiler cost equa-
tions were:
0 Detailed cost estimates
0 Segmenting costs into appropriate categories
0 Plotting costs versus input capacity
0 Determination of cost equation form
0 Derivation of cost equation
Detailed Cost Estimates
Detailed cost estimates were made for the 51 boiler/fuel/
capacity combinations described previously. In addition, from
previous work, 8 detailed cost estimates were available.
57
-------
Segmenting Costs Into Appropriate Categories
In this study, equations were to be derived to describe five
major components of costs including equipment cost, direct installa-
tion costs, indirect installation costs, variable annual operating
and maintenance costs, and nonvariable annual operating costs.
The equipment cost, direct installation costs, and indirect
installation costs are presented as subtotals in each detailed
boiler cost breakdown. Table 34 lists all items included in each
subtotal. Note that-contingencies, land, and working capital
have been excluded from the cost equations. This allows the
reader to use site-specific values. For the coal-fired boilers,
some of the equipment and direct installation cost items also
vary dependent upon the type of coal being burned. Table 34 also
indicates the items which vary with coal types.
The direct cost and overhead components of annual cost were
classified as either variable (dependent upon the period of time
the boiler operated) or non-variable (independent of boiler
operational time). Table 35 shows the items classified as variable
or nonvariable. It should be noted that although fuel is shown
as a variable cost item, for purposes of this study this cost was
excluded from the cost equations because the fuel cost can be
calculated separately as a direct product of fuel price and fuel
usage. Capital charges have also been excluded.
Plotting Costs Versus Input Capacity
The next step was to plot the costs in each category against
boiler input capacity by major boiler type/fuel classification.
For example, equipment costs for the three residual oil-fired
fire-tube boilers were plotted against the appropriate heat input
58
-------
TABLE 34. FORMAT FOR PRESENTATION OF CAPITAL COSTS
OF INDUSTRIAL BOILERS
CAPITAL COSTS
DATE OF ESTIMATE June 30, 1978 (FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts) Variable
Stack
Instrumentation
Pulverizers or stokers
Feeders Variable
Crushers Variablg-
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system Variable
Ash disposal system Variable
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel) Variable
Stack
Instrumentation
Pulverizers Variable
Feeders Variable
Crushers Variable
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system Variable
Ash disposal system Variable
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
(continued)
59
-------
TABLE 34. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
Variable
Variable
Variable
Variable
Variable
Variable
N/A
N/A
N/A
N/A
N/A - Not applicable.
-------
TABLE 35. FORMAT FOR PRESENTATION OF ANNUALIZED COSTS
OF INDUSTRIAL BOILERS
Non— vari a hi g>
Non— variable
Mon — Va f "i a h 1 e»
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
( % of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
Nnn— x/ari a hi e*
Non-variable
Variable
Variable
Variable
Variable
Variable5
Variable
Variable
Variable
Non-variable
Non-variable
Non-variable
N/A
N/A
N/A
N/A
N/A
N/A
a Not included in the equations.
N.A. - Not applicable.
61
-------
capacities (i.e. 5, 15, and 29 x 106 Btu/h). This step was fol-
lowed for all major boiler-fuel types including plots for residual
oil-fired fire-tube, distillate oil-fired fire-tube, natural gas-
fired fire-tube, stoker coal-fired package water-tube, residual
oil/natural gas-fired package water-tube, distillate oil/natural
gas-fired package water-tube, stoker coal-fired field-erected
water-tube, pulverized coal-fired field-erected water-tube,
residual oil/natural gas-fired field-erected water-tube, and
distillate oil/natural gas-fired field-erected water-tube.
Determination of Cost Equation Form
Each plot is then examined to determine the approximate form
of the cost equation. If the plot is a straight line, the equation
is a simple binomial of the form y = ax + b where a and b are con-
stants. If the plot is curved, the points are replotted on log-
log scales and on semi-log scales. If the plot on log-log scales
is a straight line, the equation is of the form y = ax , where a
and b are constants. If the plot on semi-log scales is a straight
cx
line, the equation will be of the form y = ab , where a, b, and
c are constants.
Derivation of Cost Equation
Depending upon which equation exhibits the best fit, a re-
gression analysis is performed via a computer program which will
determine the values of the constants for each equation form.
Boiler Cost Equation Results
The cost equations for the package water-tube underfeed stok-
er boilers are presented in Table 36. Equations for field-erected
water-tube spreader stoker boilers are presented in Table 37. Table
62
-------
TABLE 36. COST EQUATIONS FOR PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILERS3,b,c,d,e,f,g
Equipment cost
y = 66,392x°*622 (11,800/z) + 2257x°*819
Direct installation cost
y = 53,219x°*65 (11,800/z) + 2882x'°'796
Indirect installation cost
y = 40,188x0'646 (11,800/z)0-926
Variable annual operating cost
y = [6012x°*689 (11,800/z)0'9 (A/10.6)0'3] (H/5256)
Nonvariable annual cost
y = [308,900 -I- 7176x] (11,800/z)°'166
a x = heat input rate (106 Btu/h)
y = actual cost ($)
c z = heating value of coal (Btu/lb)
A = ash content of coal (%)
£
H = equivalent hours operated per year at maximum capacity.
Costs are in June 1978 dollars.
^ Applicable to heat inputs ranging from 15 to 60 x 10 Btu/h.
Does not include fuel cost.
Excludes capital charges.
63
-------
TABLE 37. COST EQUATIONS FOR FIELD-ERECTED,
WATER-TUBE/ SPREADER-STOKER BOILERSa'b>c'd'e'*»9
Equipment cost (size <150 x 106 Btu/h)
y = 25,052x°*906 (11,800/z) + 4,626x°'868
Equipment cost (size > 150 x 106 Btu/h)
y = 25,052x°*906 (11,800/z) + 14,205x°'714
Direct installation cost (size <_ 150 x 106 Btu/h)
y = 45,468x°'757 (11,800/z) + 2,919x°*869
Direct installation cost (size > 150 x 10 Btu/h)
y = 45,468x°-757 (11,800/z) + 9464x°'647
Indirect installation cost
y = 21,154x°-867 (11,800/z)0'86
Variable annual operating cost*1
y= 3,566x°*743 (11,800/z) (A/10.6) °'3 (^^)
Nonvariable annual costx
y = 66,924x°*574 (11,800/z)°'188
a x = heat input rate (10 Btu/h)
y = actual cost ($)
z = heating value of coal (Btu/lb)
A = ash content of coal (%)
e H = -equivalent hours operated per year at maximum capacity.
Costs are in June 1978 dollars.
g Applicable to heat inputs ranging from 75 to 200 x 10 Btu/h,
Does not include fuel cost.
1 Excludes capital charges.
64
-------
38 presents cost equations for field-erected, water-tube, pulver-
ized-coal-fired boilers. The cost equations for package fire-tube
boilers are presented in Table 39. In Table 40 are presented cost
equations for dual-fuel water-tube boilers firing residual oil/
natural gas. The cost equations for dual-fuel water-tube boilers
firing distillate oil/natural gas are presented in Table 41.
The algorithms are varied in form from boiler to boiler and
from fuel to fuel. The equations are an approximation of the way
the actual costs of boilers vary with size, fuel, and type. The
equations are composites of the costs of many components that do
not vary in the same manner between sizes, boiler types, and fuels.
However, comparisons of costs derived from the equations to de-
tailed costs presented in the appendices, show that the equations
give costs at least within 8 percent of the detailed cost
estimates.
Plots of Various Detailed Cost Items Versus Heat Input Design Capacity
Plots of different detailed cost items versus heat input
have been included. The primary advantage of the plots is that
cost trends are more readily observed than by examination of the
algorithms or detailed cost estimates. They are also useful in
comparing costs of different boiler types.
Figures 1, 2, and 3 provide the equipment costs of boilers
with fans and ducts versus heat input. Plots of total turnkey
costs versus heat input are shown in Figures 4 through 8. Figures
9 through 11 show pperating and maintenance costs (direct cost
plus overhead less fuel cost) versus equivalent hours of opera-
tion per year at maximum capacity for selected boilers.
65
-------
TABLE 38. COST EQUATIONS FOR FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILERS*>b,C,d,e,f,g
Equipment cost
y = [904,426 + 14,564x] (11,800/z) + 92,079 + 3,107x
Direct installation cost
n R R f>
y = 24,019xu'°° • (11,800/z) + 17,395 + l,254x
Indirect installation cost
y = 22,782x°'877 (11,800/z)0'87
Variable annual operating cost
y « l,586x*'uuu (11,800/z)0'9 (A/10.6)0'13
Nonvariable annual cost1
y = 60,380x°'604 (lLJOOjO.26
z
a x = heat input rate (106 Btu/h)
y = actual cost ($)
c z = heating value of coal (Btu/lb)
A = ash content of coal (%)
o
H = equivalent hours operated per year at maximum capacity.
Costs are in June 1978 dollars.
^ Applicable to heat inputs ranging from 200 to 700 x 10 Btu/h,
Does not include fuel cost.
1 Excludes capital charges.
66
-------
TABLE 39. COST EQUATIONS FOR PACKAGE
FIRE-TUBE BOILERSa'b,c,d,e
Residual Oil-Fired
Equipment cost y = 17, 3 6 Ox0*557
Direct installation cost y = 4324x + 56,177
Indirect installation cost y = 2317x + 29,749
Variable annual operating cost
(heat input 5 15 x 106 Btu/h) y = [580x + 3900] (H/3942)
Variable annual operating cost
(heat input >15 x 106 Btu/h) y = [914x - 1114] (H/3942)
Nonvariable annual
(heat input <15 x 106 Btu/h) y = ll,530x + 136,850
Nonvariable annual
(heat input >15 x 106 Btu/h) y = 900x + 296,300
Natural Gas-Fired or Distillate Oil-Fired
Equipment cost y = 15,981x°*561
Direct installation cost y = 4261x + 56,041
Indirect installation cost y = 2256x + 28,649
Variable annual operating cost
(heat input <15 x 106 Btu/h) y = [580x + 3900] (H/3942)
Variable annual operating cost
(heat input >15 x 10^ Btu/h) y = [914x - 1114] (H/3942)
Nonvariable annual costg
(heat input <15 x 10$ Btu/h) y = ll,530x + 136,850
Nonvariable annual costg
(heat input >15 x 106 Btu/h) y = 900x + 296,300
x = heat input rate (10 Btu/h) .
y = actual cost ($} .
H = equivalent hours operated
per year at maximum capacity.
Costs in June 1978 dollars.
Applicable to heat inputs
ranging from 1 to 30 x 106 Btu/h.
Does not include fuel cost.
g Excludes capital charges.
67
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TABLE 40. COST EQUATIONS FOR WATER-TUBE, DUAL-FUEL
BOILERS FIRING RESIDUAL OIL/NATURAL QASa/b/c/d
Package Units'
Equipment cost
Direct installation cost
Indirect installation cost
Variable annual operating cost
Nonvariable annual cost9
y * 15,925x
y = 54f833x
0.775
0.364
0.613
y = 16,561x
y = [202x + 24,262] (H/4818)
y = 2048x + 266,078
Field-Erected Units
Equipment cost
Direct installation cost
Indirect installation cost
Variable annual operating cost
Nonvariable annual cost^
y = 86.02x + 714,824
y = 18,427x°-866
y = 16,306x°*835
y = [269x + 25,884] (H/4818)
y = 31,628x°'61
a x = heat input rate (106 Btu/h).
y = actual cost ($).
H
equivalent hours operated per year at maximum capacity.
Costs in June 1978 dollars.
e 6
Applicable to heat inputs ranging from 30 to 150 x 10 Btu/h.
Does not include fuel cost.
g Excludes capital charges.
Applicable to heat input ranging from 200 to 700 x 10 Btu/h.
68
-------
TABLE 41. COST EQUATIONS FOR WATER-TUBE, DUAL-FUEL
BOILERS FIRING DISTILLATE OIL/NATURAL GASa,b,c,d
Package Units
Equipment cost
Direct installation cost
Indirect installation cost
Variable annual operating cost
Nonvariable annual costg
y = 14,850x
y = 54,620x
0.786
0.361
0.618
y = 15,952x
y = [202x + 24,262] (H/4818)
y = 2048x + 266,078
Field-Erected Units
Equipment cost
Direct installation cost
Indirect installation cost
Variable annual operating cost
Nonvariable annual cost"
y = 8372x + 711,271
y = 18,262x°'865
y = 4812x + 431,779
y = [269x + 25,884] (H/4818)
y = 31,628x°-61
a x = heat input rate (106 Btu/h).
y = actual cost ($).
c H = equivalent hours operated per year at maximum capacity.
Costs in June 1978 dollars.
e Applicable to heat inputs ranging from 30 to 150 x 10 Btu/h.
Does not include fuel cost.
g Excludes capital charges.
h Applicable to heat input ranging from 200 to 700 x 10 Btu/h.
69
-------
I/I
o
•o
•o
c
S
CJ
5750
5500
5250
5000
4750
4500
4250
4000
3750
3500
3250
3000
2750
2500
2250
2000
1750
1500
1250
1000
750
500
250
0
FIELD-ERECTED,
PULVERIZED
FIELD-ERECTED,
SPREADER STOKERS
PACKAGE, UNDERFEED STOKERS
0 40 80 120 160 200 240 280 320 360 400 440 480 520 560 600 640 680 720
HEAT INPUT, 106 Btu/hr
Figure 1. Equipment costs of water-tube boilers (with fans and ducts)
firing eastern low-sulfur coal versus heat Input.
70
-------
55
50
45
40
S 35
30
25
20
15
10
5h
0
5 10 15 20 25 30
HEAT INPUT. 106 Btu/hr
Figure 2. Equipment costs of package, fire-tube boilers (with fans and
ducts) firing residual oil, distillate oil or natural gas versus heat input,
71
-------
200 300 400 500
HEAT INPUT, 106 Btu/hr
600
700
Figure 3. Equipment costs of dual-fuel, water-tube boilers
(with fans and ducts} firing residual oil/natural gas or
distillate oil/natural gas versus heat input.
72
-------
3600
3400
3200
3000
2800
£2600
o
^2400
o
to
o
2200
2000
1800
1600
1400
1200
1000
10 15 20 25 30 35 40 45 50
HEAT INPUT, 106 Btu/h
55 60 65
Figure 4. Total turnkey costs of coal-fired, package,
underfeed-stoker boilers firing eastern high-sulfur
coal or subbituminous coal versus heat input.
73
-------
L SUBBITUMINOUS
COAL
EASTERN HIGH-SULFUR COAL
SO 100 150 200 250 300 350 400 450 SOO 550 600 650 700
NEAT INPUT. 106 Btu/h
Figure 5. Total turnkey costs of coal-fired,
field-erected boilers firing eastern high sulfur
coal or subbiluminous coal versus heat input.
74
-------
500
475
450
425
400
375
350
325
„ 300
s.
-------
1.8
1.7
1.6
1.5
1.4
*o
•o
^1.2
-------
20.0
19.0
18.0
17.0
16.0
15.0
13.0
£12.0
o
11.0
10.0
9.0
8.0
7.0
6.0
150 200 250 300 350 400 450 500 550 600 650 700
HEAT INPUT, 106 Btu/h
Figure 8. Total turnkey costs of dual-fuel, field-erected
boilers firing residual oil/natural gas or distillate oil/natural
gas versus heat input.
77
-------
CO
VO
o
J_
0)
o.
tn
10
o
"O
to
o
o
UJ
o
•a:
CS
O.
o
45
40
35
30
25
20
15
10
PACKAGE UNDERFEED-STOKER BOILER,
EASTERN HIGH-SULFUR COAL-FIRED,
30 x 106 Btu/h
PACKAGE, FIRE-TUBE BOILER, c
RESIDUAL OIL-FIRED, 5 x 10b Btu/h
PACKAGE FIRE-TUBE BOILER,
RESIDUAL OIL-FIRED, 15 x 106 Btu/h
PACKAGE FIRE-TUBE BOILER, ,
RESIDUAL OIL-FIRED, 29 x 106 Btu/h _
>
\ PACKAGE, WATER-TUBE, DUAL-FUEL BOILERS,
RESIDUAL OIL/NATURAL GAS-FIRED,
30 x 106 Btu/h
PACKAGE, UNDERFEED-STOKER BOILER,
EASTERN HIGH-SULFUR COAL-FIRED,
15 x 106 Btu/h
876 1752 2628 3504 4380 5256 6132 7008 7884 8760
EQUIVALENT HOURS OPERATED PER YEAR AT MAXIMUM CAPACITY
Figure 9. Operating and maintenance costs (less fuel costs)
for various boilers versus equivalent hours operated per year
at maximum capacity.
78
-------
4->
CO
Ol
o
T3
CO
O
LU
O
•a:
UJ
•en
03
QC
UJ
a.
o
16
14
12
10
8
E 4
PACKAGE, UNDERFEED-STOKER BOILER-,
EASTERN.HIGH-SULFUR COAL-FIRED,
60 x 106 Btu/h
-—— PACKAGE, WATER-TUBE, DUAL-FUEL BOILER,
RESIDUAL,OIL/NATURAL GAS-FIRED,
150 x 106 Btu/h
FIELD-ERECTED, SPREADER-STOKER BOILER,
EASTERN HIGH-SULFUR COAL-FIRED,
75 x 106 Btu/h
FIELD-ERECTED, SPREADER-STOKER BOILER,
EASTERN HIGH-SULFUR COAL-FIRED,
150 x 106 Btu/h
876 1752 2628 3504 4380 5256 6132 7008 7884 8760
EQUIVALENT HOURS OPERATED PER YEAR AT MAXIMUM CAPACITY
Figure 10. Operating and maintenance costs (less fuel costs) for
various boilers versus equivalent hours operated per year at
maximum capacity.
79
-------
8
3
+>
OQ
VO
o
J_
-------
APPENDIX A
DETAILED CAPITAL AND ANNUALIZED COST
TABLES FOR COAL-FIRED BOILERS
-------
TABLE A-l. ESTIMATED CAPITAL COSTS OF A PACKAGE,WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN HIGH-SULFUR COAL
WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTS
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 204,800
2,700
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
Incl. w/coal hand1ing
N.A.
6,100
5,000
5,000
1,400
N.A.
90,100
65,500
N.A.
N.A.
$380,600
$ 69.000
1.500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
N.A.
N.A.
1.200
1,000
1,500
400
53,800
26,900
N.A.
N.A.
A-l
-------
TABLE A-l. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 23,400
Ductwork (not incl. w/boiler) N.A.
Piping 23,400
Insulation 17,6QU
Painting 4.100
Electrical 20.000
Buildings 93.600
Total installation cost .<: i^7 ,4nn
TOTAL DIRECT COSTS
(equipment + installation) S 718.000
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 71,800
Construction and field expense
(10% of direct costs) 71,800
Construction fees
(10% of direct costs) 71,800
Start-up (2% of direct costs) 14,400
Performance tests (minimum $2000) . 3,000
TOTAL INDIRECT COSTS $ 232,800
Contingencies
(20% of direct and indirect costs) $ 190,200
Total Turnkey Costs
(direct+indirect+contingencies) 1,141,000
Land 2,000
Working capital (25% of total direct
operating costs) 102.000
GRAND TOTAL
(turnkey+land+working capital) , SI.245.OOP
N.A. - Not applicable
a Quote from Zurn Industries, Inc., May 25, 1978.
A-2
-------
TABLE A-2. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN HIGH-SULFUR COAL
WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 131,600
Supervision 68,500
Maintenance labor 64.100
Maintenance materials
Replacement parts 46.800
Electricity 25.800
Steam N.A.
Cooling water N.A.
Process water 200
Fuel 58,300
Bottom ash disposal 10.500
Chemicals 2.000
Total direct cost $ 407.800
OVERHEAD
Payroll (30% of direct labor $ 39.500
Plant (26% of labor, parts & maint.) 80,900
Total overhead costs $ 120,400
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 45.600
Capital recovery factor
( 10.61% of total turnkey costs) 121.100
Interest on working capital
(10% of working capital) 10.200
Total capital charges $ 176.900
TOTAL ANNUALIZED COSTS S 705.1QQ
a Included with replacement parts.
N.A. - Not applicable.
A-3
-------
TABLE A-3. ESTIMATED CAPITAL COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN LOW-SULFUR COAL
WITH A THERMAL INPUT OF 4.4 MW
(15 x 10° Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 175,000
2,700
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
Incl. w/condensate
N.A.
6,100
5.000
5.000
1,400
N.A.
77,000
56.000
N.A.
N.A.
$ J28.200
$ 59.000
1.500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
N.A.
N.A.
1.200
1.000
1,500
400
46.000
23.000
N.A.
N.A.
A-4
-------
TABLE A-3. (continued)
INSTALLATION COSTS, DIRECT (cont. )
Foundations and supports — 20,000
Ductwork (not incl. w/boiler) - N.A.
Piping 2°'OQO
Insulation 15.000
Painting 3. 500
Electrical 20.000
Buildings 80.000
Total installation cost $ 2 Q 2 , 1 n n
TOTAL DIRECT COSTS
(equipment + installation) $ 620/300
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 62,000
Construction and field expense
(10% of direct costs) 62,000
Construction fees
(10% of direct costs) 62,000
Start-up (2% of direct costs) 1 2 F 4 0 0
Performance tests (minimum $2000) . 3^000
TOTAL INDIRECT COSTS $ 7.ni ,
Contingencies
(20% of direct and indirect costs) $ 164.300
Total Turnkey Costs
(direct+indirect+contingencies) 986.000
Land 2,000
Working capital (25% of total direct
operating costs) 106.600
GRAND TOTAL
( turnkey* land+working capital) Sl.Q94r6on
N.A. - Not applicable.
aQuote from Zurn Industries, Inc., May 25, 1978.
A-5
-------
TABLE A-4. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN LOW-SULFUR COAL
WITH A THERMAL INPUT OF 4.4 MW
(15 x 1()6 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 131.600
Supervision 68,500
Maintenance labor £&,1nn
Maintenance materials *
Replacement parts 40.000
Electricity 22.000
Steam N.A.
Cooling water N.A.
Process water 200
Fuel 91.500
Bottom ash disposal 6.300
Chemicals 2.000
Total direct cost $ 426.200
OVERHEAD
Payroll (30% of direct labor $ 39,500
Plant (26% of labor, parts & maint.) 79.100
Total overhead costs S 118.600
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 39.400
Capital recovery factor
(10.61 % of total turnkey costs) 104.600
Interest on working capital
(10% of working capital) 10.700
Total capital charges $ 154.700
TOTAL ANNUALIZED COSTS S 699.500
'__. _,.
a Included with replacement parts.
N.A. - Not applicable.
A-6
-------
TABLE A-5. ESTIMATED CAPITAL COSTS OP A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING SUBBITUMINOUS COAL
WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 252,000
2,700
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
Incl. w/condensate
N.A.
6,100
5,000
5,000
1,400
N.A.
110,900
80,600
N.A.
N.A.
$ 463,700
$ 85,000
1,500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
N.A.
N.A.
1,200
1,000
1,500
400
66,200
33,100
N.A.
N.A.
A-7
-------
TABLE A-5. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 28,800
Ductwork (not incl. w/boiler) N.A.
Piping 28,800
Insulation 21,600
Painting 5,000
Electrical 20,000
Buildings 115,200
Total installation cost S 409.300
TOTAL DIRECT COSTS
(equipment + installation) S 873.000
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) S 87.300
Construction and field expense
(10% of direct costs) 87.300
Construction fees
(10% of direct costs) 87.300
Start-up (2% of direct costs) 17,500
Performance tests (minimum $2000) . 3,000
TOTAL INDIRECT COSTS S 282.400
Contingencies
(20% of direct and indirect costs) S 231.100
Total Turnkey Costs
(direct+indirect+contingencies) 1.386.500
Land 2.000
Working capital (25% of total direct
operating costs) 98.8QQ
GRAND TOTAL
(turnkey+lahd+working capital) $1
N.A. - Not applicable
aQuote from Zurn Industries, Inc., May 25, 1978
A-8
-------
TABLE A-6. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING SUBBITUMINOUS COAL
WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 131,600
Supervision 68'5QO
Maintenance labor 64,100
Maintenance materials
Replacement parts 57,600
Electricity 31,600
Steam N.A.
Cooling water N.A.
Process water 200
Fuel 33,100
Bottom ash disposal 6,300
Chemicals 2,000
Total direct cost $ 395,000
OVERHEAD
Payroll (30% of direct labor $ 39,500
Plant (26% of labor, parts & maint.) 83,700
Total overhead costs $ 123.200
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 55,500
Capital recovery factor
(10.61 * of total turnkey costs) 147,100
Interest on working capital
(10% of working capital) 9,900
Total capital charges $ 212,500
TOTAL ANNUALIZED COSTS $ 730,700
a Included with replacement parts.
N.A. - Not applicable.
A-9
-------
TABLE A-7. ESTIMATED CAPITAL COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing .equipment
Fuel-oil system
N.A. - Not applicable.
182.700
2,700
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
Incl. w/condensate
N.A.
6,100
5,000
5.000
1,400
N.A.
80.400
58,500
N.A.
N.A.
S 341.800
61.600
1.500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
N.A.
N.A.
1.200
1.000
1,500
400
48,000
24,000
N.A.
N.A.
A-10
-------
TABLE A-7. (continued)
INSTALLATION COSTS, DIRECT (cont. )
Foundations and supports — 2Q,9QQ
Ductwork (not incl. w/boiler)
Piping 20,900
Insulation 15,700
Painting 3,700
Electrical 20,000
Buildings 83,500
Total installation cost $ 303.900
TOTAL DIRECT COSTS
(equipment + installation) $ 645.700
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 64.600
Construction and field expense
(10% of direct costs) 64.600
Construction fees
(10% of direct costs) 64.600
Start-up (2% of direct costs) 12,900
Performance tests (minimum $2000) „ 3 ,000
TOTAL INDIRECT COSTS $ 209,700
Contingencies
(20% of direct and indirect costs) $ 171.100
Total Turnkey Costs
( dir ect+indir ect+contingencies ) 1,026,500
Land 2,000
Working capital (25% of total direct
operating costs) 104.700
GRAND TOTAL
(turnkey+land+working capital) Si. 133 r 200
aQuote from Zurn Industries, Inc., May 25, 1978
N.A. - Not applicable.
A-ll
-------
TABLE A-8. ESTIMATED ANNUALIZED COSTS OF A PACKAGE,WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 131.600
Supervision 68.500
Maintenance labor 64.100
Maintenance materials a
Replacement parts 41.800
Electricity 22.900
Steam N.A.
Cooling water N.A.
Process water 200
Fuel 74.900
Bottom ash disposal 12.600
Chemicals 2.OOP
Total direct cost S 418.6QQ
OVERHEAD
Payroll (30% of direct labor $ 39.500
Plant (26% of labor, parts & maint.) 79.600
Total overhead costs S 119.1QQ
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 41.100
Capital recovery factor
(10.61 % of total turnkey costs) i08rQnn
Interest on working capital
(10% of working capital) 10.500
Total capital charges S 160.500
TOTAL ANNUALIZED COSTS S 6Q8f2nn
a Included with replacement parts.
N.A. - Not applicable.
A-12
-------
TABLE A-9. ESTIMATED CAPITAL COSTS OF A PACKAGE,
WATER-TUBE, UNDERFEED-STOKER BOILER FIRING EASTERN HIGH-SULFUR
COAL,. WITH A THERMAL INPUT OF 8.8 MW
(30 x 10° Btu/h? 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
in. 1178 (FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans and ducts)
Stack
In strumentation
Stokers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
$ 308.900
3.000
Incl. w/boiler _
Incl. w/boiler _
Incl. w/coal handling
Incl. w/coal handling
_ 5.200 _
_ N.A. _
13.400 _
_ 7.700 _
_ 8.000 _
_ 1.400 _
_ N.A. _
136.700 _
99.500 _
_ N.A. _
_ N.A. _
$ 583.800 _
$ 105.300
1.500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
2.500
N.A.
3.000
1.100
2.000
800
81.900
41.000
N.A.
N.A.
N.A. - Not applicable.
A-13
-------
TABLE \A-9. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 35,100
Ductwork (not incl. w/boiler) N.A.
Piping 41.000
Insulation 29,300
Painting 5 ,900
Electrical 30rOOO
Buildings 140.400
Total Installation Costs $ 520.800
TOTAL DIRECT COSTS
(Equipment + Installation) $ 1,104,600
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 110,500
Construction and field expense
(10% of direct costs) 110,500
Construction fees
(10% of direct costs) 110,500
Startup (2% of direct costs) 22,100
Performance tests (minimum $2000) 3,500
TOTAL INDIRECT COSTS $ 357,100
Contingencies
(20% of direct and indirect costs) $ 292,300
Total turnkey costs
(Direct + Indirect + Contingencies) 1,754,000
Land 2,000
Working capital (25% of total direct
operating costs) 135.300
GRAND TOTAL
(Turnkey,* Land + Working Capital) $ 1,891,300
a Quote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
A-14
-------
COAL WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $—
Supervision —
Maintenance labor —
Maintenance materials —
Replacement parts —
Electricity —
Steam 1N>^'
Cooling water N'A;..
Process water !___
Fuel 116.700
Bottom ash disposal 21.000
Chemicals 2.300
Total direct cost $ 541.300
OVERHEAD
Payroll (30% of direct labor) $ 47.400
Plant (26% of labor, parts t maint.) 93.800
Total overhead costs $ 141,200
/
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G I A, taxes & insurance
(4% of total turnkey costs) $ 70,200
Capital recovery factor
(LO.61* of total turnkey costs) 186.100
Interest on working capital
(10% of working capital) 13,500
Total capital charges $ 269.800
TOTAL ANNUALIZED COSTS $ 952.300
a Included with replacement parts.
N.A. - Not applicable.
A-15
-------
TABLE A-ll. ESTIMATED CAPITAL COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN LOW-SULFUR COAL
WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans and duct)
Stack
Instrumentation
Stokers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system '
N.A. - Not applicable.
$ 264.000
3.000
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
5.200
N.A.
13.400
7.700
8,000
1,400
N.A.
116.800
85.000
N.'A.
N.A.
504.500
90.000
1,500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
2,500
2L.A..
3,000
1.100
2,000
800
70.000
35.000
N.A.
N.A.
A-16
-------
TABLE A-11.(continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 30.000
Ductwock (not incl. w/boiler) N.A.
Piping 35.000.
Insulation 25.000
Painting 5.000
Electrical 30.000
Buildings 120.000
Total Installation Costs $ 450.900
TOTAL DIRECT COSTS
(Equipment + Installation) $ 955.400
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 95.500
Construction and field expense
(10% of direct costs) 95.500
Construction fees
(10% of direct costs) 95.500
Startup (2% of direct costs) 19,100
Performance tests (minimum $2000) 3,500
TOTAL INDIRECT COSTS $ 309.100
Contingencies
(20% of direct and indirect costs) $ 252.900
Total turnkey costs
(Direct + Indirect + Contingencies) 1.517.400
Land 2,000
Working capital (25% of total direct
operating costs) 145,800
GRAND TOTAL
(Turnkey + Land + Working Capital) $ 1,665,200
a Quote from Zurn Industries, Inc., May 25, 1978
N.A. - Not applicable.
A-17
-------
TABLE A-12. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN LOW-SULFUR
COAL WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor ? 157,9QO
Supervision ??f?£?—
Maintenance labor 64,100
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water N>A*
Process water
Fuel 182,900
Bottom ash disposal 12,600
Chemicals 2'300
Total direct cost $ 583f100
OVERHEAD
Payroll (30% of direct labor) $—47'400
Plant (26% of labor, parts & tnaint.) 91fl°°
Total overhead costs $ 138^500
N.A.
BY-PRODUCT CREDITS —
CAPITAL CHARGES
G & A, taxes l insurance § 60 7QO
(4% of total turnkey costs) '.
Capital recovery factor 161,000
(10.61* of total turnkey costs) [
Interest on working capital
(10% of working capital) 14f600
Total capital charges $ 236,300
TOTAL ANNUALIZED COSTS $ 957,900
a Included with replacement parts. -
N.A. - Not applicable.
A-18
-------
TABLE A^13. ESTIMATED CAPITAL COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING SUBBITUMINOUS COAL
WITH A THERMAL INPUT OF 8.8 MW
(30 x 10° Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans and ducts)
Stack
In strumentation
Stokers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
In strumentation
Stokers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
S 380,200
3,000
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
5,200
13.400
7,700
8_,000
1.400
N.A.
168.200
122.400
N.A.
N.A.
S 709.500
S 129,600
1,500
Incl. w/boiler
Inel. w/boiler
Incl. w/coal handling
Incl. w/coal handling
2.SOO
N.A.
.3^000
1.100
2.OOP
800
100^800
N.A.
N.A.
A-19
-------
TABLE A=13.(continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 43,200
Ductwork (not incl. w/boiler) N.A.
Piping SO/TOT
Insulation 36,000
Painting 7.200
Electrical 30.000
Buildings 172.800
Total Installation Costs $ 631,300
TOTAL DIRECT COSTS
(Equipment + Installation) $ 1.340.800
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 134.100
Construction and field expense
(10% of direct costs) 134,100
Construction fees
(10% of direct costs) 134,100
Startup (2% of direct costs) 26,800
Performance tests (minimum $2000) 3,500
TOTAL INDIRECT COSTS $ 432,600
Contingencies
(20% of direct and indirect costs) $ 354,700
Total turnkey costs
(Direct + Indirect + Contingencies) 2,128,100
Land 2,000
Working capital (25% of total direct
operating costs) 127.000
GRAND TOTAL
(Turnkey> Land + Working Capital) $ 2,257,100
Quote from Zurn Industries, Inc., May 25, 1978
N.A. - Not applicable.
A-20
-------
TABLE A-14. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING SUBBITUMINOUS
COAL WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 157,900
Supervision 68,500
Maintenance labor 64.100
hJaintenance materials
Replacement parts 86,400
Electricity 49,400
Steam ^ _ N.A.
Cooling water N.A.
Process water
Fuel b b , ^ u u
Bottom ash disposal 12,600
Chemicals 2,30lT"
Total direct cost $ 507,900
OVERHEAD
Payroll (30% of direct labor) $ 47,400
Plant (26% of labor, parts t maint.) 98,000
Total overhead costs $ 145,400
/
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 85,100
Capital recovery factor
(10.61* of total turnkey costs) 225,800
Interest on working capital
(10% of working capital) 12,700
Total capital charges $ 323,600
TOTAL ANNUALIZED COSTS ' 5 976,900
a Included with replacement parts.
N.A. - Not applicable.
A-21
-------
TABLE A-15. ESTIMATED CAPITAL COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
276.000
3,000
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
5,200
N.A.
13,400
7,700
8.000
1,400
N.A.
122,000
89,000
N.A.
N.A.
525.700
94.000
1.500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
2.500
N.A.
3.000
1.100
2,000
800
73,000
37,000
N.A.
N.A.
A-22
-------
TABLE A-15. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 31,000
Ductwork (not incl. w/boiler) N.A.
Piping 37,000
Insulation 26,000
Painting 5,000
Electrical 30,000
Buildings 125,000
Total installation cost $ 468.900
TOTAL DIRECT COSTS
(equipment + installation) $ 994r6QQ
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 99,500
Construction and field expense
(10% of direct costs) 99,500
Construction fees
(10% of direct costs) 99,500
Start-up (2% of direct costs) 19,900
Performance tests (minimum $2000) . 3,50lT
TOTAL INDIRECT COSTS $ 321,900
Contingencies
(20% of direct and indirect costs) $ 263,300
Total Turnkey Costs
(direct+indirect+contingencies) 1,579,800
Land 2,000
Working capital (25% of total direct
operating costs) 141,200
GRAND TOTAL
(turnkey+land+working capital) SI.723.OOP
N.A. - Not applicable.
A-23
-------
TABLE A-16. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
i
DIRECT COST
Direct labor S 157.900
Supervision 68,500
Maintenance labor 64,100
Maintenance materials
-------
TABLE A-17. ESTIMATED CAPITAL COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN HIGH-SULFUR COAL
WITH A THERMAL INPUT OF 17.6 MW
(60 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
579.200
9^500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
13,500
N.A.
18.000
8.000
12.500
1.400
N.A.
146.300
128.700
N.A.
N.A.
S 917.100
J.93.100
4.700
Incl. w/boiler
Inc 1. w/boi1er
Incl. w/coal handling
Tncl. w/coal handling
3fOOP
NjAi
4.800
1,100
2,100
1,500
146.300
58.500
N.A.
N.A.
A-25
-------
TABLE A-17- (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct*indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
.?nn
N.A.
52,700
41,000
7,500
60,000
198,900
845.400
$1.762.500
$ 176.300
176.300
176.300
35,300
6,000
$ 570.200
$ 466.500
2.799.200
2.000
220.600
$3,021.800
Quote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
A-26
-------
TABLE A-18. ESTIMATED ANNUALLZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN HIGH-SULFUR COAL
WITH A THERMAL INPUT OF 17.6 MW
(60 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 184,300
Supervision 136,900
Maintenance labor 128,200
Maintenance materials
Replacement parts 99,500
Electricity 53.200
Steam ' _ N-A.
Cooling water _ N.A.
Process water _ 900
Fuel 233,400
Bottom ash disposal 42,000
Chemicals 4,000
Total direct cost $ 882,400
OVERHEAD
Payroll (30% of direct labor $ 55,300
Plant (26% of labor, parts & maint.) 142,700
Total overhead costs $ 198,000
BY-PRODUCT CREDITS _ N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 112,000
Capital recovery factor
(10.61 % of total turnkey costs) 297.000
Interest on working capital
(10% of working capital) 22,100
Total capital charges $ 431,100
TOTAL ANNUALIZED COSTS S 1.511.500
a Included with replacement parts.
N.A. - Not applicable.
A-27
-------
TABLE A-19. ESTIMATED CAPITAL COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN LOW-SULFUR COAL
WITH A THERMAL INPUT OF 17.6 MW
(60 x 10° Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
495^000
9.500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
13,500
N.A.
18,000
8,000
12.500
1,400
N.A.
125,000
110,000
N.A.
N.A.
$ 792.900
165.000
4.700
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
3.000
N.A.
4.800
1.100
2,100
1.500
125.000
50,000
N.A.
N.A.
A-28
-------
TABLE A-19. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 60,000
Ductwork (not incl. w/boiler) N.A.
Piping 45,000
Insulation 35,000
Painting 6.400
Electrical. 60,000
Buildings 170,000
Total installation cost $ 733r6QO
TOTAL DIRECT COSTS
(equipment + installation) Slr526.500
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) S 152.700
Construction and field expense
(10% of direct costs) 152.700
Construction fees
(10% of direct costs) 152,700
Start-up (2% of direct costs) 30.500
Performance tests (minimum $2000) , 6.000
TOTAL INDIRECT COSTS $ 494.600
Contingencies
(20% of direct and indirect costs) S 404.200
Total Turnkey Costs
(direct+indirect+contingencies) 2r425.300
Land 2.000
Working capital (25% of total direct
operating costs) 243r4QO
GRAND TOTAL
(turnkey+land+working capital) S2.670.700
aQuote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
A-29
-------
TABLE A-20. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN LOW-SULFUR COAL
WITH A THERMAL INPUT OF 17.6 MW
(60 x 10b Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 184.300
Supervision 136,900
Maintenance labor 128,200
Maintenance materials i_
Replacement parts 85,000
Electricity 45,400
Steam N.A.
Cooling water N.A.
Process water 900
Fuel 365,800
Bottom ash disposal 23,100
Chemicals 4.000
Total direct cost $ 973.600
OVERHEAD
Payroll (30% of direct labor $ 55,300
Plant (26% of labor, parts & maint.) 138.900
Total overhead costs $ 194,200
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 97.000
Capital recovery factor
(10.61% of total turnkey costs) 257.3QQ
Interest on working capital
(10% of working capital) 24.300
Total capital charges $ 378.600
TOTAL ANNUALIZED COSTS Sl.54fi.dnn
a Included with replacement parts.
N.A. - Not applicable.
A-30
-------
TABLE A-21. ESTIMATED CAPITAL COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING SUBBITUMINOUS COAL
WITH A THERMAL INPUT OF 17.6 MW
(60 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 712,800
9,500
Incl. w/boiler
Incl. w/boiler ~"
Incl. w/coal handling
Incl. w/coal handling
13.500
N.A.
18.000
8.000
12r500
1.400
N.A.
180.000
158.400
N.A.
N.A.
SI.114.100
237.600
4r7QO
Incl. w/boiler
Tncl. w/boiler
Incl. w/coal handling
Tncl. w/cnal handling
3rQQQ
N.A.
4r8QQ
irinn
2.100
1.5QO
180.000
72.QQQ
N.A.
N.A.
A-31
-------
TABLE A-21. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 86,400
Ductwork (not incl. w/boiler) N.A.
Piping . 64,800
Insulation 50,400
Painting 9,200
Electrical 60,000
Buildings 244,800
Total installation cost $1r n 2 2 f 4 n 0
TOTAL DIRECT COSTS
(equipment + installation) S2.136.500
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) s 213,700
Construction and field expense
(10% of direct costs) 213,700
Construction fees
(10% of direct costs) 213.700
Start-up (2% of direct costs) 42,700
Performance tests (minimum $2000) . 6,000
TOTAL INDIRECT COSTS $ 689,800
Contingencies
(20% of direct and indirect costs) $ 565,300
Total Turnkey Costs
(direct+indirect+contingencies) 3,391,600
Land 2,000
Working capital (25% of total direct
operating costs) 200,500
GRAND TOTAL
(turnkey+land+working capital) - $3.594.100
aQuote from Zurn Industries, Inc., May 25, 1978
N.A. - Not applicable.
A-32
-------
TABLE A-22. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED- STOKER BOILER FIRING SUBBITUMINOUS COAL
WITH A THERMAL INPUT OF 17.6 MW
(60 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 194,300
Supervision 136.900
Maintenance labor I2ar20fl
Maintenance materials _ a
Replacement parts 122,400
Electricity 65,400
Steam _ N.A.
Cooling water _ N.A.
Process water _ 900
Fuel 132,500
Bottom ash disposal 27,300
Chemicals _ 4,000
Total direct cost S 801.90Q-
OVERHEAD
Payroll (30% of direct labor $ 55,300
Plant (26% of labor, parts & maint.) 148.700
Total overhead costs S 204.000
BY-PRODUCT CREDITS _ N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 115.700
Capital recovery factor
(10.61 % of total turnkey costs)
Interest on working capital
(10% of working capital) 20.100
Total capital charges S 515.600
TOTAL ANNUALIZED COSTS g 1.521.500
a Included with replacement parts.
N.A. - Not applicable.
A-33
-------
TABLE A-23. ESTIMATED CAPITAL COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 17.6 MW
(60 x 10° Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
516.8QQ
9.500
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
13.500
N.A.
18.000
8.000
12.500
1.400
N.A.
130.500
114.800
N.A.
N.A.
S 825.000
S 172r3QQ
4r700
Incl. w/boiler
Incl. w/boil
Incl. w/coal handling
Tncl. w/coal handling
3rOQO
N.A.
4r8QQ
lrlQQ
2.100
1.5QO
130.500
52.200
N.A.
A-34
-------
TABLE A-23. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
62.600
N.A.
47.000
36,500
6.700
60,000
177,500
762.500
$lf587,500
$ 158.800
iSB,son
iqa,ann
31.800
6.000
$ 514r2QQ
$ 42Qf300
2r522fQOO
2rQQO
234.100
$2.758.100
aQuote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
A-35
-------
TABLE A-24. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, WATER-TUBE,
UNDERFEED-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 17.6 MW
(60 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 184.300
Supervision 136,900
Maintenance labor 128,200
Maintenance materials a
Replacement parts 88,700
Electricity 47,500
Steam N.A.
Cooling water N.A.
Process water 900
Fuel 299,600
Bottom ash disposal 46,300
Chemicals &,nnn
Total direct cost $ 936.400
OVERHEAD
Payroll (30% of direct labor $ 55,300
Plant (26% of labor, parts & maint.) 139.900
Total overhead costs $ 195.200
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 100.900
Capital recovery factor
(10.61 % of total turnkey costs) 267.600
Interest on working capital
(10% of working capital) 23.400
Total capital charges $ 391.900
TOTAL ANNUALIZED COSTS , Slr523r5QQ
a Included with replacement parts.
N.A. - Not applicable.
A-36
-------
TABLE A-25. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED, WATER-TUBE
SPREADER-STOKER BOILER FIRING EASTERN HIGH-SULFUR
COAL WITH A THERMAL INPUT OF 22 MW
(75 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST*
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
'Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
760,500
80,000
50,000
175,500
Incl. w/coal handling
Incl. w/coal handling
15,900
N.A.
25,300
8,700
15,000
1,400
N.A.
165,400
136,000
N.A.
N.A.
S 1.433,700
491.400
20.000
15.000
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
3.500
N.A.
5.500
1.300
2.500
1.500
175.500
70.200
N.A.
N.A.
A-37
-------
TABLE A-25. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey*land+working capital)
93,600
N.A.
58,500
46,800
8,200
75,000
234,000
Slr3Q2.5QO
$2f 736 ,.200
$ 273.600
273.600
273r600
54,700
7.000
$ 882.500
$ 723.700
4.342.400
2.000
243,300
$4.587.700
aQuote from Zurn Industries, Inc., May 25, 1978
N.A. - Not applicable.
A-38
-------
TABLE A-26. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER .BOILER FIRING EASTERN HIGH-SULFUR COAL
WITH A THERMAL INPUT OF 22 MW
(75 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 210.600
Supervision 136.900
Maintenance labor 128.200
Maintenance materials a_
Replacement parts 117. OOP
Electricity 57.600
Steam • _ N.A.
Cooling water _ N.A.
Process water _ 1.10Q
Fuel 291.700
Bottom ash disposal 25.200
Chemicals 4.900
Total direct cost S 973.200
OVERHEAD
Payroll (30% of direct labor $ 63.200
Plant (26% of labor, parts & maint.) 154.100
Total overhead costs S 217.300
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ I73
Capital recovery factor
(10.14 % of total turnkey costs) 440.300
Interest on working capital
(10% of working capital) 24,300
Total capital charges $ 638,300
TOTAL ANNUALIZED COSTS $1.828.800
a Included with replacement parts.
N.A. - Not applicable.
A-39
-------
TABLE A-27. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN LOW-SULFUR COAL
WITH A THERMAL INPUT OF 22 MW
(75 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
650,000
80,000
50,000
150.000
Incl. w/coal handling
Incl. w/coal handling
15.900
N.A.
25,300
8.700
15.000
1,400
N.A.
141.400
116.200
N.A.
N.A.
$ 1.253.900
420.000
20.000
15.QQQ
Tncl. w/boiler
Tnnl. w/coal handling
Tncl. w/coal handling
3f500
N.A.
5r5QO
1.3QQ
2.500
1.500
150.OOP
60.000
N.A.
N.A.
A-40
-------
TABLE A-27. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
80,000
N.A.
50,000
7,000
TSTOOl)
200,000
S1.131r30Q
$2.385.200
S 238.500
238r500
23Rr5nn
47.700
7.000
S 770r2QQ
S 631,100
3f786f500
2,000
275f70Q
$4,064,200 ^
a Quote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
A-41
-------
TABLE A-28. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED, WATER-TUBE
SPREADER-STOKER BOILER FIRING EASTERN LOW-SULFUR COAL
COAL WITH A THERMAL INPUT OF 22 MW
(75 x 10° Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 210,600
Supervision 136,900
Maintenance labor 128,200
Maintenance materials
Replacement parts 100,000
Electricity 49,200
Steam N-A*
Cooling water N.A.
Process water 1,100
Fuel 457,300
Bottom ash disposal 14,700
Chemicals 4,900
Total direct cost $1,102,900
OVERHEAD
Payroll (30% of direct labor $ 63,200
Plant (26% of labor, parts & maint.) 149,700
Total overhead costs $ 212,900
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 151.500
Capital recovery factor
(10.14 % of total turnkey costs) 384.000
Interest on working capital
(10% of working capital) 27,600
Total capital charges $ 563.100
TOTAL ANNUALIZED COSTS . SI.878.900
-*
a Included with replacement parts.
N.A. - Not applicable.
A-42
-------
TABLE A-29. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING SUBBITUMINOUS COAL
WITH A THERMAL INPUT OF 22 MW
(75 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
.(FOR COSTS INDEXING)
EQUIPMENT COST0
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
936,000
80,000
50,000
216^000
incl. w/coal handling
Incl. w/coal handling
15.900
N.A.
25,300
8.700
15.QQQ
1.400
N.A.
203.600
167.300
N.A.
N.A.
S 1.719.200
6Qi.nnn
2Q.QQQ
Tnrl. w/boiler
TnrO . w/onal handing
Tnrl. w/coal handl ing
550Q
1.3QQ
2.500
1.50Q
216. QQQ
86.400
N.A.
N.A.
A-43
-------
TABLE A-29. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 115.200
Ductwork (not incl. w/boiler) N.A.
Piping 72.000
Insulation 57.600
Painting 10.100
Electrical 75.000
Buildings 288,000
Total installation cost S 1,570.600
TOTAL DIRECT COSTS
(equipment + installation) $ 3r289r80Q
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) S 329.000
Construction and field expense
(10% of direct costs) 329.000
Construction fees
(10% of direct costs) 329rQQO
Start-up (2% of direct costs) 65,800
Performance tests (minimum $2000) . 7,000
TOTAL INDIRECT COSTS $ 1.059,800
Contingencies
(20% of direct and indirect costs) $ 869.900
Total Turnkey Costs
(direct+indirect+contingencies) 5,219,500
Land 2,000
Working capital (25% of total direct
operating costs) 219.200
GRAND TOTAL
(turnkey+land+working capital) $ 5.440.700
aQuote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
A-44
-------
TABLE A-30. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED, WATER-TUBE
SPREADER-STOKER BOILER FIRING SUBBITUMINOUS COAL
WITH A THERMAL INPUT OF 22.0 MW
(75 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 210,600
Supervision —136,900
Maintenance labor 128,200
Maintenance materials
Replacement parts _ 144,000
Electricity 70,900
Steam
Cooling water _ N.A.
Process water
Fuel 165,600
Bottom ash disposal 14,700
Chemicals 4,900
Total direct cost $ 876.900
OVERHEAD
Payroll (30% of direct labor $ 63,200
Plant (26% of labor, parts & maint.) 161.100
Total overhead costs $ 224.300
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 208.800
Capital recovery factor
(10.14 % of total turnkey costs) 529.300
Interest on working capital
(10% of working capital) 21.900
Total capital charges $ 760.000
TOTAL ANNUALIZED COSTS SlrRfi1 r2nn
a Included with replacement parts.
N.A. - Not applicable.
A-45
-------
TABLE A-31. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED WATER TUBE,
SPREADER-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 22 MW
(75 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
678.600
80.000
50.000
156,600
Incl. w/coal handling
Incl. w/coal handling
15,900
N.A.
25,300
8,700
15.000
1,400
N.A.
147,600
121.300
N.A.
N.A.
SI.300.400
438.500
20.OOP
15.000
Incl. w/boiler
Inel. w/coal handling
Tncl. w/coal handling
3.500
N_JLi
5.500
1.300
2.500
1.500
156.600
62,600
N.A.
N.A.
A-46
-------
TABLE A-31. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 93t5QO .
Ductwork (not incl. w/boiler) N.A.—
Piping 52,200
Insulation 41,800
Painting 7,300
Electrical 75.000
Buildings 208.800
Total installation cost SI.175.600
TOTAL DIRECT COSTS
(equipment + installation) S2.476.OOP
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 247.600
Construction and field expense
(10% of direct costs) 247.600
Construction fees
(10% of direct costs) 247.600
Start-up (2% of direct costs) 49.500
Performance tests (minimum $2000) . 7,000
TOTAL INDIRECT COSTS $ 799.300
Contingencies
(20% of direct and indirect costs) S 655.100
Total Turnkey Costs
(direct+indirect+contingencies) 3.930.400
Land 2.000
Working capital (25% of total direct
operating costs) 259.800
GRAND TOTAL
(turnkey+land+working capital) 6/J.1Q2.20Q
aQuote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
A-47
-------
TABLE A-32. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 22 MW
(75 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 210.600
Supervision 136.900
Maintenance labor 128.200
Maintenance materials a_
Replacement parts 104.400
Electricity 51.400
Steam N.A.
Cooling water N.A.
Process water 1.100
Fuel 374.500
Bottom ash disposal 27.300
Chemicals 4.900
Total direct cost $1,n39f300
OVERHEAD
Payroll (30% of direct labor S 63.200
Plant (26% of labor, parts & maint.) 15Qr8QQ
Total overhead costs $ 214
BY-PRODUCT CREDITS N.R.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) s 157,200
Capital recovery factor
(10.14 % of total turnkey costs) 398.500
Interest on working capital
(10% of working capital) 26,000
Total capital charges $ 581.700
TOTAL ANNUALIZED COSTS Slr835.QQQ
a Included with replacement parts.
N.A. - Not applicable.
A-48
-------
TABLE A-33. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN HIGH-SULFUR COAL
WITH A THERMAL INPUT OF 44 MW
(150 x 106 Btu/h; 450 psig/600°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans and ducts)
Stack
In strumentation
Stokers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
.Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
S
1.753,800
SOOjOOO
113^,500
227^600
Incl. w/coal handling
Incl. w/coal handling
21.600
N.A.
44,500
9,200
18,000
1,500
N.A.
282,300
167,500
Incl. w/coal handling
N.A.
$ 2,939,500
$ 936,000 _
_ 50,000 _
25,000
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
4,000
N.A.
7,000
1,500
3,000
1,500
292,500 find, site prep.
117.000
Incl. w/coal handling
__ N.A.
A-49
-------
TABLE A-«33. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 175f500
Ductwork (not incl. w/boiler) N.A.
Piping 81,900
Insulation 87,800
Painting 11,700
Electrical 150,000
Buildings 409,500
Total Installation Costs $ 2,353,900
TOTAL DIRECT COSTS
(Equipment + Installation) $ 5.293,400
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 529,300
Construction and field expense
(10% of direct costs) 529,300
Construction fees
(10% of direct costs) 529,300
Startup (2% of direct costs) 105,900
Performance tests 10,000
TOTAL INDIRECT COSTS $ 1,703,800
Contingencies
(20% of direct and indirect costs) $ 1,399,400
Total turnkey costs
(Direct + Indirect + Contingencies) 8,396,600
Land 2,000
Working capital (25% of total direct
operating costs) 3g5f600
•^
GRAND TOTAL
(Turnkey + Land + Working Capital) $ 8.784.200
Quote -from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-50
-------
TABLE A-34. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED
WATER-TUBE, SPREADER-STOKER BOILER FIRING EASTERN HIGH-SULFUR
COAL WITH A THERMAL INPUT OF 44 MW
(150 x 106 Btu/h; 450 psig/600°F design)
DIRECT COST
• Direct labor $ 315.900
Supervision 136,900
Maintenance labor 128,200
Maintenance materials
Replacement parts 234,000
Electricity 85,200
Steam N.A.
Cooling water N.A.
Process water 2,300
Fuel 583,400
Bottom ash disposal 50,500
Chemicals 6,000
Total direct cost $1,542,400
OVERHEAD
Payroll (301 of direct labor) $ 94,800
Plant (26% of labor, parts t maint.) 211,900
Total overhead costs $ 306. 700
/
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes t insurance
(4% of total turnkey costs) $ 335,900
Capital recovery factor
(10.14* of total turnkey costs) 851,400
Interest on working capital
(10% of working capital) 38,600
Total capital charges si
TOTAL ANNUALIZED COSTS $3.075.000
a Included with replacement parts.
N.A. - Not applicable.
A-51
-------
TABLE A-35. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, SPREADER-STOKER BOILER FIRING EASTERN LOW-
SULFUR COAL WITH A THERMAL INPUT OF 44 MW
(150 x 106 Btu/h; 450 psia/600°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30. 1978
(FOR COSTS INDEXING)
EQUIPMENT COST a
Boiler (with fans and ducts)
Stack
Instrumentation
Stokers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Cher.ical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 1.499.000
300.000
113.500
194.500
Incl. w/coal handling
Incl. w/coal handling
21.600
N.A.
44.500
9.200
18.000 '
1.500
N.A.
241.300
143.200
Incl. w/coal handling
N.A.
$ 2.586.300
$ 800.000
50.000
25,000
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
4,000
N.A.
7,000
1,500
3,000
1,500
250,000 (incl. site prep.)
100.000
Incl. v/coal handling
N.A.
A-52
-------
TABLE A-35.. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 150 f 0.00
Ductfcorfc^ (not incl. w/boiler) N.A.
Piping 70.000
Insulation 75.000
Painting 10.000
Electrical 150.000
Buildings 350.000
Total Installation Costs $ 2.047.000
TOTAL DIRECT COSTS
(Equipment + Installation) $ 4,633,300
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 463,300
Construction and field expense
(10% of direct costs) 463,300
Construction fees
(10% of direct costs) 463,300
Startup (2% of direct costs) 92,700
Performance tests (minimum $2000) 10,000
TOTAL INDIRECT COSTS $ 1.492.600
Contingencies
(20% of direct and indirect costs) $ 1.225.200
Total turnkey costs
(Direct + Indirect + Contingencies) 7.351.100
Land _^ 2,000
Working capital (25% of total direct
operating costs) 451,000
GRAND TOTAL
(Turnkey + Land + Working Capital) $ 7.804.100
a Quote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-53
-------
TABLE A»36. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, SPREADER-STOKER BOILER FIRING EASTERN LOW-
SULFUR COAL WITH A THERMAL INPUT OF 44 MW
(150 x 106 Btu/h; 450 psig/600°F design)
DIRECT COST
, v $ 315,900
Direct labor nnn
Supervision 136,900
Maintenance labor .128,200
Maintenance materials
Replacement parts" "" 200,000
Electricity — 72.8QQ
Steam - N-±Aj
Cooling water - N.A.
Process water 2,300
Fuel 914,500
Bottom ash disposal 27,300
Chemicals - 6f°°°
Total direct cost $1,803,900
OVERHEAD
Payroll (30% of direct labor) $ — 94,800
Plant (26% of labor, parts t maint.) 203'100
Total overhead costs $ 297,900
/
BYPRODUCT CREDITS N'A*
CAPITAL CHARGES
G i A, taxes t insurance
(4% of total turnkey costs) ?
Capital recovery factor
(10.14* of total turnkey costs) 745.400
Interest on working capital
(10% of working capital) 45.100
Total capital charges $ 1.084.500
TOTAL ANNUALIZED COSTS $ 3,186,300
Included with replacement parts.
N.A. - Not applicable.
A-54
-------
TABLE A-37. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, SPREADER-STOKER BOILER FIRING SUBBITUMINOUS
COAL WITH A THERMAL INPUT OF 44 MW
(150 x 10^ Btu/h- 450 Psia/600cF design) ^^^
CAPITAL COSTS
DATE OF ESTIMATE
June 30^ 1978 (FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans and ducts)
Stack
In strumentation
Stokers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 2,158,600
300,000
113,500
280,100
Incl. w/coal handing
Incl. w/coal hanidling
21,600
N.A.
44,500
9,200
18,000
1,500
N.A.
347.500
206.200
Incl. w/coal handling
N.A.
$ 3.500.700
S 1.152.000
50,000
25,000
Incl. w/boiler
Jncl. w/coal handling
Incl. w/coal handling
4,000
N.A.
7,000
1,500
3,000
1,500
360,000 (incl. site prep.
144,000
Incl. w/coal handling
N.A.
A-55
-------
TABLE A-37. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 216,000
Ductwork (not incl. w/boiler) N.A.
Piping 100,800
Insulation 108.000
Painting 14.400
Electrical 150.000
Buildings 504,000
Total Installation Costs $ 2,841,200
TOTAL DIRECT COSTS
(Equipment + Installation) $ 6,341,900
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 634,200
Construction and field expense
(10% of direct costs) 634,200
Construction fees
(10% of direct costs) 634,200
Startup (2% of direct costs) 126,800
Performance tests (minimum $2000) 10,000
TOTAL INDIRECT COSTS $ 2,039,400
Contingencies
(20% of direct and indirect costs) $ 1,676,300
Total turnkey costs
(Direct + Indirect + Contingencies) 10,057,600
Land 2,000
Working capital (25% of total direct
operating costs) 336.200
GRAND TOTAL
(Turnkey + Land + Working Capital) $10,395,800
Quote from Babcock & Wilcox, Inc., August 17, 1978
N.A. - Not applicable.
A-56
-------
TABLE A-38. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, SPREADER-STOKER BOILER FIRING SUBBITUMINOUS
COAL WITH A THERMAL INPUT OF 44 MW
(150 x 106 Btu/h; 450 psig/600°F design)
DIRECT COST
Direct labor $ 315.90.0
Supervision
Maintenance labor
Maintenance materials
Replacement parts 288,000
Electricity 104,800
Steam N»A'
Cooling water
Process water _ 2,300
Fuel ' 331,100
Bottom ash disposal 31, 5JKT
Chemicals 6,OQO~
Total direct cost $1,344,700
OVERHEAD
Payroll (30% of direct labor) $ 94,800
Plant (26% of labor, parts t maint.) 225.900
Total overhead costs $ 320.700
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance § 4Q2 300
(4% of total turnkey costs) _ '
Capital recovery factor
(10.14* of total turnkey costs) 1,019,800
Interest on working capital
(10% of working capital) 33,600
Total capital charges $1,455,700
TOTAL ANNUALIZED COSTS $ 3,121,100
a Included with replacement parts.
N.A. - Not applicable.
A-57
-------
TABLE A-39. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 44.0 MW
(150 x 106 Btu/h; 450 psig/600°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST a
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 1.565.000
300,000
113,500
203,000
Incl. w/coal handling
Incl. w/coal handling
21,600
N.A.
44,500
9,200
18,000
1,500
N.A.
252,000
150,000
Incl. w/coal handling
N.A.
$ 2,678.300
$ 835.000
50.000
25,000
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
4.000
N.A.
7,000
1,500
3,000
1,500
261.000
104,000
Incl. w/coal handling
N.A.
A-58
-------
TABLE A-39. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 157,0
Ductwork (not incl. w/boiler) N.A.
Piping 73,000
insulation 78,000
Painting iu,uuu
Electrical 150,000
Buildings 365,000
Total installation cost $ 2.125.000
TOTAL DIRECT COSTS
(equipment + installation) S 4.803.300
INSTALLATION COSTS, INDIRECT
Engineering ^
(10% of direct costs) $ 480.300
Construction and field expense
(10% of direct costs) 4anr3QQ
Construction fees
(10% of direct costs) 4anr30Q
Start-up (2% of direct costs) 96.100
Performance tests (minimum $2000) . 1Q, QQQ
TOTAL INDIRECT COSTS S Tr547.QOO
Contingencies
(20% of direct and indirect costs) $ if27QrlQO
Total Turnkey Costs
(direct+indirect+contingencies) 7f62Qr400
Land 2.000
Working capital (25% of total direct
operating costs) 419,500
GRAND TOTAL
(turnkey+land+working capital) $ 8.041.900
aQuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-59
-------
TABLE A-40. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 44.0 MW
(150 x 106 Btu/h; 450 psig/600°F design)
DIRECT COST
Direct labor $ 315,900
Supervision 136f9QQ
Maintenance labor i?Rr20Q
Maintenance materials a_
Replacement parts 208.800
Electricity 76,100
Steam N.A.
Cooling water N.A.
Process water 2,300
Fuel 749,000
Bottom ash disposal 54,700
Chemicals 6.000
Total direct cost $1.677.900
OVERHEAD
Payroll (30% of direct labor $ 94.800
Plant (26% of labor, parts & maint.) 205.300
Total overhead costs $ 300.100
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 304.800
Capital recovery factor
(10.14 % of total turnkey costs) 772r7QQ
Interest on working capital
(10% of working capital) 42.000
Total capital charges $1.119.500
TOTAL ANNUALIZED COSTS $3rQ97r5QQ
a Included with replacement parts.
N.A. - Not applicable.
A-60
-------
TABLE A-41. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN HIGH-SULFUR COAL
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
S 2.049.OOP
375,000
123.700
258.000
117.000
Incl. w/coal handling
28.000
N.A.
58.000
18.000
20.000
1.500
18.000
316.000
205.000
Incl. w/coal handling
N.A.
$ 3.587.200
S 1.0B2rOQO
fi5rPOO
4QrOQQ
Tnel. w/boiler
Tr^cl. w/cnal handl ing
Tncl . w/c;oa3. handling
6fOOP
N.A.
8.500
2rPPP
3.500
1.500
322.000
146.000
Incl. w/coal handling
A-61
-------
TABLE A-41. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 199,OOP
Ductwork (not incl. w/boiler) N.A.
Piping 100.000
Insulation 100.000
Painting 12f QQQ
Electrical lfi5rQQQ
Buildings 468.OOP
Total installation cost 52.72P.5PP
TOTAL DIRECT COSTS
(equipment + installation) S6,3P7r7PP
INSTALLATION COSTS, INDIRECT
Engineering
(1P% of direct costs) $ 63P,8PP
Construction and field expense
(1P% of direct costs) 630.800
Construction fees
(1P% of direct costs) 63P.8PP
Start-up (2% of direct costs) 126,2PP
Performance tests (minimum $2PPP) . IP,PPP
TOTAL INDIRECT COSTS S2.028.600
Contingencies
(20% of direct and indirect costs) $1, 667,300
Total Turnkey Costs
(direct+indirect+contingencies) 10,003,600
Land 2,000
Working capital (25% of total direct
operating costs) 504,600
GRAND TOTAL
(turnkey*land+working capital) $10.510.200
aQuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-62
-------
TABLE A-42. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN HIGH-SULFUR COAL
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor $ 421,200
Supervision 136.900
Maintenance labor 192.200
Maintenance materials &.
Replacement parts 304.200
Electricity 110.200
Steam N.A.
Cooling water N.A.
Process water 3.000
Fuel 777,900
Bottom ash disposal 65.200
Chemicals 7.500
Total direct cost $ 2.018.300
OVERHEAD
Payroll (30% of direct labor $ 126.400
Plant (26% of labor, parts & maint.) 274.200
Total overhead costs S 400.600
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 400.100
Capital recovery factor
( 10.14% of total turnkey costs) i f m4rAnn
Interest on working capital
(10% of working capital) 50.500
Total capital charges $ 1,465,000
TOTAL ANNUALIZED COSTS $3.883.900
a Included with replacement parts.
N.A. - Not applicable.
A-63
-------
TABLE A-43. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN LOW-SULFUR COAL
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 1,751,200
375,000
123,700
220,800
100.QQQ
Incl. w/coal handling
28.000
N.A.
58.000
18,000
2QrQOQ
1.500
15.000
270.000
175.000
Incl. w/coal handling
N.A.
S 3.156.200
925.000
65rQQQ
40.000
Tnr;!. w/boiler
Tnc!l. w/coal handling
Tnr-1 . w/cnal handl ing
6rOQQ
N.A.
8.5QQ
2.OOP
3.500
1.500
275.000
125.000
Incl. w/coal handling
. N.A.
A-64
-------
TABLE A-43. (continued)
INSTALLATION COSTS, DIRECT (cont. )
Foundations and supports - 170rOOO
Ductwork (not incl. w/boiler) - N.A.
Piping 85,000
Insulation 85,000
Painting 10,000
Electrical 165.000
Buildings 400,000
Total installation cost $ 2r366.500
TOTAL DIRECT COSTS
(equipment + installation) $ 5r522.70Q
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) »
Construction and field expense
(10% of direct costs) 552,300
Construction fees
(10% of direct costs) 552,300
Start-up (2% of direct costs) 110,500
Performance tests (minimum $2000) . 10,000
TOTAL INDIRECT COSTS $ 1.777.400
Contingencies
(20% of direct and indirect costs) S 1.460.000
Total Turnkey Costs
(direct+indirect+contingencies) 8.760,100
Land _ 2.000
Working capital (25% of total direct
operating costs) 593rlQQ
GRAND TOTAL
(turnkey+land+working capital) $Q
aQuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-65
-------
TABLE A-44. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN LOW-SULFUR COAL
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor g 42lr20Q
Supervision 136.900
Maintenance labor 192.200
Maintenance materials §_
Replacement parts 260.000
Electricity 94.200
Steam _ N.A.
Cooling water _ N.A.
Process water _ 3.000
Fuel 1.219.400
Bottom ash disposal 37.800
Chemicals 7.500
Total direct cost S2. 372. 200
OVERHEAD
Payroll (30% of direct labor S 126.400
Plant (26% of labor, parts & maint.) 262.700
Total overhead costs S 389.100
BY-PRODUCT CREDITS _ N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $
Capital recovery factor
(10.14 % of total turnkey costs) 888.300
Interest on working capital
(10% of working capital) 59,300
Total capital charges $1.298.000
TOTAL ANNUALIZED COSTS $4.059.300
a Included with replacement parts.
N.A. - Not applicable.
A-66
-------
TABLE A-45. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING SUBBITUMINOUS COAL
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 2.522.000
375,000
123,700
318,000
144,000
Incl. w/coal handling
28,000
N.A.
58,000
18,000
20.000
1,500
22,000 •
389,000
252,000
Incl. w/coal handling
N.A.
$ 4.271.200
$ 1.332.000
65.000
40.000
Incl. w/boiler
Incl. w/coal handling
Incl. w/coal handling
6.000
N.A.
8.500
2.000
3.500
1.500
396,000
180.000
Incl. w/coal handling
N.A.
A-67
-------
TABLE A-45. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 245,000
Ductwork (not incl. w/boiler) N.A.
Piping 122,000
Insulation 122.000
Painting 14,000
Electrical 165,000"
Buildings 576,000"
Total installation cost $3,278,500
TOTAL DIRECT COSTS
(equipment + installation) $7,549,700
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 755,000
Construction and field expense
(10% of direct costs) 755,000
Construction fees
(10% of direct costs) 755,000
Start-up (2% of direct costs) 151,000
Performance tests (minimum $2000) . 10,000
TOTAL INDIRECT COSTS $2,426,000
Contingencies
(20% of direct and indirect costs) $1,995,100
Total Turnkey Costs
(direct+indirect+contingencies) 11,970,800
Land 2,000
Working capital (25% of total direct
operating costs) 438,600
GRAND TOTAL
(turnkey+land+working capital) $12.411.400
apuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-68
-------
TABLE A-46. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING SUBBITUMINOUS COAL
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor $ 421,200
Supervision 136,900
Maintenance labor 192,200
Maintenance materials
Replacement parts 374,400
Electricity 135,700
Steam N-A*
Cooling water N.A.
Process water 3,000
Fuel 441,500
Bottom ash disposal 42,000
Chemicals 7,500
Total direct cost $1,754,400
OVERHEAD
Payroll (30% of direct labor $ 126,400
Plant (26% of labor, parts & maint.) 292,400
Total overhead costs $ 418.800
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 478.800
Capital recovery factor
(10.14 % of total turnkey costs) 1.213.800
Interest on working capital
(10% of working capital) 43,900
Total capital charges $1.736.500
TOTAL ANNUALIZED COSTS $3.909.700
a Included with replacement parts.
N.A. - Not applicable.
A-69
-------
TABLE A-47. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Stoker
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
S 1.828.000
375,000
123.700
231,000
104.000
Incl. w/coal handling
28,000
N.A.
58,000
18,000
20.000
1,500
16,000
282,000
183.000
Incl. w/coal handling
N.A.
$ 3.268.200
966.000
65.000
40.000
Incl. w/boiler
w/coal handl ing
Incl. w/coal handling
_ 6.000
_ N.A.
_ 8.500
_ 2.000
_ 3.500
_ 1.500
287.000
131.000
Incl. w/coal handling
_ N.A.
A-70
-------
TABLE A-47. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 178,000
Ductwork (not incl. w/boiler) N'A1
Piping 89,000
Insulation 89,000
Painting 10/000
Electrical 165,000
Buildings 418,000
Total installation cost $ 2.459.500
TOTAL DIRECT COSTS
(equipment + installation) $ 5.727.700
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 572.800
Construction and field expense
(10% of direct costs) 572.800
Construction fees
(10% of direct costs) 572.800
Start-up (2% of direct costs) 114,600
Performance tests (minimum $2000) . 10,000
TOTAL INDIRECT COSTS $ 1.843,000
Contingencies
(20% of direct and indirect costs) S 1.514.100
Total Turnkey Costs
(direct+indirect+contingencies) 9.084,800
Land 2,000
Working capital (25% of total direct
operating costs) 550.700
GRAND TOTAL
(turnkey+land+working capital) $ 9,637,500
aQuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-71
-------
TABLE A-48. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED, WATER-TUBE,
SPREADER-STOKER BOILER FIRING EASTERN MEDIUM-SULFUR COAL
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor $ 421,200
Supervision 136,900
Maintenance labor 192,200
Maintenance materials
Replacement parts 271,400
Electricity 98,400
Steam N-A-
Cooling water _ N.A.
Process water 3,000
Fuel 998,600
Bottom ash disposal 73. 600
Chemicals 7.500
Total direct cost S2.2Q2.8QQ
OVERHEAD
Payroll (30% of direct labor S 126.400
Plant (26% of labor, parts & maint.) 265.600
Total overhead costs 5 392rQQQ
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $
Capital recovery factor
(10.14 % of total turnkey costs) 921.200
Interest on working capital
(10% of working capital) 55,100
Total capital charges $1,339,700
TOTAL ANNUALIZED COSTS - $3,934.500
a Included with replacement parts.
N.A. - Not applicable.
A-72
-------
TABLE A-49. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
HIGH-SULFUR COAL WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST a
Boiler (with fans and ducts)
Stack
In strumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
$ 2,492.100
365.000
228.000
613.100
128.700
Incl. w/coal handling
29.000
Incl. w/boiler
58.000
16.300
20.000
1.500
23.400
308.800
210.600
Incl. w/coal handling
N.A.
4 .494 . 5Qfl
$ 1.270.000
60.000
35,000
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
5,000
Incl. w/boiler
8,000
2,000
3,500
1,-SOO
321,800 (incl. site prep.)
140,400
Incl. w/coal handling
N.A.
N.A. - Not applicable.
A-73
-------
TABLE A-49. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Duct work (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total Installation Costs
TOTAL DIRECT COSTS
(Equipment + Installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Startup (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total turnkey costs
(Direct + Indirect + Contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(Turnkey + Land + Working Capital)
210.600
N.A.
93.600
93.600
11.700
160.000
444,600
S 7
ann
147.100
10,000
$ 2
QDD
1 1
grin
2,000
536.ann
$l2.202.4nn
a Quote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. /- Not applicable.
A-74
-------
TABLE A-50.• ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED COAL-FIRED BOILER FIRING EASTERN
HIGH-SULFUR COAL WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor $ 421.200
Supervision 136,900
Maintenance labor 192,200
Maintenance materials
Replacement parts 7^92,500
Electricity 278.300
Steam N.A.
Cooling water N.A.
Process water 3,000
Fuel 777,900
Bottom ash disposal 37.300
Chemicals 7.500
Total direct cost $2.147.300
OVERHEAD
Payroll (301 of direct labor) $ 126,400
Plant (26% of labor, parts t maint.) 271.100
Total overhead costs $ 397.500
/
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G 4 A, taxes t insurance
(4% of total turnkey costs) $ 466,500
Capital recovery factor
(10.14* of total turnkey costs) 1,182,700
Interest on working capital
(10% of working capital) 53,700
Total capital charges 51,702,900
TOTAL ANNUALIZED COSTS $4,247,700
a Included with replacement parts.
N.A. - Not applicable.
A-75
-------
TABLE A-51. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
LOW-SULFUR COAL WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June.30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans and ducts)
Stack
In strumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system ,
$ 2,130,000
365,000
228,000
524,500
110,000
Incl. w/coal handling
29,000
Incl. w/boiler
58,000
16,300
20,000
1,500
20,000
263.900
160,000
Incl. w/coal handling
N.A.
$ 3,946,200
$ l,t)85,000
60,000
35,000
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
5,000
Incl. w/boiler
8,000
2.000
3,500
1.500
275.000finel. site prep.)
120.000
Incl. W/eoal handling
N.A.
N.A. - Not applicable.
A-76
-------
TABLE A-51. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 180,000
Duct work (not incl. w/boiler) N.A.
Piping 80,000
Insulation 80,000
Painting 10.000
Electrical 160.000
Buildings 380.000
Total Installation Costs $ 2.485.000
TOTAL DIRECT COSTS
(Equipment + Installation) $ 6.431.200
INSTALLATION COSTS, INDIRECT
Engineering c
(10% of direct costs)
Construction and field expense
(10% of direct costs) 643,100
Construction fees
(10% of direct costs) 643.100
Startup (2% of direct costs) 128.600
Performance tests (minimum $2000) 10,000
TOTAL INDIRECT COSTS $ 2.067.900
Contingencies
(20% of direct and indirect costs) $ 1.699.800
Total turnkey costs
(Direct + Indirect + Contingencies) 10.198.900
Land 2,000
Working capital (25% of total direct
operating costs) 622,300
GRAND TOTAL
(Turnkey + Land + Working Capital) $10,823,200
a Quote from Babcock & Wilcox, Inc., August 17, 1978
N.A. - Not applicable.
A-77
-------
TABLE A-52.- ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE PULVERIZED-COAL-FIRED BOILER FIRING EASTERN LOW-SULFUR
COAL WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor $ 421,200
Supervision 136,900
Maintenance labor 192,200
Maintenance materials
Replacement parts 250,000
Electricity 237.900
Steam N.A.
Cooling water N.A.
Process water 3,000
Fuel 1,219,400
Bottom ash disposal 21,o61T
Chemicals 7,500"
Total direct cost $2,489,100
OVERHEAD
Payroll (30% of direct labor) $ 126,400
Plant (26% of labor, parts & maint.) 2finrtoo
Total overhead costs $ 386.500
t
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes t insurance
(4% of total turnkey costs) $ 408,000
Capital recovery factor
CL0.14« of total turnkey costs) 1,034,200
Interest on working capital
(10% of working capital) 62.200
Total capital charges $1.504.400
TOTAL ANNUALIZED COSTS 54,380,000
3 Included with replacement parts.
N.A. - Not applicable.
A-78
-------
TABLE A-53. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING SUBBITUMINOUS
COAL WITH A THERMAL INPUT OF 58.6 MW
(200 x 10° Btu/h; 750 psig/750° F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST a
Boiler (with fans and ducts)
Stack
In strumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
In strumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
$ 3,067.200
365,000
228,000
754.600
158.400
Incl. w/coal handling
29.000
Incl. w/boiler
58.000
16.300
20.000
1.500
28.800
380.000
259.200
Incl. w/coal handling
N.A.
$ 5.366.000
$ 1,56.0^-OOQ
60,000
35,000
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
5,000
Incl. w/boiler
8,000
2,000
3., 500
1,500
396.000
172,800
Incl. w/coal handling
N.A.
N.A. - Not applicable.
A-79
-------
TABLE A-53. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Duct work (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total Installation Costs
TOTAL DIRECT COSTS
(Equipment + Installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Startup (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total turnkey costs
(Direct + Indirect + Contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(Turnkey + Land +' Working Capital)
259,200
N.A.
115.200
.?nn
14 .4DD
160.000
547,200
3.455^000
S P
nnn
$ ga? inn
RR2.inn
176 .400
10,000
S 2,832,700
S 2.330.700
ann
2,000
482.000
$ 14,468,400
Quote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable
A-80
-------
TABLE A-54. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING SUBBITUMINOUS
COAL WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor S 421.200
Supervision 136,900
Maintenance labor 192,200
Maintenance materials
Replacement parts 360,000
Electricity 342.500
Steam N.A.
Cooling water N.A.
Process water . 3,000
Fuel 441,500
Bottom ash disposal 23,100
Chemicals 7,500
Total direct cost $1,927,900
OVERHEAD
Payroll (30% of direct labor) $ 126,400
Plant (26% of labor, parts & maint.) 288'700
Total overhead costs $ 415.100
/
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G l A, taxes t insurance
(4% of total turnkey costs) $ 559,400
Capital recovery factor
(10.14* of total turnkey costs) 1,418.000
Interest on working capital
(10% of working capital) 48,200
Total capital charges S7
TOTAL ANNUALIZED COSTS £4.368.600
3 Included with replacement parts.
N.A. - Not applicable.
A-81
-------
TABLE A-55. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
MEDIUM-SULFUR COAL WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/hr; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 2.224.000
365.OOP
228rOQQ
548,nnn
115.QQQ
incl. w/coal handling
29.000
incl. w/boiler
58.000
1 6r3QQ
2QfQQQ
1.500
21.000
276.OOQ
188.000
incl w/coal handling
N.A.
$ 4.089.800
$ 1.133rOOQ
60.000
35fOOP
lnc;l , VT/hni
incl. w/boiler
incl. w/coal handling
5fQOQ
incl. w/boiler
8fQQQ
2,000
3f5QQ
lr50Q
287fOOP
125fOOQ
incl. w/coal handling
A-82
-------
TABLE A-55. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 188,OOP
Ductwork (not incl. w/boiler) N.A.
Piping 84,000
Insulation 84,000
Painting 10.000
Electrical . 160,000
Buildings 397.000
Total installation cost $ 2,583,000
TOTAL DIRECT COSTS
(equipment + installation) $ 6r672r8QQ
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 667.300
Construction and field expense
(10% of direct costs) 667.3QQ
Construction fees
(10% of direct costs) 667.300
Start-up (2% of direct costs) 133,500
Performance tests (minimum $2000) . 10,000
TOTAL INDIRECT COSTS $ 2.145.400
Contingencies
(20% of direct and indirect costs) S lr763f6QQ
Total Turnkey Costs
(direct+indirect+contingencies) lQr581r8QQ
Land 2PQOQ
Working capital (25% of total direct
operating costs) 577,700
GRAND TOTAL
(turnkey*land+working capital) $11,161,500
aQuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-83
-------
TABLE A-56. ESTIMATED ANNUALZZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
MEDIUM-SULFUR COAL WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/hr; 750 psig/750°F design)
DIRECT COST
Direct labor S 421.200
Supervision 136.900
Maintenance labor 192.200
Maintenance materials _ a
Replacement parts 261.000
Electricity 248.300
Steam N.A.
Cooling water N.A.
Process water _ 3 .000
Fuel 998.600
Bottom ash disposal 42.000
Chemicals _ 7.500
Total direct cost $2.310.700
OVERHEAD
Payroll (30% of direct labor $ 126.400
Plant (26% of labor, parts & maint.) 262.900
Total overhead costs $ 389.300
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 423r3QQ
Capital recovery factor
(10.14 % of total turnkey costs) l f
Interest on working capital c7
(10% of working capital) ;>/,
Total capital charges $1,554,100
TOTAL ANNUALIZED COSTS $4.254.100
a Included with replacement parts.
N.A. - Not applicable.
A-84
-------
TABLE A-57- ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
HIGH-SULFUR COAL WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/hr; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE.
June 30. 1978 fFOB COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans fc ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
$ 4,002,300
650,000
378.600
982,800
209.300
Incl. v/coal handling
60,000
Incl. w/boiler
150,000
25,000
60,000
4, OP'S"
46.800
1,170,000
386,100
Incl. v/coal handling
N.A.
$ 8,124,900
$ 2,538,900
Incl, w/equipment
llQrQQQ
Tncl. w/boiler
Tncl. w/boiler
Inel. w/eoal handling
12.000 '
Incl. w/boiler
18:000
16.000 .
2.000
737.100
304,200
Incl. w/coal handling
N.A.
N.A. - Not applicable.
A-85
-------
TABLE A-57.(continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 386,000
Duct work (not incl. w/boiler) N.A.
Piping 146,000
Insulation 129,000
Painting .19.000
Electrical 340,000
Buildings 761,000
Total installation cost $ 5,529,200
TOTAL DIRECT COSTS
(equipment + installation) S13r654rinn
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $_L
Construction and field expense
(10% of direct costs) __L
Construction fees
(10% of direct costs) 1,365,400
Startup (2% of direct costs) 273f100
Performance tests (minimum $2000) *" ~"
TOTAL INDIRECT COSTS ' $ 4,384,300
Contingencies
(20% of direct and indirect costs) $ 3,607,700
Total Turnkey Costs
(direct+indirect+contingencies) 21,646,100
Land 4'00&
Working capital (25% of total direct
operating costs). 987,900
tSRAND TOTAL
- (turnkey+land+working capital) $ 22,638,000
Quote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-86
-------
TABLE A-58. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERI ZED-COAL-FIRED BOILER FIRING EASTERN
HIGH-SULFUR COAL WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/hr; 750 psig/750°F design)
DIRECT COST
Direct labor $ 737,100
Supervision 205.400
Maintenance labor 384,5^0"
Maintenance materials _ a
Replacement parts 409,500
Electricity 561.600
Steam N.A.
Cooling water N'A* —
Process water 6.100
Fuel 1 555 aoo
Bottom ash disposal 75 f. 50 6
Chemicals i
Total direct cost $_3.951f5QO
OVERHEAD
Payroll (30% of direct labor) $ 221,100
Plant (26% of labor, parts & jnaint.) 451,500
Total overhead costs $ 672,600
BYPRODUCT CREDITS N>A>
CAPITAL CHARGES
G & A, taxes £ insurance
(4% of total turnkey costs) $ 865,800
Capital recovery factor
(10.14^ of total turnkey costs) 2.194.900
Interest on working capital
(10% of working capital) 98,800
Total capital charges $ 3,159,500
TOTAL ANNUALIZED COSTS $ 7,733,600
£
Included in replacement parts.
N.A. - Not Applicable
A-87
-------
TABLE A-59. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
LOW-SULFUR COAL WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/hr; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE.
June 30, 1978 ryQR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans fc ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
$ 3.420.800
650,000
378.600
840,000
178,900
Incl. w/coal handling
60,000
Incl. w/boiler
150,000
25,000
60, POTT
4,000
40,OOlT
1,000, OOTT
330.000
Incl. w/coal handling
N.A.
$ 7,137,300
$ 2,170,000
Incl. w/equipment
110,000
Incl. w/boiler
JEncl. w/boiler
Incl. w/coal handling
12,000
Incl. w/boiler
18,OOlT
10,O
16,000
'
2,0'ffTr
630,000
inel. w/eoal handling
N.A.
N.A. - Not applicable.
A-88
-------
TABLE A-59. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 330,000
Duct work (not incl. w/boiler) N.A*—
Pipina 125,000
Insulation 110,000
Painting If/OQQ
Electrical 340,000
Buildings 650,000
Total installation cost $_A
TOTAL DIRECT COSTS
(equipment + installation) $11,936,300
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 1.193.600
Construction and field expense
(10% of direct costs) 1,193,600
Construction fees
(10% of direct costs) 1,193.6.0.0
Startup (2% of direct costs) 238.700
Performance tests (minimum 52000) 15.000
TOTAL INDIRECT COSTS ' $ 3,834,500
Contingencies
(20% of direct and indirect costs) $ 3.154,200
Total Turnkey Costs
(direct+indirect+contingencies) 18,925,000
Land 4'000
Working capital (25% of total direct
operating costs) 1,165
•GRAND TOTAL
. (turnkey+land+working capital) s2Qf094TOQO
a Quote from Babcock & Wilcox, Inc., Augustl? , 1978.
N.A. - Not applicable.
A-89
-------
TABLE A-60. ESTIMATED.ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
LOW-SULFUR COAL WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/hr; 750 psig/750°F design)
DIRECT COST
Direct labor $ 737,100
Supervision 205,400
Maintenance labor 384,500
Maintenance materials _ a _
Replacement parts 350.000
Electricity 480. OOP
Steam N.A.
Cooling water N.A.
Process water 6,100
v ^- , .
Bottom ash disposal 42 000
Chemicals ' ifi'
Total direct cost $ 4,659,900
OVERHEAD
Payroll (30% of direct labor) S 221. 1QQ
Plant (26% of labor, parts t maint.) 436.000
Total overhead costs $ 657.100
BYPRODUCT CREDITS N^A
CAPITAL CHARGES
G i A, taxes t insurance
(4% of total turnkey costs) $ 757,000
Capital recovery factor
(10.14^ of total turnkey costs) 1,919,000
Interest on working capital
(10% of working capital) 116,500
Total capital charges $2.792,500
TOTAL ANNUALI ZED COSTS $ 8,109,500
Included with replacement parts.
N.A. - Not Applicable
A-90
-------
TABLE A-61. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING
SUBBITUMINOUS COAL WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/hr; 750 psig/750°F design)
-CAPITAL COSTS
DATE OF ESTIMATE.
June 30, 1978 (FOP COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans i ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
4.926.OOP
650.000
378.600
1,209.600
257.600
Incl. w/coal handling
60.000
Incl. w/boiler
150.000
25.000
60,000
4,000
57,600
1,440,000
475,200
Incl. w/coal handling
N.A.
$ 9/693,600
$ 3,124,800
Incl. w/equipment
iio.o"bT
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
12,000
Incl. w/boiler
18,000
10,000
16,000
2,000
907,200
374,400
Incl. w/coal handling
N.A.
N.A. - Wot applicable.
A-91
-------
TABLE A-61.(continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 4.75,0.0.0
Duct work (not incl. w/boiler) N.A.
Piping . 180.000
Insulation 158,000
Painting 23,000
Electrical 340,000
Buildings 936,000
•
Total installation cost $ 6.686,400
TOTAL DIRECT COSTS
(equipment + installation) $16,380,000
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 1,638,000
Construction and field expense
(101 of direct costs) 1,638,000
Construction fees
(10% of direct costs) l,638fOOO
Startup (2% of direct costs) 327,6Qfl
Performance tests (minimum $2000) I5ronn
TOTAL INDIRECT COSTS $ 5y256f600
Contingencies ,.. _ ,
(20% of direct and indirect costs) » 4,3Z/,300
Total Turnkey Costs
(direct+indirect+contingencies) 25,Qfi3,Qnn
Land 4 rQQQ
Working capital (25% of total direct
operating costs) 868f700
•GRAND TOTAL
(turnkey-Hand+working capital) $26,836,600
Quote from Babcock & Wilcox, Inc., August 17, 1978.
NYA. - Not applicable-.
A-92
-------
TABLE A-62. ESTIMATED ANNUALIZED COSTS FOR A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING
SUBBITUMINOUS COAL WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/hry 750 psig/750°F design)
DIRECT COST
Direct labor $ 737.100
Supervision 205.400
Maintenance labor 384.500
Maintenance materials a
Replacement parts 504 fOOP
Electricity fioix?nn
Steam TJ.A.
Cooling water TJ.&.
Process water 6.100
Fuel 883.000
Bottom ash disposal 47.300
Chemicals J.6f OOP
Total direct cost S 3.474.600
OVERHEAD
Payroll (30% of direct labor) $ 221.100
Plant (26% of labor, parts & maint.) 476,100
Total overhead costs s 697.200
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G t A, taxes t insurance
(4% of total turnkey costs) $ 1.038.600
Capital recovery factor
(10.14* of total turnkey costs) 2,632,700
Interest on working capital
(10% of working capital) 86.900
Total capital charges $ 3^758.200
TOTAL ANNUALIZED COSTS $ 7.930,000
alncluded in replacement parts.
N.A. - Not Applicable
A-93
-------
TABLE A-63. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
MEDIUM-SULFUR COAL WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/hr; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE.
June 30. 1978 frnp COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans fc ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel) .
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
$ 3,571,300
fisn nnn
378.600
877,000
186,800
Incl. w/coal handling
60.000
. v/boiler
150,000
25,000
60,000"
4,00"0~
41,80"0"
1,044,000
344,500
Incl. w/coal handling
N.A
$7,393,000
$2,265.500
Incl. w/eouipment
110,000
Incl. w/boiler
Incl. w/boiler
Incl. w/coal handling
12,000
Incl. w/boiler
18,000
10,000
16,000
2,0015
657,700
271,400
Incj.. w/coal handling
"
N.A. - Not applicable.
A-9 4
-------
TABLE A-63.(continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 344r500
Duct work (not incl. w/boiler) N!A*
Pipina "0,500
Insulation
Paintina
Electrical 340,000
Buildings 678,600
Total installation cost $ 4,987,700
TOTAL DIRECT COSTS
(equipment + installation) $ 12,380,700
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 1,238,100
Construction and field expense
(101 of direct costs) 1,238,100
Construction fees
(10% of direct costs) ^»2^8,101p
Startup (2% of direct costs) Z4/,6UU
Performance tests (minimum $2000) 15,000
TOTAL INDIRECT COSTS ' $ 3,976,900
Contingencies
(20% of direct and indirect costs) $ 3,271,500
Total Turnkey Costs
(direct+indirect+contingencies) 19,629,100
Land . 4,000
Working capital (25% of total direct
operating costs) 1.074.200
<3RAND TOTAL
(turnkey+land+working capital) $ 20,707,300
a Quote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-95
-------
TABLE \A-64. ESTIMATED ANNUALIZED COSTS OF-A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
MEDIUM-SULFUR COAL WITH A THERMAL INPUT OF 117.2 MW
(400 x 10^ Btu/hr; 750 psig/750°F design)
DIRECT COST
Direct labor $ 737,100
Supervision 205,400
Maintenance labor 384,500
Maintenance materials
Replacement parts 365,400
Electricity 501,100
Steam N.A.
Cooling water N.A.
Process water 6,100
Fuel 1.997.000
Bottom ash disposal 84,000
Chemicals 16,000"
Total direct cost S4.296.600
OVERHEAD
Payroll (30% of direct labor) $ 221,100
Plant (26% of labor, parts t maint.) 440,000
Total overhead costs $ 661,100
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 785,200
Capital recovery factor
(10.14* of total turnkey costs) ifQQQf4QQ
Interest on working capital ....
(10% of working capital) ' 107,400
Total capital charges $ 2,883,000
TOTAL ANNUALIZED COSTS $ 7,840,700
a Included with replacement parts.
N.A. - Not applicable.
A-96
-------
TABLE A-65. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
HIGH-SULFUR COAL WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/hr; 900 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 6,487,000
1,250,000
610r800
1,625,000
334,000
incl. w/coal handling
85,000
incl. w/boiler
195,000
35,000
90,000
4,000
60,000
1,747,000
819,000
incl. w/coal handling
N.A.
$13,341,800
$ 3,604,000
incl. w/equipment
160,000
incl. w/boiler
incl. w/boiler
incl. w/coal handling
19,000
incl. w/boiler
25,000
16,000
28,000
2,000
1.092,000
546,000
incl. w/coal hand1ing
N.A.
A-97
-------
TABLE A-65. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 710,000
Ductwork (not incl. w/boiler) N.A.
Piping 262,000
Insulation 208,000
Painting 32,000
Electrical 650,000
Buildings 1.365.000
Total installation cost $ 8r719fQQQ
TOTAL DIRECT COSTS
(equipment + installation) $22,060,800
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 2.206.100
Construction and field expense
(10% of direct costs) 2f306.100
Construction fees
(10% of direct costs) 2f20fifinn
Start-up (2% of direct costs) 441.200
Performance tests (minimum $2000) . 25.000
TOTAL INDIRECT COSTS S 7rQ84r5nn
Contingencies
(20% of direct and indirect costs) $ 5,829,100
Total Turnkey Costs
(direct+indirect+contingencies) 34,974,400
Land 2,000
Working capital (25% of total direct
operating costs) 1,513,800
GRAND TOTAL
(turnkey+land+working capital) $36,490,200
Quote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-98
-------
TABLE A-66. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-CO^L-FIRED BOILER FIRING EASTERN
HIGH-SULFUR COAL WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/hr; 900 psig/750°F design)
DIRECT COST
Direct labor $ 1,000,300
Supervision 205,400
Maintenance labor 512,600
Maintenance materials a
Replacement parts 463,300
Electricity 983,000
Steam N.A.
Cooling water N.A.
Process water ' 10,600
Fuel 2,722,600
Bottom ash disposal 132,500
Chemicals 25.000
Total direct cost $ 6,055.300
OVERHEAD
Payroll (30% of direct labor $ 300,100
Plant (26% of labor, parts & maint.) 567.200
Total overhead costs S 867.300
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 1.399.000
Capital recovery factor
(10.14 % of total turnkey costs) 3.546.4QQ
Interest on working capital
(10% of working capital) 151.400
Total capital charges $ 5.096.800
TOTAL ANNUALIZED COSTS S12r019.4QQ
a Included with replacement parts.
N.A. - Not applicable.
A-99
-------
TABLE A-67. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
LOW-SULFUR COAL WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/hr; 900 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
S 5,524,000
1,250,000
sio,ann
1,, "334,000
284,000
incl. w/coal handling
85,000
incl. w/boiler
195,000
35,000
90.000
4.000
51.000
1,488,000
698.000
incl. w/coal handling
N.A.
$11.698.800
$ 3.069.000
incl. w/equipment
16QrOOO
incl. w/boiler
incl. w/boiler
incl. w/coal handling
19.000
incl. w/boiler
25.000
16.000
28,000
2.000
930.000
465.000
incl. w/coal handling
N.A.
A-100
-------
TABLE A-67. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 605.000
Ductwork (not incl. w/boiler) N.A.
Piping 223,000
Insulation 177.000
Painting 27,000
Electrical 650,000
Buildings 1,163,000
Total installation cost $ 7,559,000
TOTAL DIRECT COSTS
(equipment + installation) $19,257,800
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 1.925.800
Construction and field expense
(10% of direct costs) lr925.80Q
Construction fees
(10% of direct costs) 1,925,800
Start-up (2% of direct costs) 385.200
Performance tests (minimum $2000) . 25.000
TOTAL INDIRECT COSTS S 6r187.6QO
Contingencies
(20% of direct and indirect costs) $ 5,089,100
Total Turnkey Costs
(direct+indirect+contingencies) 30,534,500
Land 2,000
Working capital (25% of total direct
operating costs) 1,832,700
GRAND TOTAL
(turnkey+land+working capital) $32,369,200
aQuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-101
-------
TABLE A-68. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
LOW-SULFUR COAL WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/hr; 900 psig/750°F design)
DIRECT COST
Direct labor $ 1.000,300
Supervision 205,400
Maintenance labor 512,600
Maintenance materials a
Replacement parts 395,300
Electricity 840,100
Steam N.A.
Cooling water N.A.
Process water 10,600
Fuel 4,267,900
Bottom ash disposal 73.600
Chemicals 25,000
Total direct cost $ 7.330.800
OVERHEAD
Payroll (30% of direct labor $ 300.100
Plant (26% of labor, parts & maint.) 549.500
Total overhead costs S 849.600
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 1.221.400
Capital recovery factor
(10.14 % of total turnkey costs) 3rQ96.200
Interest on working capital
(10% of working capital) 183.300
Total capital charges $ 4.500.900
TOTAL ANNUALIZED COSTS S12,681
a Included with replacement parts.
N.A. - Not applicable.
A-102
-------
TABLE A-69. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING SUBBITUMINOUS
COAL WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/hr; 900 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST*
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 7.960rOOO
1. 250. OOP
61Q 800
409.000
incl. w/coal handling
85,000
incl . w/boiler
195,000
35,000
90,000
4,000
74,000
2,144,000
1,005,000
incl. .w/eoal handling
N.A. _
$15,855,800
$ 4.422.000
inc 1. w/ ecru ipmen t
160.000
incl. w/boiler
incl. w/boiler
incl. w/coal hand1ing
19.000
incl. w/boiler
25.000
16.000
28,000
2.000
1,340,000
670.000
incl. w/coal handling
N.A.
A-103
-------
TABLE A-69. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 871,000
Ductwork (not incl. w/boiler) N.A.
Piping 322,000
Insulation 255,000
Painting 39,000
Electrical 650,000
Buildings 1,675,000
Total installation cost $10,494,000
TOTAL DIRECT COSTS
(equipment + installation) $26,349,800
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 2,635,000
Construction and field expense
(10% of direct costs) 2,635,000
Construction fees
(10% of direct costs) 2,635,000
Start-up (2% of direct costs) 527,000
Performance tests (minimum $2000) . 25,000
TOTAL INDIRECT COSTS $ 8.457,000
Contingencies
(20% of direct and indirect costs) $ 6.961.400
Total Turnkey Costs
(direct+indirect+contingencies) 41,768,200
Land 2,000
Working capital (25% of total direct
operating costs) 1.290.100
GRAND TOTAL
(turnkey+land+workin,g capital) $43 .060r300
Quote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-104
-------
TABLE A-70. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING SUBBITUMINOUS
COAL WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/hr; 900 psig/750°F design)
DIRECT COST
Direct labor $ 1,000,300
Supervision 205,400
Maintenance labor 512,600
Maintenance materials a
Replacement parts 569,500
Electricity 1,209,600
Steam N.A.
Cooling water N.A.
Process water 10/600
Fuel 1.545,300
Bottom ash disposal 82,000
Chemicals 25.000
Total direct cost $ 5,160.300
OVERHEAD
Payroll (30% of direct labor $ 300.100
Plant (26% of labor, parts & maint.) 594.800
Total overhead costs $ 894.900
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 1,670,700
Capital recovery factor
(10,14 % of total turnkey costs) 4.235.300
Interest on working capital
(10% of working capital) 129.000
Total capital charges $ 6.035.000
TOTAL ANNUALIZED COSTS $12.Q9Qr2QQ
a Included with replacement parts.
N.A. - Not applicable.
A-105
-------
TABLE A-71. ESTIMATED CAPITAL COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
MEDIUM-SULFUR COAL WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/hr; 900 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30. 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 5,762,000
1.250,000
610.800
1,443,000
296.000
incl. w/coal handling
85.000
incl. w/boiler
195.000
35P000
90rQQQ
4fOOO
53.000
1,552,OOP
728.000
incl. w/coal hand1i ng
N.A.
S12.1Q3.800
S 3.201.000
incl. w/equipment
160.000
inr;l. w/bolle>r
incl. w/boiler
incl. w/coal handling
19fOOQ
incl. w/boiler
25fQQQ
16rQQO
28rOQO
2 .000
970.QQQ
485.QQQ
inr;l. w/coal h^ndl i ng
A-106
-------
TABLE A-71. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 631,000
Ductwork (not incl. w/boiler) N.A.
Piping 233,000
Insulation 1*4,000
Painting 28,000
Electrical 650,000
Buildings 1,213,000
Total installation cost $ 7,845,000
TOTAL DIRECT COSTS
(equipment + installation) $19.948.800
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 1,994.900
Construction and field expense
(10% of direct costs) 1.994.900
Construction fees
(10% of direct costs) 1.994.900
Start-up (2% of direct costs) 399,000
Performance tests (minimum $2000) . 25,000
TOTAL INDIRECT COSTS $ 6.408.700
Contingencies
(20% of direct and indirect costs) S 5.271.5QQ
Total Turnkey Costs
(direct+indirect+contingencies) 31.629.000
Land 2.000
Working capital (25% of total direct
operating costs) lf671r4QQ
GRAND TOTAL g
(turnkey+land+working capital) $.*.*,302,4uu
aQuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
A-107
-------
TABLE A-72. ESTIMATED ANNUALIZED COSTS OF A FIELD-ERECTED,
WATER-TUBE, PULVERIZED-COAL-FIRED BOILER FIRING EASTERN
MEDIUM-SULFURfiCOAL WITH A THERMAL INPUT OF 205.1 MW
(700 x 10° Btu/hr,- 900 psig/750°F design)
DIRECT COST
Direct labor $ 1,000,300
Supervision 205,400
Maintenance labor 512,600
Maintenance materials S
Replacement parts 412,300
Electricity 876,800
Steam N.A.
Cooling water N.A.
Process water 10,600
Fuel 3,495,200
Bottom ash disposal 147,20~0
Chemicals 25,000
Total direct cost $ 6,685,400
OVERHEAD
Payroll (30% of direct labor $ 300.100
Plant (26% of labor, parts & maint.) 554.000
Total overhead costs $ 854.100
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 1,265,200
Capital recovery factor
( 10.14% of total turnkey costs) 3.207.200
Interest on working capital
(10% of working capital) 167,100
Total capital charges $ 4,639,500
TOTAL ANNUALIZED COSTS $12.179rQQQ
a Included with replacement parts.
N.A. - Not applicable.
A-108
-------
APPENDIX B
DETAILED CAPITAL AND ANNUALIZED COST TABLES
FOR PACKAGE, FIRE-TUBE BOILERS FIRED BY
RESIDUAL OIL, DISTILLATE OIL, AND
NATURAL GAS
-------
TABLE B-l. ESTIMATED CAPITAL COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING RESIDUAL OIL WITH A THERMAL INPUT OF 1.5 MW
(5 x 106 Btu/h; 125 hp; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
19,100
2,000
Incl. w/boiler
N.A.
N.A.
Incl. w/condensate
N.A.
3.500
4,000
1,200
Incl. w/boiler
N.A.
N.A.
N.A.
N.A.
13.000
42,800
3.OOP
1.000
Incl. w/ boiler
MT A.
N.A.
N.A.
N.A.
N.A.
800
800
1.000
200
N.A.
N.A.
N.A.
3.OOP
B-l
-------
TABLE B-l. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 2,500
Ductwork (not incl. w/boiler) N.A.
Piping 12,000
Insulation 8,000
Painting 2,500
Electrical 10,000
Buildings 35,000
Total installation cost $ 79,800
TOTAL DIRECT COSTS
(equipment + installation) $ 122,600
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 12,300
Construction and field expense
(10% of direct costs) 12,300
Construction fees
(10% of direct costs) 12,300
Start-up (2% of direct costs) 2,500
Performance tests (minimum $2000) . 2,000
TOTAL INDIRECT COSTS $ 41,400
Contingencies
(20% of direct and indirect costs) $ 32,800
Total Turnkey Costs
(direct+indirect+contingencies) 196,800
Land 2.000
Working capital (25% of total direct
operating costs) 44.900
GRAND TOTAL
(turnkey*land+working capital) s 243,700
a Quote from Cleaver-Brooks, May 11, 1978.
N.A. - Not applicable.
B-2
-------
TABLE B-2. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING RESIDUAL OIL WITH A THERMAL INPUT OF 1.5 MW
(5 x 106 Btu/h; 125 hp; 150 psig/sat. temp, design)
DIRECT COST
Direct labor S 105.300
Supervision Q_
Maintenance labor 16*000
Maintenance materials a
Replacement parts 8/000
Electricity 6,000
Steam N.A.
Cooling water N.A.
Process water 100
Fuel 43,600
Bottom ash disposal N.A.
Chemicals 700
Total direct cost $ 179,700
OVERHEAD
Payroll (30% of direct labor ) $ 31,600
Plant (26% of labor, parts & maint.) 33,600
Total overhead costs $ 65.200
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 7,900
Capital recovery factor
(11.75 % of total turnkey costs) 23,100
Interest on working capital
(10% of working capital) 4.500
Total capital charges $ 35,500
TOTAL ANNUALIZED COSTS $ 280.400
a Included with replacement parts.
N.A. - Not applicable.
B-3
-------
TABLE B-3. ESTIMATED CAPITAL COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING RESIDUAL OIL WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 300 hp; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST a
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 36,100
2,700
Incl. w/boiler
N.A.
N.A.
N.A.
4,000
N.A.
6,100
5,000
1>400
Incl. w/boiler
N.A.
N.A.
N.A.
N.A.
22,000
77,300
5,000
1,500
Incl. w/boiler
N.A.
N.A.
N.A.
1,500
N.A.
1,200
1,000
1,500
400
N.A.
N.A.
N.A.
4,000
B-4
-------
TABLE B-3. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 3/500
Ductwork (not incl. w/boiler) N.A.
Piping 20,000
Insulation 10,000
Painting 3,000"
Electrical 15,000'
Buildings . 50,000"
Total installation cost $ 117,600
TOTAL DIRECT COSTS
(equipment + installation) $ 194,900
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 19*500
Construction and field expense
(10% of direct costs) 19,500
Construction fees
(10% of direct costs) 19,500
Start-up (2% of direct costs) 3,900
Performance tests (minimum $2000) . 2,000
TOTAL INDIRECT COSTS $ 64,400
Contingencies
(20% of direct and indirect costs) $ 51,900
Total Turnkey Costs
(direct+indirect+contingencies) 311,200
Land 2,000
Working capital (25% of total direct
operating costs) 91,000
GRAND TOTAL
(turnkey+land+working capital) s 404,20_p_
a Quote from Cleaver-Brooks, May 11, 1978.
N.A. - Not applicable.
B-5
-------
TABLE B-4. ESTIMATED ANNUALIZED COSTS OP A PACKAGE, FIRE-TUBE
BOILER FIRING RESIDUAL OIL WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 300 hp; 150 psig/sat. temp design)
DIRECT COST
Direct labor $ 105,300
Supervision 68,500
Maintenance labor 32,000
Maintenance materials
Replacement parts 15,000
Electricity 11,600
Steam N.A.
Cooling water
Process water _ 2°0
Fuel 130,700
Bottom ash disposal N.A.
Chemicals 800
Total direct cost $ 364,100
OVERHEAD
Payroll (30% of direct labor) $ 31,600
Plant (26% of labor, parts & maint.) 57,400
Total overhead costs $ 89,000
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 12.400
Capital recovery factor
(11.75 % of total turnkey costs) 36.600
Interest on working capital
(10% of working capital) 9,100
Total capital charges $ 58.100
TOTAL ANNUALIZED COSTS S511.200
a Included with replacement parts.
N.A. - Not applicable.
B-6
-------
TABLE B-5. ESTIMATED CAPITAL COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING RESIDUAL OIL WITH A THERMAL INPUT OF 8.5 MW
(29 x 106 Btu/h; 700 hp; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
S 51,000
4,000
Incl. w/boiler
N.A.
N.A.
N.A.
5,000
N.A.
13,000
6.OOP
2.000
1,400
N.A.
N.A.
N.A.
N.A.
32,000
$ 114.400
9.000
2,000
Incl. w/bo i 1 er
N.A.
N.A.
2.500
N.A.
3rOQO
l.QQQ
2.000
1.500
N.A.
N.A.
N.A.
8. OOP
B-7
-------
TABLE B-5. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 15.000
Ductwork (not incl. w/boiler) N.A.
Piping 25,000
Insulation 20,000
Painting 4,000"
Electrical 20,000
Buildings 70,000"
Total installation cost $ 183,000
TOTAL DIRECT COSTS
(equipment + installation) $ 297,400
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 29,700
Construction and field expense
(10% of direct costs) 29,700
Construction fees
(10% of direct costs) 29,700
Start-up (2% of direct costs) 5.900
Performance tests (minimum $2000) . 2,000
TOTAL INDIRECT COSTS $ 97,000
Contingencies
(20% of direct and indirect costs) $ 78,900
Total Turnkey Costs
(direct+indirect+contingencies) 473,300
Land 2,000
Working capital (25% of total direct
operating costs) 127.200
GRAND TOTAL
(turnkey+land+working capital) s 602,50_0_
Quote from Cleaver-Brooks, May 11, 1978.
N.A. - Not applicable.
B-8
-------
TABLE B-6. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING RESIDUAL OIL WITH A THERMAL INPUT OF 8.5 MW
(29 x 106 Btu/h; 700 hp; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 105.300
Supervision 68,500
Maintenance labor 32/000
Maintenance materials a
Replacement parts 25,000
Electricity 24,000
Steam N.A.
Cooling water N.A.
Process water 400
Fuel 252,600
Bottom ash disposal N.A.
Chemicals 1.000
Total direct cost $ 508,800
OVERHEAD
Payroll (30% of direct labor) $ 31,600
Plant (26% of labor, parts & roaint.) 60,000
Total overhead costs $ 91.600
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 18r9QQ
Capital recovery factor
(11.75 % of total turnkey costs) 55r6QQ
Interest on working capital
(10% of working capital) 12.700
Total capital charges $ 87.200
TOTAL ANNUALIZED COSTS S 687,600
a Included with replacement parts.
N.A. - Not applicable.
B-9
-------
TABLE B-7. ESTIMATED CAPITAL COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING DISTILLATE OIL WITH A
g THERMAL INPUT OF 1.5 MW
(5 x 10 Btu/h; 125 hp; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE June 30. 1978 _ (FOR COSTS INDEXING)
EQUIPMENT COST a
Boiler (with fans & ducts) $ 19.100 _
Stack 2.000 _
Instrumentation Incl. w/boiler
Pulverizers _ N.A. _
Feeders _ N.A. _
Crushers _ N.A. _
Deaerators Incl. w/condensate
Heaters N.A. _
Boiler feed pumps 3f500 _
Condensate systems 4 r QOQ _
Water treating system 1/200 _
Chemical feed Incl. w/boiler
Compressed air system N.A. _
Coal handling system _ MLA* _
Ash disposal system _ N.A. _
Thawing equipment _ N.A. _
Fuel-oil system 10.000 _
Total Equipment Cost $ 39,800 _
INSTALLATION COST, DIRECT
Boiler (including founda
tions and steel)
Stack inno
Instrumentation
Pulverizers
Feeders _ N.A.
Crushers _ N.A.
Deaerators _ N.A.
Heaters N.A.
Boiler feed pumps _ 800
Condensate system _ 800
Water treating system 1.000
Chemical feed _ 200
Coal handling system _ N.A.
Ash disposal system _ N.A.
Thawing equipment _ N.A.
Fuel-oil system 2.500
N.A. - Not applicable.
B-10
-------
TABLE B-7. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 2,500
Ductwork (not incl. w/boiler) N.A.
Piping 12,000
Insulation 8/000
Painting ^500"
Electrical 10,000
Buildings 3^>
Total installation cost $ 79,300
TOTAL DIRECT COSTS
(equipment + installation) $ 119,100
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 11,900
Construction and field expense
(10% of direct costs) 11,900
Construction fees
(10% of direct costs) 11.900
Start-up (2% of direct costs) 2,400
Performance tests (minimum $2000) . 2,000
TOTAL INDIRECT COSTS S 40.100
Contingencies
(20% of direct and indirect costs) $ 31.800
Total Turnkey Costs
(direct+indirect+contingencies) 191.000
Land 2.000
Working capital (25% of total direct
operating costs) 48 .800
GRAND TOTAL
(turnkey+land+working capital) $ 241.80.fl.
a Quote from Cleaver-Brooks, May 11, 1978.
N.A. - Not applicable.
B-ll
-------
TABLE B-8. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING DISTILLATE OIL WITH A THERMAL INPUT OF 1.5 MW
(5 x 106 Btu/h; 125 hp; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 105,300
Supervision
Maintenance labor 16,000
Maintenance materials
Replacement parts 8,000
Electricity 6,000
Steam N.A.
Cooling water N.A.
Process water 100
Fuel 59,100
Bottom ash disposal N.A.
Chemicals 700
Total direct cost $ 195,200
OVERHEAD
Payroll (30% of direct labor ) $ 31,600
Plant (26% of labor, parts & maint.) 33,600
Total overhead costs $ 65.200
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 7,600
Capital recovery factor
(11.75 % of total turnkey costs) 22,500
Interest on working capital
(10% of working capital) 4,900
Total capital charges $ 34,900
TOTAL ANNUALIZED COSTS $ 295.300
a Included with replacement parts.
N.A. - Not applicable.
B-12
-------
TABLE B-9. ESTIMATED CAPITAL COSTS OF A PACKAGE FIRE-TUBE
BOILER FIRING DISTILLATE OIL WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 300 hp? 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans and duct)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems.
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N,A. - Not applicable.
S 36.100
2.700
Incl. w/boiler
N.A.
N.A.
N.A.
4,000
N.A.
6.100
5.000
1.400
Incl. w/boiler
N.A.
N.A.
N.A.
N.A.
16,000
$ 71,300
$ 5.000
1,500
Incl. w/boiler
N.A.
N.A.
N.A.
1,500
N.A.
1,200
1,000
1,500
400
N.A.
N.A.
N.A.
3,000
B-13
-------
TABLE B-9. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 3,500
Duct work (not incl. w/boiler) N.A.
Piping 20,000
Insulation 10.000
Painting 3,000
Electrical 15.000
Buildings 50,000
Total Installation Costs $ 116.600
TOTAL DIRECT COSTS
(Equipment + Installation) $ 187.900
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 18.800
Construction and field expense
(10% of direct costs) 18.800
Construction fees
(10% of direct costs) 18.800
Startup (2% of direct costs) 3,800
Performance tests (minimum $2000) 2,000
TOTAL INDIRECT COSTS $ 62.200
Contingencies
(20% of direct and indirect costs) S 50.000
Total turnkey costs
(Direct + Indirect + Contingencies) 300,100
Land 2,000
Working capital (25% of total direct
operating costs) 102,700
GRAND TOTAL
(Turnkey + Land + Working Capital) $ 404^800
a Quote from Cleaver-Brooks, May 11, 1978.
N.A. - Not applicable.
B-14
-------
TABLE B-10. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING DISTILLATE OIL WITH A THERMAL INPUT 'OF 4 . 4 MW
(15 x 106 Btu/h; 300 hp; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 105,300
Supervision 68,500
Maintenance labor 32.000
Maintenance materials ' _ a
Replacement parts 15,OOU
Electricity
Steam _ N.A.
Cooling water _ N.A.
Process vater _ 200
Fuel 177,400
Bottom ash disposal N.A.'
Chemicals 800
Total direct cost $ 410.800
OVERHEAD
Payroll (30% of direct labor) $ 31,600
Plant (26% of labor, parts & maint.) 57,400
Total overhead costs $ 89,000
/
BYPRODUCT CREDITS _ N.A.
CAPITAL CHARGES
G t A, taxes & insurance
(4% of total turnkey costs) $ 12,000
Capital recovery factor
(11.75* of total turnkey costs) 35.300
Interest on working capital
(10% of working capital) 10,300
Total capital charges $ 57,600
TOTAL ANNUALIZED COSTS $ 557,400
Included with replacement parts.
N.A. - Not applicable.
B-15
-------
TABLE B-ll. ESTIMATED CAPITAL COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING DISTILLATE OIL WITH A THERMAL INPUT OF 8.5 MW
(29 x 106 Btu/h; 700 hp; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30. 1978
(FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 51,000
4,000
Incl. w/boiler
N.A.
N.A.
N.A.
5,000
N.A.
13,000
6,000
2,000
1,400
N.A.
N.A.
N.A.
N.A.
25,000
$ 107,400
9,000
2,000
Incl. w/boiler
N.A.
N.A.
N.A.
2.500
N.A.
3.000
1.000
2.000
1.500
N.A.
N.A.
N.A.
6.000
B-16
-------
TABLE B-ll. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 15/000
Ductwork (not incl. w/boiler) N.A.
Piping 25,000
Insulation 20,000
Painting 4,000
Electrical 20,000
Buildings 70,000
Total installation cost S181fOOO
TOTAL DIRECT COSTS
(equipment + installation) $288,400
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 28,800
Construction and field expense
(10% of direct costs) 28,800
Construction fees
(10% of direct costs) 28,800
Start-up (2% of direct costs) 5.800
Performance tests (minimum $2000) . 2.000
TOTAL INDIRECT COSTS $ 94,200
Contingencies
(20% of direct and indirect costs) $ 76,500
Total Turnkey Costs
(direct+indirect+contingencies) 459,100
Land 2fnnn
Working capital (25% of total direct
operating costs) iAQ,pnn
GRAND TOTAL
(turnkey+land+working capital) $61Q.9QQ_
a Quote from Cleaver-Brooks, May 11, 1978
N.A. - Not applicable.
B-17
-------
TABLE B-12. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING DISTILLATE OIL WITH A THERMAL INPUT OF 8.5 MW
(29 x 106 Btu/h; 700 hp; 150 psig/sat. temp, design)
DIRECT COST
Direct labor * 105'300
Supervision 68,500
Maintenance labor 32,000
Maintenance materials
Replacement parts 25,000
Electricity 24,000
Steam N.A.
Cooling water N.A.
Process water 400
Fuel 343,000
Bottom ash disposal N.A.
Chemicals 1.000
Total direct cost $ 599.200
OVERHEAD
Payroll (30% of direct labor) $ 31,600
Plant (26% of labor, parts & maint.) 60.000
Total overhead costs S 91.600
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 18,400
Capital recovery factor
(11.75 % of total turnkey costs) 53,900
Interest on working capital
(10% of working capital) 15.000
Total capital charges S 87,300
TOTAL ANNUALIZED COSTS <; 778,100
-»
a Included with replacement parts.
N.A. - Not applicable.
B-18
S
-------
TABLE B-13. ESTIMATED CAPITAL COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING NATURAL GAS WITH A THERMAL INPUT OF 1.5 MW
(5 x 106 Btu/h; 125 hp; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30. 1978
(FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
19.100
2.000
Incl. w/boiler
N.A.
N.A.
N.A.
Incl. w/condensate
N.A.
3.500
4rQQQ
I200
. w/boiler
N.A.
N.A.
N.A.
N.A.
10,000
5 39f800
1,000
Incl. w/boiler
N.A.
N.A.
N.A.
N.A.
N.A.
800
800
1,000
200
N.A.
N.A.
N.A.
2,500
B-19
-------
TABLE B-13. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 2.500
Ductwork (not incl. w/boiler) N.A.
Piping 12,000
Insulation 8,000
Painting 2,500
Electrical 10,000
Buildings 35,000
Total installation cost $ 79r30Q
TOTAL DIRECT COSTS
(equipment + installation) $ 119.100
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 11.900
Construction and field expense
(10% of direct costs) 11.900
Construction fees
(10% of direct costs) Ilr900
Start-up (2% of direct costs) 2,400
Performance tests (minimum $2000) . 2.000
TOTAL INDIRECT COSTS $ 40.100
Contingencies
(20% of direct and indirect costs) $ 31f800
Total Turnkey Costs
(direct+indirect+contingencies) 191fQQQ
Land 2 .POD
Working capital (25% of total direct
operating costs) 41rfinn
GRAND TOTAL
(turnkey+land+working capital) $ 236.600
Quote from Cleaver-Brooks, May 11, 1978.
N.A. - Not applicable.
B-20
-------
TABLE B-14. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING NATURAL GAS WITH A THERMAL INPUT OF 1.5 MW
(5 x 106 Btu/h; 125 hp; 150 psig/sat. temp, design)
DIRECT COST
Direct labor S 105.300
Supervision 0_
Maintenance labor 16/000
Maintenance materials a
Replacement parts 8,OOP
Electricity 6,000
Steam N.A.
Cooling water N.A.
Process water 100
Fuel 38/400
Bottom ash disposal N.A.
Chemicals 700
Total direct cost $ 174,500
OVERHEAD
Payroll (30% of direct labor) $ 31,600
Plant (26% of labor, parts & maint.) 33,600
Total overhead costs $ 65.200
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) S 7.600
Capital recovery factor
( 11.75% of total turnkey costs) 3?,4nn
Interest on working capital
(10% of working capital) 4,400
Total capital charges $ 34.400
TOTAL ANNUALIZED COSTS $ 274,100
a Included with replacement parts.
N.A. - Not applicable.
B-21
-------
TABLE B-15. ESTIMATED CAPITAL COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING NATURAL GAS WITH A THERMAL INPUT OF 4.4 MW
(15 x 10 Btu/h; 300 hp; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans and ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COSTS, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerator
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 36.100
2.700
Incl. w/boiler
N.A.
N.A.
N.A.
4.000
N.A.
6.100
5.000
1.400
Inel. w/boiler
N.A.
N.A.
N.A.
N.A.
16.000
$ 71,300
$ 5,000
1,500
Incl. w/boiler~
N.A.
N.A.
N.A.
1,500
N.A.
1,200
1.000
1,500
400
N.A.
N.A.
N.A.
3^000
B-22
-------
TABLE 'B-15.(continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 3,500
Duct work (not incl. w/boiler) N.A.
Piping 20.000
Insulation iof OOP
Painting 3,000
Electrical 15rQQO
Buildings • 50, OOP
Total Installation Costs $ 116.600
TOTAL DIRECT COSTS
(Equipment + Installation) $ 187,900
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 18,800
Construction and field expense
(10% of direct costs) 18,800
Construction fees
(10% of direct costs) IB,BOO
Startup (2% of direct costs) 3 f800
Performance tests (minimum $2000) 2.000
TOTAL INDIRECT COSTS $ 62,200
Contingencies
(20% of direct and indirect costs) $ 50,000
Total turnkey costs
(Direct + Indirect + Contingencies) 300,100
Land 2,000
Working capital (25% of total direct
operating costs) 87,200
GRAND TOTAL
(Turnkey + Land + Working Capital) $ 389,300
a Quote from Cleaver-Brooks, May 11, 1978
N.A. - Not applicable.
B-23
-------
TABLE B-16. ESTIMATED ANNUALIZED COSTS OF A PACKAGE,FIRE-TUBE
BOILER FIRING NATURAL GAS WITH A THERMAL INPUT OF 4.4 MW
(15 x 106 Btu/h; 300 hp; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 105.300
Supervision 68,500
Maintenance labor 32,000
Maintenance materials
Replacement parts j-5,9?0
Electricity 11,600
Steam N.A.
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals _ son
Total direct cost $ 348.7QQ
OVERHEAD
Payroll (30% of direct labor) $ 31,600
Plant (26% of labor, parts & maint.) 57,400
Total overhead costs $ 89,000
/
BYPRODUCT CREDITS N.A.
CAPITAL CHARGES
G i A, taxes t insurance
(4% of total turnkey costs) ? 12,000
Capital recovery factor
(11.75* of total turnkey costs) 35,300
Interest on working capital
(10% of working capital) 8'700
Total capital charges $ 56,000
TOTAL ANNUALIZED COSTS $ 493,700
Included with replacement parts.
N.A. - Not applicable.
B-24
-------
TABLE B-17. ESTIMATED CAPITAL COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING NATURAL GAS WITH A THERMAL INPUT OF 8.5 MW
(29 x 106 Btu/h; 700 hp; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
51.000
4.000
Incl. w/hoiler
M a
N.A.
N.A.
5.000
N.A.
13.000
6.000
2,000
1.400
N.A.
N.A.
N.A.
N.A.
25.000
$ 107,400
9,000
2,000
Incl. w/boiler
N.A.
N.A.
N.A.
2,500
N.A.
3,000
1,000
2,000
1,500
N.A.
N.A.
N.A.
6.000
B-25
-------
TABLE B-17. (continued)
INSTALLATION COSTS, DIRECT (cont. )
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
15,000
N.A.
25rOOO
20,000
4,000
20,000
70.000
Total installation cost $ 181fQQO
TOTAL DIRECT COSTS
(equipment + installation) $ 288,400
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) $ 28.800
Construction and field expense
(10% of direct costs) 28.800
Construction fees
(10% of direct costs) 28.800
Start-up (2% of direct costs) 5,800
Performance tests (minimum $2000) . 2,000
TOTAL INDIRECT COSTS $ 94.200
Contingencies
(20% of direct and indirect costs) $ 76.500
Total Turnkey Costs
(direct+indirect+contingencies) 459.100
Land 2,000
Working capital (25% of total direct
operating costs) 119,800
GRAND TOTAL
(turnkey+land+worki-ng capital) $ 580,900 •
-------
TABLE B-18. ESTIMATED ANNUALIZED COSTS OF A PACKAGE, FIRE-TUBE
BOILER FIRING NATURAL GAS WITH A THERMAL INPUT OF 8.5 MW
(29 x 106 Btu/h; 700 hp; 150 psig/sat. temp, design)
DIRECT COST
Direct labor $ 105,300
Supervision 68,500
Maintenance labor 32,000
Maintenance materials
a Included with replacement parts.
N.A. - Not applicable.
B-27
Replacement parts 25,000
Electricity 24,000
Steam N.A.
Cooling water
Process water _ 400
Fuel 222,900
Bottom ash disposal _ N.A.
Chemicals 1/000
Total direct cost $ 479,100
OVERHEAD
Payroll (30% of direct labor) $ 31,600
Plant (26% of labor, parts & maint.) 60,000
Total overhead costs $ 91.600
BY-PRODUCT CREDITS N.A.
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs) $ 18.400
Capital recovery factor
(11.75 % of total turnkey costs) 53.900
Interest on working capital
(10% of working capital) 12,000
Total capital charges $ 84.300
TOTAL ANNUALIZED COSTS S
-------
APPENDIX C
DETAILED CAPITAL AND ANNUALIZED COST TABLES
FOR DUAL-FUEL BOILERS
-------
TABLE C-l. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 150,000
5.000
incl. w/boiler
N.A.
N.A.
N.A.
7.000
N.A.
13.500
3.500
8.000
1.500
N.A.
N.A.
N.A.
N.A.
33.000
$ 221.500
10.000
3,000
incl. w/boiler
N.A.
N.A.
N.A.
2.500
N.A.
3.000
l.OQO
2.000
1.500
N.A.
N.A.
N.A.
8.000
C-l
-------
TABLE C-l. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
15.000
N.A.
29,000
20,000
4,000
21,000
70,000
$ 190,000
$ 411,500
$
41,200
41,200
41.200
8,200
2,000
$
133.800
$ 109.100
654.400
2.000
146,500/137,100
$ 802,900/793,500
'Quote from Zurn Industries, Inc., May 25, 1978,
N.A. - Not applicable.
C-2
-------
TABLE C-2. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor.- parts & ma int.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
( 10.61% of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
a Included with replacement parts.
N.A. - Not applicable.
$ 105,300
68,51TD
32,000
a
30,000
29,300
N.A.
N.A.
400
319,400/281,900
N.A.
1,000
$ 585,900 /548,400
31,600
61,300
92,900
N.A.
26.200
69.400
14.700/13,700
110.300/109,300
S 789.100/750,600
C-3
-------
TABLE C-3. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 17.6 MW
(60 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST a
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
280.000
9.500
incl. w/boiler
N.A
N.A.
N.A.
13.500
N.A.
18.000
4.500
12.500
1.500
N.A.
N.A.
N.A.
N.A.
41.000
380.500
15.500
4.700
incl
MA
N.A.
nnn
N.A.
48QQ
1100
2. 100
1.500
N.A.
c-4
-------
TABLE C-3. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment 4- installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey*land+working capital)
21,000
N.A.
43,000
22,500
4 .100
26.500
76.500
$ 241,800
$ 622,300
62,200
62,200
62,200
12,400
3,500
$ 202,500
$ 165,000
989,800
2,000
238,700/219.900
$1.230.500/1,211,7QC
Quote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
C-5
-------
TABLE C-4. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 17.6 MW
(60 x 106 Btu/h; 150 psig/sat. temp, design)
S 105.300
68.500
64.100
a
42.000
32.900
N.A.
N.A.
800
638.900/563.700
N.A.
2 .200
S 954.700/879.500
31.600
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.61% of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
72.800
104.400
N.A.
105,000
23,900/22,000
$ 168,500/166,600
$1,227,600/1,150,500
a Included with replacement parts.
N.A. - Not applicable.
C-6
-------
TABLE C-5. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 29.3 MW
(100 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE June 30. 1978 (FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans & ducts) $ 440,000
Stack 12,000
Instrumentation incl. w/boiler
Pulverizers N.A.
Feeders . N.A.
Crushers N.A.
Deaerators I8/ OOP
Heaters N.A.
Boiler feed pumps 35,000
Condensate systems 5, 500
Water treating system 16, OOP
Chemical feed 1/500
Compressed air system N.A.
Coal handling system N.A.
Ash disposal system N.A.
Thawing equipment N.A.
Fuel-oil system 45,000
Total Equipment Cost $ 573,000
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel) $ 18,000
Stack 5,500
Instrumentation incl. w/boiler
Pulverizers N.A.
Feeders N.A.
Crushers N.A.
Deaerators 3,500
Heaters N.A.
Boiler feed pumps 6, OOP
Condensate system 1,500
Water treating system 2/500
Chemical feed 1/500
Coal handling system N.A.
Ash disposal system N.A.
Thawing equipment N.A.
Fuel-oil system 18,000
N.A. - Not applicable.
C-7
-------
TABLE C-5. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
25,000
N.A.
57,000
25,000
4,500
33,000
88,000
$ 289,000
S 862.000
86.200
86.200
fifi.200
17.200
3,50Q
S 279f3QO
S 228r3QQ
1.369.600
2.000
362.4QQ/331.1QQ
$1.734.000/1.702.700
Quote from Zurn Industries, Inc., May 25, 1978
N.A. - Not applicable.
C-8
-------
TABLE C-6. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 29.3 MW
(100 x 106 Btu/h; 150 psig/sat. temp, design)
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.61 % of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
a Included with replacement parts.
N.A. - Not applicable.
157,900
68,500
64,100
50,000
39,300
N.A.
N.A.
1,400
1,064,800/939,500
N.A.
3,700
$ 1,449,700/1,324,400
47,400
88,500
135,900
N.A.
54,800
145.300
36,200/33,100
$ 236,300/233,200
$ 1.821.9QO/1.693.5QQ
C-9
-------
TABLE C-7. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 44 MW
(150 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
600,000
14,500
incl. w/boiler
N.A.
N.A.
N.A.
21,600
N.A.
53,600
6,700
18,000
1,500
N.A.
N.A.
N.A.
N.A.
50,000
765,900
20,000
6,500
incl . w/boiler
N.A.
N.A.
4 .000
N.A.
7.500
1,500
3,000
1.500
N.A.
N.A.
N.A.
20.000
C-10
-------
TABLE C-7. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey*land+working capital)
30,000
N.A.
74,000
30,000
5,000
40,000
100,000
343,000
$ 1,108,900
110,900
110,900
110,900
22,200
3,500
358,400
293,500
1,760.800
2,000
513.800/466.800
$ 2,276,600/2,229,60
Quote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
C-ll
-------
TABLE C-8. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 44 MW
(150 x 106 Btu/h; 750 psig/750°F design)
S 210.600
68.500
64.100
a
60.000
47.100
N.A.
N.A.
2.100
1.597.200/1.409.300
N.A.
5.500
S2.Q55rlQQ/l-867.2nQ
63.200
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.61 % of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
104.800
168.000
N.A.
S 70.400
ann
51r4nO/4fir7QQ
, 9 0 0
, 3 3 9 , 1 0 0
a Included with replacement parts
N.A. - Not applicable.
C-12
-------
TABLE C-9.. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, FIEJLD-ERECTED,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE June 30. 1978 (FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts) $ lyZ91'?99
Stack 262,800
Instrumentation 182,400
Pulverizers N.A.
Feeders . N.A
Crushers N.A.
Deaerators 29,000
Heaters N.A.
Boiler feed pumps 58,000
Condensate systems 16.300
Water treating system 20,000
Chemical feed 500
Compressed air system 12,500
Coal handling system N.A.
Ash disposal system
Thawing equipment N. A.
Fuel-oil system 150.000
Total Equipment Cost $ 2.436.500
INSTALLATION COST, DIRECT
Boiler (including founda- 868 000
tions and steel) J '.
Stack 50.000
Instrumentation 28 ,QQQ
Pulverizers TJ. A.
Feeders _ N_JL
Crushers
Deaerators _ 5, QQQ
Heaters N.A.
Boiler feed pumps 8tOOQ
Condensate system 2,000
Water treating system 3,500
Chemical feed 1/500
Coal handling system N,A,
Ash disposal system N.A.
Thawing equipment
Fuel-oil system 75,000
N.A. - Not applicable.
C-13
-------
TABLE C-9. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
144,000
N.A.
100,000
75,000
8,000
128,000
304,000
$ 1,800,000
$ 4.236.500
423.700
423.700
423.7nn
84.700
5,000
S lr3fiQf8QQ
S lf119r5QQ
6.716.800
2.000
693,200/630,500
$ 7,412,000/7,349,300
aQuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
C-14
-------
TABLE C-10. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, .FIELD-ERECTED,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
a Included with replacement parts,
N.A. - Not applicable.
S 263.2QQ
102.700
96.100
a
100.000
70.700
N.A.
N-A.
2 .800
7.5QQ
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
( 10.14* °f total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
2.129.600/1.879.000
N.A.
S2r772f6QQ/2.522.QQQ
79.000
146.100
225.100
M.A.
268 .700
681,100
69,300/63,100
$1,019,100/1,012,900
$4,016,800/3,760,000
C-15
-------
TABLE Oil. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, FIELD-ERECTED,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE June 30, 1978 (FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans & ducts) S 2;736r600
Stack 5QOfQQQ
Instrumentation 302,800
Pulverizers TJ. A.
Feeders N.A. _
Crushers N.A. _
Deaerators _ 60. OOP
Heaters N.A. _
Boiler feed pumps 150.000
Condensate systems _ 25f OOP
Water treating system _ 6Qf OOP
Chemical feed _ 4 rPOQ
Compressed air system _ 25,000
Coal handling system N.A. _
Ash disposal system N.A. _
Thawing equipment N.A. _
Fuel-oil system _ 29P,PPP
Total Equipment Cost S 4r153r4QQ
INSTALLATION COST- DIRECT
Boiler (including founda-
tions and steel) $ 1,736,000
Stack incl . w/equipment
Instrumentation _ 88.000
Pulverizers _ 1LJL _
Feeders _ N.A. _
Crushers _ N.A. _
Deaerators _ 12.000
Heaters N.A.
Boiler feed pumps _ 18 ,000
Condensate system _ 10, OOP
Water treating system _ 16,000
Chemical feed _ 2. OOP
Coal handling system _ N.A.
Ash disposal system N.A.
Thawing equipment N.A.
Fuel-oil system 145,OOP
N.A. - Not applicable.
C-16
-------
TABLE C-ll. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
264,000
N.A.
156,000
100,000
13,000
272,000
520,000
$ 3.352.000
$ 7.505.400
750.500
750.500
750. 500
150,100
13,000
$ 2.414.600
$ 1.984.000
11.904.000
_ 2.000
1,319,900/1,194,600
$13.225.900/13.100.61
aQuote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
C-17
-------
TABLE C-12. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, FIELD-ERECTED,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
( 10.14% of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
a Included with replacement parts
N.A. - Not applicable.
473,800
136,900
128.200
150.000
110,000
N.A.
N.A.
5.600
4,259,100/3.758.000
N.A.
16.000
$ 5,279,600/4,778,500
142.100
231.100
373.200
N.A.
476.200
lr2Q7flQQ
132.000/119.500
S 1.815.3QQ/1.802.800
$ 7.468.100/6.954.500
C-18
-------
TABLE C-13. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, FIELD-ERECTED,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 205.1 MW
(700 x 10° Btu/h; 900 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 4.419.000
900.000
489.000
N.A.
N.A.
N.A.
85.000
N.A.
195.000
35.000
90rQOO
4.000
30.000
N.A.
N.A.
N.A.
490.000
6.737.0QQ
$ 2,455,000
incl. w/equipment
128,000
N.A.
N.A.
N.A.
19.000
N.A.
25,000
16.000
28,000
2,000
N.A.
N.A.
N.A.
245,000
C-19
-------
TABLE C-13. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey*land+working capital)
484.000
N.A.
279,000
165,000
22,000
520,000
930,000
$ 5.318.000
$12.055.000
$ 1.205.500
-.205.500
1.2Q5r50Q
241,100
16,000
$ 3.873.600
$ 3.185.700
19.114.300
2.000
2.215.100/1.995.900
$21.331.400/21.112.201
aQaote from Babcock & Wilcox, Inc., August 17, 1978.
N.A. - Not applicable.
C-20
-------
TABLE C-14. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, FIELD-ERECTED,
WATER-TUBE BOILER FIRING RESIDUAL OIL/NATURAL GAS
WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/h; 900 psig/750°F design)
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.14 % of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
$ 605,400
136,900
224,3W
a
225,000
180,650"
N.A.
N.A.
9,700"
7,453,461)76,576,600
N.A.
25,000
$8,860,300/7,983,500
$ 181,600
309,800
$ 491,400
N.A.
$ 764,600
1,938,200
221,500/199,600
$2,924,300/2,902,400
$12.276.000/11.377.300
a Included with replacement parts.
N.A. - Not applicable.
C-21
-------
TABLE C-15. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL GAS
WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30. 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
a
Boiler (with fans 6 ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 150,000
5,000
incl. w/boiler
N.A.
N.A.
N.A.
7,000
N.A.
13T500
3,500
8.000
1,500
N.A.
N.A.
N.A.
N.A.
26,000
$ 214,500
10,000
3,000
incl. w/boiler
N.A.
N.A.
N.A.
2.500
N.A.
3.000
1.000
2.000
1.500
N.A.
N.A.
N.A.
6.000
C-22
-------
TABLE C-15. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
15.000
N.A.
29.000
20,000
4,000
21,000
70,000
$ 188.000
$ 402.500
$ 40.300
40.300
40.300
8,100
2,000
S 131.000
$ 106,700
640,200
2,000
175,000/137.100
$ 817.200/779.300
aQuote from Zurn Industries, Inc., May 25, 1978.
N.A. - Not applicable.
C-23
-------
TABLE C-16. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL GAS
WITH A THERMAL INPUT OF 8.8 MW
(30 x 106 Btu/h; 150 psig/sat. temp, design)
a Included with replacement parts.
N.A. - Not applicable.
105.300
68.500
32.000
30.000
29.300
N.A.
N.A.
400
1,000
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.61 % of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
433,600/281,900
N.A.
700,100/548,400
31,600
61.300
92.900
N.A.
25.600
67.900
17.500/13.700
$ 111.000/107,200
S 904.000/748.500
C-24
-------
TABLE C-17. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL GAS
WITH A THERMAL INPUT OF 17.6 MW
(60 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
280,000
incl. w/boiler
N.A.
N.A.
N.A.
13,500
N.A.
187001)
4,500
N.A.
N.A,
32.onn
15,500
4,700
incl. w/boiler
N.A.
N.A.
N.A.
3,000
N.A.
4,800
1,100
2,100
1,500
N.A.
N.A.
N.A.
11,500
C-25
-------
TABLE C-17. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect-f contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey*land+working capital)
21.000
N.A.
43,000
22,500
4.100
26.500
76.500
$ 237,800
6QQ.30Q
60.900
12.200
3. 500
$ 198.400
$ 161.500
969.200
2.000
295.800/219.900
$1,267.000/1.191.100
.Quote from Zurn Industries, Inc., May 25, 1979.
N.A. - Not applicable.
C-26
-------
TABLE C-18. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL GAS
WITH A THERMAL INPUT OF 17.6 MW
(60 x 106 Btu/h; 150 psig/sat. temp, design)
a Included with replacement parts.
N.A. - Not applicable.
68,500
64.100
42.000
32,900
N.A; .
N.A.
800
2^200
SI.183.000/879.500
31,600
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
( 10.61 * of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
867.200/563.700
N.A.
72,800
$ 104.400
N.A.
$ ' 38,800
102.800
29,600/22,000
$ 171,200/163,600 _
$1.458.600/1.147.500
C-27
-------
TABLE C-19. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL GAS
WITH A THERMAL INPUT OF 29.3 MW
(100 x 106 Btu/h; 150 psig/sat. temp, design)
CAPITAL COSTS
DATE OF ESTIMATE
June 30, 1978
(FOR COSTS INDEXING)
EQUIPMENT COST
Boiler (with fans & ducts)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate systems
Water treating system
Chemical feed
Compressed air system
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
Total Equipment Cost
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel)
Stack
Instrumentation
Pulverizers
Feeders
Crushers
Deaerators
Heaters
Boiler feed pumps
Condensate system
Water treating system
Chemical feed
Coal handling system
Ash disposal system
Thawing equipment
Fuel-oil system
N.A. - Not applicable.
$ 440,000
12,000
incl. w/boiler
N.A.
N.A.
N.A.
18,000
N.A.
35,000
5,500
16.000
1,500
N.A.
N.A.
N.A.
N.A.
35,000
$ 563,000
$ 18,000
5,500
incl. w/boiler
N.A.
N.A.
N.A.
3.500
N.A.
6.000
1.500
2.500
1.500
N.A.
N.A.
N.A.
13,500
C-28
-------
TABLE C-19. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
25,000
N.A.
57,000
25,000
4,500
33,000
88,000
284.500
847.500
84 .800
84,800
84,800
17,000
3,500
$ 274,900
$ 224,500
1,346,900
2,000
457,600/331,100
$1,806,500/1,680,0(
aQuote from Zurn Industries, Inc., May 25, 1978,
N.A. - Not applicable.
C-29
-------
TABLE C-20. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL GAS
WITH A THERMAL INPUT OF 29.3 MW
(100 x 106 Btu/h; 150 psig/sat. temp, design)
a Included with replacement parts.
N.A. - Not applicable.
157.900
68,500
64.100
50.000
39.300
N.A.
N.A.
1.400
3.7QQ
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.61 % of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
1.445.400/939.500
N.A.
$ 1.83Q.3QQ/1.324.40Q
47.400
88.500
135.900
N.A.
53.900
142,900
45,800/33,100
S 242ffinn/229,900
$ 2.208.80Q/1.690.200
C-30
-------
TABLE C-21. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL GAS
WITH A THERMAL INPUT OF 44 MW
(150 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE June 30, 1978 _ (FOR COSTS INDEXING)
EQUIPMENT COST3
Boiler (with fans & ducts) $ 600.000 _
Stack 14.500 _
Instrumentation Incl. w/boiler
Pulverizers _ N. A. _
Feeders _ N.A. _
Crushers • _ N.A. _
Deaerators 21f 600 _
Heaters _ N.A. _
Boiler feed pumps 53.600 _
Condensate systems 6 f 700 _
Water treating system 18f OOP _
Chemical feed If500 _
Compressed air system J _ N.A. _
Coal handling system
Ash disposal system _ N.A.
Thawing equipment _ N.A.
Fuel-oil system 39f OOP
Total Equipment Cost $ 754,900
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel) $ 2QfOQQ
Stack 6.500
Instrumentation Tncl. w/boiler
Pulverizers _ N. A.
Feeders _ N.A.
Crushers _ TJ.A.
Deaerators 4rQQQ
Heaters _ N.A.
Boiler feed pumps _ 7f 500
Condensate system _ 1,500
Water treating system _ 3f OOP
Chemical feed 1 r5on
Coal handling system _ N.A.
Ash disposal system _ N.A.
Thawing equipment -- N.A.
Fuel-oil system 15f OOP
N.A. - Not applicable.
C-31
-------
TABLE C-21. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports 30,000
Ductwork (not incl. w/boiler) N.A.
Piping 74,000
Insulation 30,000"
Painting 5,000
Electrical 40,000
Buildings 100,000
Total installation cost S 338.000
TOTAL DIRECT COSTS
(equipment + installation) $1.092.900
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs) S 109.300
Construction and field expense
(10% of direct costs) 109.300
Construction fees
(10% of direct costs) 109,300
Start-up (2% of direct costs) 21,900
Performance tests (minimum $2000) . 3,500
TOTAL INDIRECT COSTS $ 353.300
Contingencies
(20% of direct and indirect costs) $ 289.200
Total Turnkey Costs
(direct+indirect+contingencies) lf735.400
Land 2.000
Working capital (25% of total direct 656,500/
operating costs) 466.800
GRAND TOTAL $2,393,900/
(turnkey+land+working capital) 9,?na
aBased on quote from Zurn Industries, Inc., May 25, 1978
N.A. - Not applicable.
C-32
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TABLE C-22. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, PACKAGE,
WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL GAS
WITH A THERMAL INPUT OF 44 MW
(150 x 10° Btu/h, 750 psig/750°F design)
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.61 % of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
210.600
68,500
64.100
60.000
47.100
N.A.
N.A.
2.100
2.168.100/1.409,300
N.A.
5.500
S2.626.000/1.867.200
63,200
104.800
168.000
N.A.
69.400
1B4.10n
65.700/46.700
319.200/300.200 '''
2,3 3 5,4 0 0
a Included with replacement parts.
N.A. - Not applicable.
C-33
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TABLE C-23. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, FIELD-
ERECTED, WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL
GAS WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE June 30, 1978 (FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts) $ 1,704,000
Stack 262,800
Instrumentation 182,400
Pulverizers N.A.
Feeders N.A.
Crushers N.A.
Deaerators 29,000
Heaters N.A.
Boiler feed pumps 58,000
Condensate systems 16,300
Water treating system 20,000
Chemical feed 1.500
Compressed air system 12,500
Coal handling system N.A.
Ash disposal system N.A.
Thawing equipment N.A.
Fuel-oil system 100,000
Total Equipment Cost $ 2,386,500
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel) $ 868.000
Stack 50,000
Instrumentation 28 .000
Pulverizers N.A.
Feeders N.A.
Crushers N.A.
Deaerators 5.000
Heaters N.A.
Boiler feed pumps 8 .000
Condensate system 2.000
Water treating system 3.500
Chemical feed 1.500
Coal handling system N.A.
Ash disposal system N.A.
Thawing equipment N.A.
Fuel-oil system 5Q.QOQ
N..A. - Not applicable.
C-34
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TABLE C-23. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey*land+working capital)
144 rnnn
N.A.
100.000
75,000
8,000
128.000
304,000
i .775.nno
S 4.161.500
416.200
83,200
5,000
$ 1.336.800
S 1.099.700
6.598.000
_ 2.000
883.5QQ/63Q.5QQ
7,483,500/7,230,500
a Based on quote from Babcock & Wilcox, Inc., August 17, 1978
N.A. - Not applicable.
C-35
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TABLE C-24. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, FIELD-
ERECTED, WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL
GAS WITH A THERMAL INPUT OF 58.6 MW
(200 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor)
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.14 % of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
$ 263,200
102,700
96,100
a
100,000
70,700
N.A.
N.A.
2,800
2,890,800/1,879,000
N.A.
7.500
$ 3,533,800/2.522,000
$79,000
146.100
$225.100
N.A.
$263.900
88.400/63.100
S 1.021.300/996.000
$ 4.780.200/3.743,100
a Included with replacement parts.
N.A. - Not applicable.
C-36
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TABLE C-25. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, FIELD-
ERECTED, WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL
GAS WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/h; 750 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE June 30, 1978 (FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts) $2,736,600
Stack 500,000
Instrumentation 302,800
Pulverizers N.A.
Feeders N.A.
Crushers ' N.A.
Deaerators 60.000
Heaters N.A.
Boiler feed pumps 150,000
Condensate systems 25.000
Water treating system 60.000
Chemical feed 4.000
Compressed air system 25.000
Coal handling system N.A.
Ash disposal system N.A.
Thawing equipment N.A.
Fuel-oil system 195.000
Total Equipment Cost $4 .058 .400
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel) Sl.736ronn
Stack Incl. w/equip.
Instrumentation 88.000
Pulverizers N.a.
Feeders N.A.
Crushers ^Ji*A-
Deaerators 12 fnnn
Heaters N.A.
Boiler feed pumps 18 fOOP
Condensate system 1Qfnnn
Water treating system 16,000
Chemical feed 2.000
Coal handling system N.A.
Ash disposal system N.A.
Thawing equipment N.A.
Fuel-oil system Q7rnnn
N.A. - Not applicable.
C-37
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TABLE C-25. .(.continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
i
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+work}.ng capital)
264,000
N.A.
156,000'
100,000
13,000
272,000
520,000
$3.304,000
$7.362.400
$ 736.200
736.200
736.200
147,200
13,000
$2.368.800
$1.946.200
11.677.400
2.000
1 .700.500/1.194,600
fti if-37Q, gnn/12,874 ,000
a Based on quote from Babcock & Wilcox, Inc., August 17, 1978
N.A. - Not applicable.
C-38
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TABLE C-26. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, FIELD-
ERECTED, WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL
GAS WITH A THERMAL INPUT OF 117.2 MW
(400 x 106 Btu/h; 750 psig/750°F design)
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.14 % of total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
a Included with replacement parts.
N.A. - Not applicable.
$ 473.800
136r90Q
128.200
a
150,000
110,000
N.A.
N.A.
5,600
5,781,600/3,758,800
N.A.
16.000
S 6.802.100/4,778.500
142.100
231.100
373 .200
N.A.
i nn
1.184.100
170. inn/119. 5QQ
$ lrB21. 300/1. 770. 700
$ a
C-39
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TABLE C-27. ESTIMATED CAPITAL COSTS OF A DUAL-FUEL, FIELD-
ERECTED WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL
GAS WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/h; 900 psig/750°F design)
CAPITAL COSTS
DATE OF ESTIMATE June 30. 1978 (FOR COSTS INDEXING)
EQUIPMENT COSTa
Boiler (with fans & ducts) S 4r419.0QQ
Stack 900,000
Instrumentation 4flgfnnn
Pulverizers N.A.
Feeders _ N.A.
Crushers _ N.A.
Deaerators 85.000
Heaters _ N.A.
Boiler feed pumps 195,000
Condensate systems _ 35.000
Water treating system 90.000
Chemical feed _ 4.000
Compressed air system _ 30 ,000
Coal handling system _ N.A.
Ash disposal system _ N.A.
Thawing equipment _ N.A.
Fuel-oil system 325,000
Total Equipment Cost $ 6.572,000
INSTALLATION COST, DIRECT
Boiler (including founda-
tions and steel) $ 2. 455. OOP
Stack Incl. w/equip.
Instrumentation 128 .000
Pulverizers _ Tq.a .
Feeders _ N.A.
Crushers _ N.A.
Deaerators _ 19f OOP
Heaters _ N.A.
Boiler feed pumps _ 25,000
Condensate system _ 16,000
Water treating system _ 28 , QQQ
Chemical feed _ 2rQQQ
Coal handling system
Ash disposal system _ N.A.
Thawing equipment _ TJ.A.
Fuel-oil system I65f onn
N.A. - Not applicable.
C-40
-------
TABLE C-27. (continued)
INSTALLATION COSTS, DIRECT (cont.)
Foundations and supports
Ductwork (not incl. w/boiler)
Piping
Insulation
Painting
Electrical
Buildings
Total installation cost
TOTAL DIRECT COSTS
(equipment + installation)
INSTALLATION COSTS, INDIRECT
Engineering
(10% of direct costs)
Construction and field expense
(10% of direct costs)
Construction fees
(10% of direct costs)
Start-up (2% of direct costs)
Performance tests (minimum $2000)
TOTAL INDIRECT COSTS
Contingencies
(20% of direct and indirect costs)
Total Turnkey Costs
(direct+indirect+contingencies)
Land
Working capital (25% of total direct
operating costs)
GRAND TOTAL
(turnkey+land+working capital)
484,000
N.A.
279,000
165.000
22.000
520.000
930.000
nnn
$11.810,000
$ 1,181,000
1.181.000
1.181.000
236,200
16,000
$ 3.795.200
$ 3.121.000
18.726.200
2.000
2.881.200/1.995.900
$21,609,400/20,724,100
Based on quote from Babcock & Wilcox, Inc., August 17, 1978
N.A. - Not applicable.
C-41
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TABLE C-28. ESTIMATED ANNUALIZED COSTS OF A DUAL-FUEL, FIELD-
ERECTED, WATER-TUBE BOILER FIRING DISTILLATE OIL/NATURAL
GAS WITH A THERMAL INPUT OF 205.1 MW
(700 x 106 Btu/h; 900 psig/750°F design)
DIRECT COST
Direct labor
Supervision
Maintenance labor
Maintenance materials
Replacement parts
Electricity
Steam
Cooling water
Process water
Fuel
Bottom ash disposal
Chemicals
Total direct cost
OVERHEAD
Payroll (30% of direct labor
Plant (26% of labor, parts & maint.)
Total overhead costs
BY-PRODUCT CREDITS
CAPITAL CHARGES
G & A, taxes & insurance
(4% of total turnkey costs)
Capital recovery factor
(10.14 * °f total turnkey costs)
Interest on working capital
(10% of working capital)
Total capital charges
TOTAL ANNUALIZED COSTS
605.400
136.900
224.300
225.000
180.600
N.A.
N.A.
9.700
10.117.800/6.576.600
N.A.
25.000
Sll.524.700/7.983.500
181.600
309.800
./inn
M.A.
nnn
1.898 .800
288,100/199.600
$ 2.935.900/2,847.400
S14. 952 r 000/11. 322. 300
a Included with replacement parts
N.A. - Not applicable.
C-42
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