EPA
TVA
United States
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Research Triangle Park NC 27711
EPA-600/7-79-210
August 1979
Tennessee Valley
Authority
Office of Power
Ertission Control
Development Projects
Muscle Shoals AL 35660
ECDP B-3
Shawnee
Scrubbing Computerized
Design/Cost-estimate
Model Users Manual
Interagency
Energy/Environment
R&D Program Report
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded under the 17-agency Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the transport of energy-related pollutants and their health and ecological
effects; assessments of, and development of, control technologies for energy
systems; and integrated assessments of a wide range of energy-related environ-
mental issues.
EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for publication. Approval does not signify that the contents necessarily reflect
the views and policies of the Government, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/7-79-210
ECDP B-3
August 1979
Shawnee Lime/Limestone Scrubbing
Computerized Design/Cost-estimate
Model Users Manual
by
C. D. Stephenson and R. L Torstrick
TVA, Office of Power
Emission Control Development Projects
Muscle Shoals, Alabama 35660
EPA-IAG-D8-E72I-BL
Program Element No. INE624A
EPA Project Officer: John E. Williams
Industrial Environmental Research Laboratory
Office of Environmental Engineering and Technology
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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DISCLAIMER
The Tennessee Valley Authority makes no representation or warranty of
any kind, including, but not limited to, representation or warranties,
expressed or implied, or merchantability, fitness for use or purpose,
accuracy or completeness of processes, procedures, designs, definitions,
instructions, information, or functioning of this model and related material;
nor does TVA assume any liability, responsibility, or obligation arising from
the use of the model or related materials.
ii
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ABSTRACT
This manual provides a general description of the Shawnee lime-limestone
scrubbing computerized design - cost-estimate model and the detailed proce-
dures for using it. All inputs and outputs are described along with the
options available. The model is based on Shawnee Test Facility scrubbing
data and includes a combination of material balance models provided to the
Tennessee Valley Authority (TVA) by Bechtel National, Incorporated, and
capital investment - revenue requirement models developed by TVA. The model
provides an estimate of total capital investment, first year operating revenue
requirements, and lifetime revenue requirements for a lime or limestone
scrubbing facility. Also provided are a material balance, equipment list,
and a breakdown of costs by processing areas. The primary uses of the model
should be for projecting comparative economics of lime or limestone flue gas
desulfurization processes (on the same basis as the model) or in the evalua-
tion of system alternatives prior to the development of a detailed design.
The model is not intended for use in projecting the final design of a system.
iii
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CONTENTS
Abstract ill
Figures v
Tables vi
Introduction 1
General Information 3
Current Scope 3
Future Development 3
Availability 4
Model Description 5
Input 5
Output 5
Options 5
Print Options '. 7
Particulate Collection Device Options 10
Particulate Removal Options . . 10
S02 Removal Options 12
Operating Parameter Calculation 13
Lime or Limestone Scrubbing Option 14
Redundancy Options 18
Sludge Disposal Option 18
Pond Design Option 27
Pond Liner Option 30
Pond Capacity Option 30
Operating Profile Option 32
Usage of the Model 35
References 46
Appendix A: Process Flowsheets and Layouts 47
Appendix B: Detailed Descriptions of Model Input Variables 53
Appendix C: Base Case Input and Printout 70
iv
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FIGURES
Number
1 Pond dike construction details 28
2 Operating profile assumed for IOPSCH =1 33
3 Operating profile assumed for IOPSCH = 2 based on Federal
Energy Regulatory Commission 1969-1973 data 34
4 Conceptual map of the model investment program 40
A-l Limestone scrubbing process utilizing TCA absorber 48
A-2 Lime handling and preparation area for lime scrubbing option . 49
A-3 Plan and elevation for limestone scrubbing area 50
A-4 Waste disposal options 1 and 2 51
A-5 Waste disposal options 3 and 4 52
v
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TABLES
Number
1 Variable Ranges 6
2 Sample Short-Form Printout 8
3 Mechanical Collector Cost Illustration 11
4 Lime Scrubbing Output Listing 15
5 Lime Option Inputs 16
6 Lime Redundancy . 19
7 Example Equipment List for Sludge Option 2 22
8 Example Equipment List for Sludge Option 3 23
9 Example Equipment List for Sludge Option 4 24
10 Sample First-Year Revenue Requirements for Sludge Fixation
Alternative (Sludge Option 4) 25
11 Sample Lifetime Revenue Requirements for Sludge Fixation
Alternative (Sludge Option 4) 26
12 Fixed Pond Depth Example 29
13 Synthetic Pond Liner Example 31
14 Sample Output Using the Detailed Cost Estimates Operating
Profile 36
15 Sample Output Using a User-Supplied Operating Profile .... 37
16 Linkage-Editor Control Cards for the Shawnee Lime-Limestone
Computer Program 38
17 Sample Procedure for Executing the Model in Batch Modes ... 42
18 Sample Batch Run to Execute the Model Using a Procedure
File 43
19 Sample Procedure for Executing the Model Interactively ... 44
B-l Model Inputs - FORTRAN Variable Names 54
B-2 Model Input Variable Definitions 55
B-3 Limestone Fineness of Grind Index Factor 64
B-4 Indirect Investment and Allowance Cost Factors 65
B-5 Interest During Construction 66
B-6 Annual Capital Charges for Power Industry Financing 67
B-7 Maintenance Rate Guideline 68
B-8 Cost Indexes and Projections 69
C-l Base Case Input Data Set 71
C-2 Base Case Printout 72
vi
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INTRODUCTION
Since 1968 the U.S. Environmental Protection Agency (EPA) has conducted
a flue gas desulfurization (FGD) test facility at the Tennessee Valley
Authority (TVA) coal-fired Shawnee Steam Plant near Paducah, Kentucky. TVA
is the constructor and operator and Bechtel National, Incorporated, is the
major contractor. The test facility originally consisted of three prototype-
size scrubber units, each capable of processing about 30,000 aftVmin (10 MW
equivalent) of flue gas. One unit, a marble-bed absorber, was shut down in
1973 and converted to a cocurrent scrubber in 1978. The other two units, a
mobile-bed absorber and a venturi spray tower, have been operated under a
variety of conditions since 1972.
Bechtel and TVA have jointly developed a computer model capable of
projecting comparative capital investment and annual lifetime revenue require-
ments for lime and limestone FGD scrubbing systems based on the Shawnee
results. The model provides a simplified, consistent method for obtaining
comparative projections on a common design and cost basis. It is not the
primary purpose of the model to calculate the economics of an individual
system to a high degree of accuracy, but there is sufficient detail to allow
projections of preliminary conceptual design and costs for various lime or
limestone scrubbing case variations. The model permits the estimation of the
relative economics of these systems for variations in process design alterna-
tives (such as limestone versus lime scrubbing, or alternative sludge disposal
methods) or variations in the values of independent design criteria [such as
scrubber gas velocity, liquid to gas (L/G) ratio, alkali stoichiometry,
slurry residence time, reheat temperature, and sludge disposal method].
The development of the Shawnee computer economics model began in 1975,
with the responsibility shared by Bechtel and TVA. Bechtel's major responsi-
bility was developing models for calculating the overall material balance
flow rates and stream compositions. TVA was responsible for determining the
sizes of the required equipment, accumulating cost data for the major equip-
ment items, and developing both a model for calculating equipment costs
versus capacities and a model for projecting overall capital investment costs.
TVA then developed procedures to use the output of these models in an
existing TVA model that projects annual and lifetime revenue requirements.
The model should be useful to utility companies as well as architectural
and engineering contractors who are involved in the selection and design of
FGD facilities. It is intended to assist in the evaluation of system alter-
natives leading to the development of a detailed design rather than to
project a final detailed design. It should also be useful for evaluating
the potential effects of various process variables on economics as a guide
for planning research and development activities. Although the model has
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not been validated for comparing projected lime or limestone scrubber
economics with the economics of alternate processes, these comparisons
should be valid if the assumptions for the alternate systems are equivalent
to the model assumptions for lime or limestone systems.
The model has already been used for several applications other than
those for which it was specifically developed. Some examples are simulated
industrial and utility boiler FGD applications, smelter FGD applications,
partial scrubbing applications, plant fuel optimization studies, and compari-
son of coal-cleaning economics with total scrubbing. Probably the most
important use to date has been support work for both EPA and the National
Economic Research Associates assessment of nationwide effect of new-source
performance standards (NSPS) revisions on the electric utility industry.
This manual provides the information and defines the procedures
necessary to use the Shawnee lime and limestone computer model. It does not
provide the concepts and background information basic to the model develop-
ment. Presentations related to the model have been given at EPA industry
briefings (1, 2) and an FGD symposium (3). The publications associated with
these presentations discuss the model in general, describe the process and
program options, and show sample results. Copies of these publications
should be used in conjunction with the manual. Process flowsheets and
diagrams are included in Appendix A to provide the user with the assumed
equipment layout.
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GENERAL INFORMATION
CURRENT SCOPE
The present model projects a complete conceptual design package for
either a lime or limestone scrubbing system. It is designed for a wide
range of options that are applicable to new coal-fired power units. Currently
a mobile-bed (TCA) scrubber is assumed and four separate sludge disposal
options are provided. Equipment size and layout configurations are based on
units that range in size from 100 to 1300 MW and for coal sulfur contents
that range from 2% to 5%. Because extreme variations in equipment sizes and
layout configurations can result from factors other than unit size and coal
sulfur content, ranges for some of these variables have been defined as
follows:
Scrubber gas velocity 8-12.5 ft/sec
Liquor recirculation rate 25-75 gal/kft^
Slurry residence time in 2-25 minutes
hold tank
Number of scrubbing trains 1-10
S02 concentration 1500-4000 ppm
The validity of results for operating conditions outside the ranges shown
above has not been determined. However, results for intermediate-sized
plants operating outside these boundaries may still be valid in some cases.
Several model runs may be required to fully analyze the combined effects
of individual input factors, especially if the specified ranges are exceeded.
The effect of variations in inputs (such as scrubber gas velocity, degree of
S02 removal, reheat temperature, alkali stoichiometry, or L/G ratio) on
process design and economics can be determined individually by varying only
one factor per model run, or the cumulative effect can be determined by
varying several factors simultaneously.
FUTURE DEVELOPMENT
Further modifications to the model are expected to be made as test data
from Shawnee become available. Bechtel and TVA are incorporating the results
of the venturi spray tower tests at Shawnee into a design and cost model for
that option. Other options which are being considered for incorporation as
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sufficient data become available include (1) series scrubbers/high-alkali
utilization systems, (2) forced-oxidation systems, (3) alternate scrubber
configuration systems, and (4) systems with scrubber-loop additives such as
magnesium oxide or adipic acid.
AVAILABILITY
The model is available to the public through TVA. Upon receipt of a
written request, TVA provides a copy of the model suitable for loading onto
an online computer system, along with FORTRAN program listings and the documen-
tation required to execute the model.
TVA is presently loading the Shawnee Computer Model on the Control Data
Corporation (CDC) CYBERNET system which is a nationwide, commercial data
processing network. When this is complete, the program can be made available
to the public after the appropriate authorization for use is cleared by TVA
and billing arrangements are made between the user and CDC. Updated versions
of the program will be maintained on this system and made available in the
same manner as described above. Inputs are subject to change as the model
is expanded.
Requests for copies of the computer model or additional information
should be made to the authors at the following address: Emission Control
Development Projects, Tennessee Valley Authority, Muscle Shoals, Alabama
35660, telephone number (205) 383-4631, extension 2516.
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MODEL DESCRIPTION
INPUT
The overall model requires a minimum of 14 lines of input. Additional
input is required when a variable operating profile is chosen instead of
the built-in profiles. A detailed FORTRAN variable list of the model input
is shown in Table B-l of Appendix B. The variables are defined in Table B-2
of Appendix B. Ranges for key variables to aid in establishing input data
to the model are shown in Table 1.
As new options are incorporated, the required inputs are subject to
change. When this occurs, the list of variables and the associated defini-
tions will be updated and made available as necessary.
OUTPUT
The outputs of the Shawnee lime-limestone computer model provide a
complete conceptual design package for lime or limestone scrubbing, consisting
of (1) a detailed material balance including properties of the major streams;
(2) a detailed water balance itemizing water availability and water required;
(3) specifications of the scrubber system design; (4) a display of overall
pond design and costs; (5) specifications and costs of the process equipment
by major processing area; (6) a detailed breakdown of the projected capital
investment requirements; (7) an itemized breakdown of the projected revenue
requirements by component for the first year of operation of the system;
(8) a lifetime revenue requirement analysis showing projected costs for each
year of operation of the plant as well as lifetime cumulative and discounted
costs and equivalent unit revenue requirements; and (9) a particulate removal
cost table which lists operating conditions and itemizes installed and
operating costs for a cold electrostatic precipitator (ESP), a hot ESP, a
baghouse, and a wet scrubber. The output for the upstream particulate
removal options has not yet been integrated into the lifetime economic
projections. These outputs are illustrated in the base case printout shown
in Appendix C.
OPTIONS
A detailed list of all of the model inputs is included in Tables B-l and
B-2 of Appendix B. These tables include a number of options for selecting
process design and controlling model output. These options are listed below:
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TABLE 1. VARIABLE RANGES
Item
Description
Power plant
Fuel sulfur content
Scrubber gas velocity
Liquor recirculation rate
Effluent hold tank residence
time
Number of scrubbing trains
Number of spare scrubbing
trains
Sulfur to overhead as S02 gas
Ash to overhead as fly ash
System pressure drop
Investment year
Revenue requirement year
New, 100-1300 MW
2-5%
8-12.5 ft/sec
25-75 gal/kft3
2-25 minutes
1-10
0-10
0-100%
0-100%
Should not exceed 3 inches
per TCA stage
Midpoint of project
expenditure schedule
First year of operation of
plant
Note: The variable ranges were established for model
development purposes. Values beyond these ranges are not
necessarily invalid but the margin for error is potentially
greater when these ranges are exceeded.
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• Print options
• Particulate collection device options
• Particulate removal specification options
• S02 removal specification options
• Operating parameter calculation options
• Lime or limestone scrubbing option
• Redundancy options
• Sludge disposal options
• Pond design options
• Pond liner options
• Pond capacity option
• Operating profile options
Some examples of the various options are shown on the pages that follow. For
illustration purposes the appropriate data line is shown and the particular
option code is indicated. An explanation of each option and sample output
resulting from its usage is provided where necessary. Values for all vari-
ables must be entered for each case even though a variable value is being
calculated by the model as a result of a user-specified option. When this
condition occurs, the calculated value will override the input value. A
value of zero will be appropriate for many variables but the value cannot be
omitted. Spaces cannot be used to take the place of variables which have a
value equal to zero.
Some user-specified input values result in the use of default values of
other variables for consistency in the calculations. For the options that
allow defaults, the option code that must be input and the default values that
are assumed are described.
Print Options
Line No. Input Data
1 1, 1, 1, 1, 1
2 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1
3 1, 1, 1
The options on the first three lines of the input data control printed
output from the model. These options are described in the input definition
list in Appendix B, Table B-2. The only print option requiring further
explanation is the first option on line 3. This option controls the printout
of the investment and revenue requirement sections. The short form printout
is shown in Table 2 and may be compared with the long printout of the base
case example in Appendix C.
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TABLE 2. SAMPLE SHORT-FORM PRINTOUT
LIMESTONE SLURRY PROCESS — BASIS: 500 MW UNIT, 1980 STARTUP
BASE CASE EXAMPLE 300 ™
PROJECTED CAPITAL INVESTMENT REQUIREMENTS
INVESTMENT* THOUSANDS Of 1979 DOLLARS
SUBTOTAL DIRECT INVESTMENT
TOTAL CAPITAL INVESTMENT
RAW MATERIAL
HANDLING AND
PREPARATION
3969.
6B26.
SCRUBBING
19725.
33884,
WASTE
DISPOSAL
7826.
14664.
CASE 002
TOTAL
31520.
55374.
oo
(continued)
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TABLE 2 (continued)
PROJECTED FIRST YEAR REVENUE REQUIREMENTS
ANNUAL OPERATION
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Particulate Collection Device Options
Line No. Input Data
2, 500, 9000, 10500, 33, 300, 2, 175, 470, 751
I
XESP
The particulate collection device (4) option is controlled by the XESP code.
The value of XESP may be 0, 1, or 2. A zero value is used if a particulate
removal device is not desired. A value of 1 is used if a mechanical collector
(33% efficient) is selected. If option 1 is chosen, the code for upstream
removal (ASHUPS, see Table B-2) should have an input value of 33 (% removal).
If an XESP value of 2 is selected, a separate particulate removal cost model
projects the investment and operating costs for particulate removal and the
results are listed after the investment printout. The percentage particulate
removal required for this option is specified by the ASHUPS variable. The
investment and revenue requirements for the particulate removal device are
printed separately. They are not included with the first year and lifetime
FGD costs.
Sample outputs corresponding to XESP values are as follows:
XESP = 0 No illustration required
XESP = 1 Table 3 shows a printout of equipment lists itemized for
mechanical collector costs
XESP = 2 Refer to the printout shown in the base case example in
Appendix C
Particulate Removal Options
Line No. Input Data
6 57.56 4.14 7.00 1.29 3.12 .1 16.0 10.74 95 80 1 98.5 50
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TABLE 3. MECHANICAL COLLECTOR COST ILLUSTRATION
SCRUBBING
INCLUDING 4 OPERATING AND 1 SPARE SCRUBBING TRAINS
ITEM
DESCRIPTION
NO, MATERIAL LABOR
MECHANICAL ASH COLLECTOR
F.D. FANS
»
SHELL
RUBBER LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES
GRIDS
SPHERES
TOTAL TCA SCRJBBER COSTS
REHEATERS
SOOTBLQWERS
EFFLUENT HOLD TANK
EFFLUENT HOLD TANK AGITATOR
COOLING SPRAY PUMPS
ABSORBER RECYCLE PUMP$
MAKEUP WATER PUMPS
TOTAL EQUIPMENT COST
33x PARTICULATE REMOVAL
20.0IN H20/ WITH 1613.
HP MOTOR AND DRIVi
231287.GAL* 3*.OFT DIA/
34.OFT HT, FLAKEGUSS-
LINED CS
63. HP
1274.GPM 100FT HEAD/
59,HP* 4 OPERATING
AND 6 SPARE
8761.GPM/ 100FT HEAD/
406.HP/ 8 OPERATING
AND 7 SPARE
2549.GPM/ 200.FT HEAD/
215,HP/ 1 OPERATING
AND 1 SPARE
1
5
5
5
60
5
5
10
424515.
1873839.
812283.
1199962.
368717.
313679.
471794.
175683.
3342115.
1046932.
404468.
181225.
345851.
117520.
78325.
113586,
278548.
43290.
298505.
354208.
127622.
17392.
15 636657.
19790.
51730,
1826.
8414911. 1)64980,
11
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the upstream ash collector and the TCA scrubber as both percent removal and
Ib/MBtu. Sample output for an IASH option equal to 1 is shown in Appendix C;
printouts for the other options are very similar. A summary of the options
is shown below.
IASH = 0 ASHUPS default value = 33% removal
ASHSCR default value = 99.2% removal
IASH = 1 ASHUPS input value as percent removal
ASHSCR input value as percent removal
(Appendix C shows sample printout using IASH = 1)
IASH = 2 ASHUPS input value as Ib/MBtu to scrubber
ASHSCR input value as Ib/MBtu from scrubber
IASH = 3 ASHUPS input value as percent removal
ASHSCR default value equals 75% removal
SO? Removal Options
Line No. Input Data
7 55 0 0 12.5 25 1 85 12 1 0.0 1 0 0 2.85 500
4 \*
IS02 XS02
The model has four methods for specifying SC>2 outlet concentrations or
removal. The controlling variables are the IS02 option and the actual value
to be removed, XS02. If IS02 = 1, XS02 is input as percent S02 removed. If
IS02 = 2, XS02 is input as the scrubber outlet emission expressed as pounds
S02/MBtu. If IS02 = 3, XS02 is input as ppm S02 in the scrubber outlet
stream. A fourth method for specifying S02 removal (S02 removal calculated) is
described in the operating parameter options section. Sample output for
IS02 option 1 is shown in Appendix C. Regardless of the option chosen, the
equivalent S02 removal in all three units is displayed. The input value is
indicated as having been specified and the other values are indicated as
having been calculated. A summary of the input options is shown below.
IS02 = 1 XS02 is input as percent removal
IS02 = 2 XS02 is input as pounds S02/MBtu at the scrubber outlet
IS02 = 3 XS02 is input as ppm S02 in the scrubber outlet stream
The S02 removal options are long-term average removals and are not to be
construed as 3-hour or 24-hour averages. At this point an important design
consideration should be emphasized. When sizing an FGD facility the raw
material handling, feed preparation, and scrubbing areas should be based on
the maximum sulfur content of the coal rather than the long-term average.
The waste disposal pond, however, should be sized on the long-term average
sulfur content. The user may accomplish this by inputting the weight percent
12
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sulfur as the maximum expected and then entering the pond capacity factor
(discussed later) to adjust the total amount of sludge generated back to the
equivalent long-term average amount.
Operating Parameter Calculation Option
Line No. Input Data
XLG XS02 XSR SRIN
t t t t
7 55 0 0 12.5 25 1 85 12 1 0.0 1 0 0 2.85 500
8 15 40 .2 40 30 65 1.2 7.0 0 12 20
4-
PHLIME
Four options are available in the model to allow either user input or
model calculation of the major operating parameters which include L/G
(expressed as scrubber liquor recirculation rate in gallons of liquor recircu-
lated per 1000 actual cubic feet of gas at the scrubber outlet), stoichiometry
(expressed as moles CaC03 or CaO added per mole of S02 absorbed), and S02
removal. The options differ slightly for the limestone scrubbing system and
the lime scrubbing system described below; therefore the description is
divided into two sections. First, for limestone scrubbing (XIALK =1) the
variables are XSR, XLG, SRIN, and XS02. XSR is the controlling option and
takes values from 0 to 3. If XSR has an input value of 0, the L/G (XLG),
stoichiometry (SRIN), and SC>2 removal (XS02) are all user input values. If
XSR is equal to 1, XLG and XS02 are input and the model calculates stoichio-
metry. When XSR is equal to 2, SRIN and XS02 are input and the model calcu-
lates XLG. If XSR is equal to 3, both XLG and SRIN are input and the model
calculates XS02. A summary of the various options for a limestone scrubbing
system is shown below.
XSR = 0 XLG is input
SRIN is input
XS02 is input
XSR = 1 XLG is input
SRIN is calculated
XS02 is input
(XSR = 1 is shown in the base case printout in Appendix C)
XSR = 2 XLG is calculated
SRIN is input
XS02 is input
XSR = 3 XLG is input
SRIN is input
XS02 is calculated
13
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Similar options are available in the lime scrubbing option (XIALK = 2)
except that the variable PHLIME replaces SRIN. The model does not calculate
the lime stoichiometry but does calculate the pH of the recirculation liquor.
Values for SRIN and PHLIME must be entered even when values for these vari-
ables are being calculated within the program (zero is typically input if
this is the case). When inputting SRIN, values of 1.01 or greater should be
used. A summary of the options for a lime scrubbing system is shown below.
XSR = 0 XLG is input
PHLIME is input
XS02 is input
XSR = 1 XLG is input
XS02 is input
PHLIME is calculated
XSR = 2 PHLIME is input
XS02 is input
XLG is calculated
XSR = 3 XLG is input
SRIN is input
XS02 is calculated
The output listing for the lime scrubbing option is similar to that for
the limestone option except that the stoichiometry is printed out for CaO
instead of CaC03, as shown in Table 4.
Lime or Limestone Scrubbing Option
Line No. Input Data
7 55 0 0 12.5 25 1 85 12 1 0.0 1 0 0 2.85 500
4-
XIALK
The model allows the choice of either lime or limestone absorbent. The
input variable controlling this option is XIALK. If XIALK = 1, limestone
slurry is selected as the scrubbing medium. If XIALK = 2, lime slurry is
selected. The base case printout in Appendix C shows an example of the
limestone scrubbing option. Table 5 shows how the lime option output differs
from limestone in both the input display and the raw material preparation
area equipment list.
14
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TABLE A. LIME SCRUBBING OUTPUT LISTING
SCRUBBER SYSTEM
TOTAL NUMBER OF SCRUBBING TRAINS < OPERAT ING+REDUNQANT)
S02 REMOVAL * 85.0 PERCENT
PARTICIPATE REMOVAL IN SCRUBBER SYSTEM « 50,0 PERCENT
TCA PRESSURE DROP ACROSS 3 BEDS « 8.6 IN, H20
TOTAL SYSTEM PRESSURE DROP = H.8 IN. HZO
OVERRIDE TOTAL SYSTEM PRESSURE DROP • 20,0 IN, H20
SPECIFIED LIQUID-TO-GAS-RATIO • 55, GAL/IOOO ACF
LIME ADDITION » 0.2139E+05 LB/HR DRY LIME
CALCULATED LIME STOICHIOMETRY
SOLUBLE CAO FROM FLY ASH
TOTAL SOLUBLE MGO
TOTAL STOICHIOMETRY
1,10 MOLE CAD ADDED AS LIME
PER MOLE S02 ABSORBED
0.0 MOLE PER MOLE S02 ABSORBED
0.0 MQLE PER MOLE S02 ABSORBED
1.10 MOLE SOLUBLE (CA+MG)
PER MOLE S02 ABSORBED
SCRUBBER INLET LIQUOR PH » 6.99
MAKE UP HATER • 579, GPM
CROSS-SECTIONAL AREA PER SCRUBBER •
SYSTEM SLUDGE DISCHARGE
424. SQ FT
SPECIES
CAS03 ,1/2 M20
CAS04 ,2H20
CAC03
T M
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TABLE 5. LIME OPTION INPUTS
BASE CASE EXAMPLE 900 MW CASE 00*
*** INPUTS ***
BOILER CHARACTERISTICS
MEGAWATTS • 300.
BOILER HEAT RATE " 9000. BTU/KWH
EXCESS AIR • 33. PERCENT, INCLUDING LEAKAGE
HOT CAS TEMPERATURE • 300. DEC F
COAL ANALYSIS/ WT % AS FIRED t
C H 0 N S CL ASH H20
97,56 4.L* 7.00 1.29 3.12 0.10 16.00 10.7*
SULFUR OVERHEAD • 95.0 PERCENT
ASH OVERHEAD • 80,0 PERCENT
HEATING VALUE OP COAL • 10900. BTU/LB
EFFICIENCY, EMISSION/
FLYA5H REMOVAL % LBS/M BTU
UPSTREAM OF SCRUBBER 98.9 0.16
WITHIN SCRUBBER 50.0 0.09
ALKALI
LIME I
CAO " 97.15 WT X DRY BASIS
SOLUBLE MGO • o.o
INERTS • 2.85
MOISTURE CONTENT t 5.00 LB H20/100 LBS DRY LIME
FLY ASH I
SOLUBLE CAO * 0.0 WT %
SOLUBLE MGO • 0.0
INERTS • 100.00
RAW MATERIAL HANDLING AREA
NUMBER OF RlDUNDANT ALKALI PREPARATION UNITS > 1
(continued)
16
-------
TABLE 5 (continued)
RAW MATERIAL HANDLING AND PREPARATION
INCLUDING 2 OPERATING AND 1 SPARE PREPARATION UNITS
ITEM
DESCRIPTION
NO, MATERIAL LABOR
CONVEYOR FROM CALCINATION
PLANT
STORAGE SILO ELEVATOR
CONCRETE STORAGE SILO
STORAGE SILO HOPPER BOTTOM
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOR
FEED BIN ELEVATOR
FEED BELT CONVEYOR
FEED CONVEYOR TRIPPER
FEED BIN
BIN VIBRATING FEEDER
BIN NEIGH FEEDER
SLAKER
SLAKER PRODUCT TANK
SLAKER PRODUCT TANK AGITATOR
LIMi SYSTEM DUST COLLECTORS
SLAKER PRODUCT TANK SLURRY
PUMPS
SLURRY FEED TANK
SLURRY FEED TANK AGITATO*
SLURRY FEED TANK PUMPS
TOTAL EQUIPMENT COST
1JOOFT HORIZONTAL* 30HP
123, FT HIGH, 30 HP
128311, FT3, 47, 8FT DIA /
71.6FT STRAIGHT SIDE
STORAGE HT
60 DEGREE* CS
3.5HP
123, FT HORIZONTAL/ 3HP
SOFT HIGH/ 50HP
SOFT HORIZONTAL* SHP
30FPM* 1HP
10FT DIA/ UFT STRAIGHT
SIDE HT* COVERED/ CS
3, SHP
12FT, 12IN SCREW, 1HP
5.TPH, 10, HP
10HP
POLYPROPYLENE BAG TYPE
2200 CFM*7.SHP
125, GPM, 60FT HEAD/
4, HP* 2 OPERATING
AND i SPARES
133293.
132390. GAL/ 28.2FT
28.2FT HTj FLAKEGLASS-
LINEO CS
48, HP
63. GPM* 60 FT HEAD/
2, HP* It OPERATING AND
4 SPARE
1
1
1
1
1
1
1
1
3
3
3
3
3
3
5
3
1
1
8
104830.
72886.
11292.
12134.
17279.
49615.
12943.
13482.
8089.
13752.
17797.
169543.
18201.
21437.
26290.
10863.
22023.
47310.
20654.
2128,
174769,
33619,
1866,
4236,
995.
2114.
2488,
14925.
4851.
1866.
15641.
28358.
1119.
62189.
2279.
47199,
3492.
3980.
823718. 454255.
17
-------
Redundancy Options
Line No. Input Data
9 2 3 4 5 35 .0000001 30 10 1.35 141.1
NSPREP NORTRAN NOREDN
Options for redundancy in the model apply to the raw material prepara-
tion area and the scrubbing area. The controlling input variables are NSPREP,
NOTRAN, and NOREDN. NSPREP specifies the number of spare preparation units
(ball mills or slakers) and may be given any value, 0, 1, 2, 3, .... NOTRAN
specifies the number of operating scrubbers. A program override automati-
cally changes the value of NOTRAN if the specified number requires a scrubber
larger than the maximum available size. NOREDN indicates the number of spare
scrubber trains. The base case equipment list in Appendix C shows the output
for a limestone scrubbing system designed with redundancy in both ball mills
and scrubbers. For comparison, Table 6 shows similar output for a lime
system with redundancy in both the preparation area (slakers) and scrubber
area.
Sludge Disposal Option
Line No . Input Data
10 1 0 500 3500 25 25 5280 1 12 2.5
\^
ISLUDG SDFEE
Four sludge disposal options are provided in the model. The input variables
are ISLUDG and SDFEE. ISLUDG may take the values 1, 2, 3, or 4. SDFEE
specifies the cost per dry ton to fix or treat the sludge. When ISLUDG = 1
the model assumes an onsite ponding sludge disposal system. If ISLUDG = 2
a disposal system consisting of a gravity thickener and an onsite pond is
assumed. For ISLUDG = 3 the disposal system includes costs for a gravity
thickener and fixation. Total fixation and disposal costs are input as $/ton
of dry sludge to be fixed. Option 4 is similar to option 3 except that a
rotary vacuum filter is added to the system downstream from the thickener
prior to fixation. The fixation fee is applied in the same manner as for
ISLUDG = 3; however, in this case the material being fixed is the filter cake.
Ordinarily SDFEE will be zero for options 1 and 2 but an additional fee for
fixation of the sludge in the pond can be included by setting SDFEE equal to
the desired fee value. The base case printout in Appendix C is an example of
the onsite ponding option. Sample output for the other sludge disposal
options are shown in Tables 7-9. Year 1 and lifetime revenue requirements
corresponding to sludge disposal option 4 are shown in Tables 10 and 11. A
summary of the available sludge disposal options is given on page 27.
18
-------
TABLE 6. LIME REDUNDANCY
SCRUBBER SYSTEM VARIABLIS
NUMBER OF OPERATING SCRUBBING TRAINS • 4
NUMBER OF REDUNDANT SCRUBBING TRAINS » 1
MUMBER OF BEDS • 3
NUMBER OF GRIDS • 4
HEIGHT OF SPHERES PER BCD • 5.0 INCHES
LIQUID-TO-GAS RATIO » 35. GAL/IOOO ACF
SCRUBBER GAS VELOCITY • 12.5 FT/SEC
S02 REMOVAL • 85. PERCENT
STQICHIOMETRY RATIO TO BE CALCULATED
ENTRAPMENT LEVEL » 0.10 WT X
EHT RESIDENCE TIME « 12.0 MIN
S02 OXIDIZED IN SYSTEM • 30.0 PERCENT
SOLIDS IN RECIRCULATED SLURRY « 15,0 WT «
SOLIDS DISPOSAL SYSTEM
COST OF LAND • 3500.00 DOLLARS/ACRE
SOLIDS IN SYSTEM SLUDGE DISCHARGE • 40,0 WT X
MAXIMUM POND AREA • 500. ACRES
MAXIMUM EXCAVATION » 25.00 FT
DISTANCE TO POND « 5280. FT
POND LINED WITH 12,0 INCHES CLAY
STEAM REHEATER (IN-LINE)
SATURATED STEAM TEMPERATURE « 470, DEG F
HEAT OF VAPORIZATION OF STEAM » 751, BTU/LB
OUTLET FLUE GAS TEMPERATURE • 175, DEG F
SUPERFICIAL GAS VELOCITY (FACE VELOCITY) « 25,0 FT/SBC
(continued)
19
-------
TABLE 6 (continued)
RAW MATERIAL HANDLING AND PREPARATION
INCLUDIMG 2 OPERATING AND 1 SPARR PREPARATION UNITS
ITEM
DESCRIPTION
NO, MATERIAL LABOR
CONVEYOR FROM CALCINATION
PLANT
STORAGE SILO ELEVATOR
CONCRETE STORAGE SILO
STORAGE SILO HOPPER BOTTOM
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOR
FEED BIN ELEVATOR
FEED BELT CONVEYOR
FEED CONVEYOR TRIPPER
FEED BIN
BIN VIBRATING FEEDER
BIN WEIGH FEEDER
SLAKER
SLAKER PRODUCT TANK
SLAKER PRODUCT TANK AGITATOR
LIMI SYSTEM DUST COLLECTORS
SLAKER PRODUCT TANK SLURRY
PUMPS
SLURRY FEED TANK
SLURRY FEED TANK AGITATOR
SLURRY FEED TANK PUMPS
TOTAL EQUIPMENT COST
1500FT HORIZONTAL* 30HP
123,FT HIGH/ 50 HP
128311.FT3/47.8FT DIA /
71.6FT STRAIGHT SIDE
STORAGE HT
60 DEGREE* CS
3.5HP
U3iFT HORIZONTAL* 3HP
SOFT HIGH/ 30HP
SOFT HORIZONTAL/ 5HP
30FPM/ 1HP
10FT DIA/ 15FT STRAIGHT
SIDE HT/ COVERED/ CS
3.5HP
12FT/ 12IN SCREW/ 1HP
5,TPH/ lOtHP
10HP
POLYPROPYLENE BAG TYPE
2200 CFM/7.5HP
125,GPM/ 60FT HEAD/
4,HP/ 2 OPERATING
AND 1 SPARES
132390.GAL/ 28.2FT DIA/
28.2FT HT/ FLAKEOLASS-
LINED CS
48,HP
63.GPM/ 60 FT HEAD/
2,HP/ 4 OPERATING AND
4 SPARE
(continued)
20
193293,
46144.
1
1
1
1
1
1
1
1
3
3
3
3
3
3
5
3
1
1
8
104830.
72886.
11292.
12134.
17279.
49615.
12943.
13482.
8089.
13752.
17797.
169545.
18201.
21437.
26290.
10865.
22023.
47310.
20654.
2128.
174769,
33619.
1866,
4236.
995.
2114.
2488.
14925.
*85l.
1866.
15641.
28358.
1119.
62189.
Z279.
47199.
3492.
3980.
823718. 454255.
-------
TABLE 6 (continued)
SCRUBBING
INCLUDING 4 OPERATING AND 1 SPARB SCRUBBING TRAINS
ITEM
DESCRIPTION
NO, MATERIAL LABOR
F.O. PANS
SHELL
RUBBER LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES
GRIDS
SPHERES
TOTAL TCA SCRUBBER COSTS
REHIATERS
SOOT&LdWERS
EFFLUENT HOLD TASK
iFFLUENT HOLD TANK AGITATOR
COOLING SPRAY PUMPS
ABSORBER RECYCLE PJMPS
MAKIUP WATER PUMPS
TOTAL EQUIPMENT COST
20.0IN HZO' WITH 1615.
HP MOTOR AND DRIVE
1873839. 113386.
230676.GALi 3*.OFT DIA*
34.OFT HTj FLAKEGLASS-
LINED CS
63, HP
1271,GPM 100FT HEAD*
59,HP* 4 OPERATING
AND 6 SPARE
1738.GPM, 100FT HEAD, 15
405,HP* 8 OPERATING
AND 7 SPARE
2542.GPM* 200.FT HEAD* 2
214.HP* 1 OPERATING
AND 1 SPARE
5
5
60
5
5
10
810950.
11»7826.
167711.
312705.
470533,
175220.
3334943.
1044633.
404468.
1809Q7.
345122.
117460.
278051.
43199,
298505.
353585,
127353.
17336,
698180.
19759,
51682,
1823,
7979309. 1285116,
21
-------
TABLE 7. EXAMPLE EQUIPMENT LIST FOR SLUDGE OPTION 2
WASTE DISPOSAL
ITEM
DESCRIPTION
MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATOR
POND FEED SLURRY PUMPS
POND SUPERNATE PUMPS
THICKENER FEED PJMP
THICKENER
THICKENER OVERFLOW PUMPS
THICKENER OVERFLOW TANK
TOTAL EQUIPMENT COST
37760.GALj 17,OFT DIA,
34.0FT HT, FLAKGIASS-
LINED CS
36,HP
237.GPM* 130.FT HEAD
9,HP, Z OPERATING
AND 2 SPARE
561.GPM* 192.FT HEAD* 2
45,HP/ 1 OPERATING
AND 1 SPARE
760.GPM/ 60FT HEAD/ 2
21,HP/ 1 OPERATING
AND 1 SPARE
20872.SQ.FT.,163,FT DIA/ 1
8.9FT HT
500.GPM/ 73.0FT HEAD/ 2
16,HP/ 1 OPERATING
AND 1 SPARE
8256.GAL, 12.6FT DIA/ 1
8.9FT HT
1 U379. 31228.
Z1377.
8632.
13266.
366700.
618*..
1788.
1511.
3810.
796.
2887.
*01B7o,
570,
<»288.
653193.
22
-------
TABLE 8. EXAMPLE EQUIPMENT LIST FOR SLUDGE OPTION 3
WASTE DISPOSAL
ITEM
DESCRIPTION
NO, MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGJTATOR
THICKENER FEED PUMP
THICKENER
THICKENER OVERFLOW PUMPS
THICKENER OVERFLOW TANK
SLUDGE FIXATION FEED PUMP
S7760.GAL, 17,OFT DIA,
34.OFT HT, FLAKGIASS-
LINEO CS
36,HP
760.GPM, 60FT HEAD/
21,HP/ 1 OPERATING
AND 1 SPARE
20872.SO,FT,,163.FT DIA, 1
8.9FT HT
500.GPM, 75,OFT HEAD/ 2
16,HP> 1 OPERATING
AND 1 SPARE
8256.GAL,
8.9FT HT
12.6FT OIA,
237.GPM, 30FT HBAD,
7,HP* 1 OPERATING
AND 1 SPARE
6184.
1*379,
20467.
13266. 2687.
366700. 401870,
570,
1788. 4288.
10629. 1905,
TOTAL EQUIPMENT COST
633612, 444239.
23
-------
TABLE 9. EXAMPLE EQUIPMENT LIST FOR SLUDGE OPTION 4
WASTE DISPOSAL
ITEM
DESCRIPTION
NO, MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATOR
THICKENER FEED PJMP
THICKENER
THICKENER OVERFLOW PjMpj
THICKENER OVERFLOW TANK
FILTER FEED SLURRY PUMP
FILTER
FILTRATE PUMP (PER FILTER)
FILTRATi SURGE TANK
FILTRATE SURGE TANK PUMP
TOTAL EQUIPMENT COST
57760.GAL, 17,OFT DIA,
34.OFT HT, FLAKGLASS-
LINED CS
36,HP
745.GPM, 6QFT HEAD*
21,HP* 1 OPERATING
AND 1 SPARE
20448,SQ.FT.,161,FT DIA, 1
8.8FT HT
490.GPM* 75,OFT HEAD*
15,HP* 1 OPERATING
AND 1 SPARE
8088.GAL, 12.5FT DIA*
8.8FT HT
116.GPM, SOFT HIAO,
3,HP* 2 OPERATING
AND 1 SPARE
307,so FT FILTRATION
AREA
59,GPM, 20,OFT HEAD,
O.HP* 2 OPERATING
AND 2 SPARE
14579.
31228.
1952. GAL,
6.9FT HT
6.9FT DIA*
118.GPM, 85,OFT HEAD*
4,HP* 1 OPERATING
AND 1SPARE
1
2
1
2
1
3
2
4
1
2
20467.
13236.
561905.
6141.
1764,
10815.
193446,
6513.
713.
4144.
1511,
2866,
396238,
566.
*23l.
2216,
17846.
601.
1711,
382.
833724. 459416,
24
-------
TABLE 10. SAMPLE FIRST-YEAR REVENUE REQUIREMENTS FOR SLUDGE FIXATION ALTERNATIVE
(SLUDGE OPTION 4)
LIMESTONE SLURRY PROCESS — BASISl 500 MM UNIT, I960 STARTUP
PROJECTED REVENUE REQUIREMENTS - BASE CASE EXAMPLE 300 MM
CASE 007
DISPLAY SHEET FOR YEAR" 1
ANNUAL OPERATION KW-HR/KW • 4512
30.73 TONS PER HOUR DRY
TOTAL FIXED INVESTMENT 45720000
Q1BECI-C3SIS
BAW.MAIEBiAl
LIMESTONE 107.5 K TONS 8.00/TUN
LIME 0.0 K TONS 40.00/TUN
SUBTOTAL RAW MATERIAL
CONUEBSIQN-COSXS
OPERATING LABOR AND
SUPERVISION 32930.0 MAN-MR 12.00/MAN-HR
UTILITIES
STEAN 413440.0 K LB 1.70/K LB
PROCESS MATER 144220.0 K GAL 0.12/K GAL
ELECTRICITY 19015960.0 KWH 0.030/KWH
MAINTENANCE
LABOR AND MATERIAL
ANALYSES 2420.0 HR 17.00/HR
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
INOmCI.CDSIS
DEPRECIATION
COST OF CAPITAL AND TAXES, 17.20X OF UNDEPRECIATED INVESTMENT
INSURANCE t INTERIM REPLACEMENTS/ i.px OF TOTAL CAPITAL INVESTMENT
OVERHEAD
PLANT' 50, OX OF CONVERSION COSTS ItSS UTILITIES
ADMINISTRATIVE/ RESEARCH/ AND SERVICE/
10, OX Uf OPERATING LABOR AND SUPERVISION
SUBTOTAL INDIRECT COSTS
SUBTOTAL ANNUAL REVENUE REQUIREMENT
SLUDGE FIXATION COSTS ns7oo.o TONS IS.OO/TUN
T3TAL ANNUAL REVENUE REQUIREMENT
EOUIVALENT UNIT REVENUE REQUIREMENT/ MILLS/KWH
HEAT RATE 9000, BTU/KHH - H8AT VALUE OF CDAL 10500 BTU/LB
SLUDGE
TOTAL
ANNUAL
COSI**
839900
. 0
859900
395100
702900
17300
1170300
1626300
.... *1200
3955300
4815200
1463400
7861900
534900
1022300
39500
10954000
15769200
...2010300
...126*8200
7,91
CCAL RATE 966900 TONS/YR
-------
TABLE 11. SAMPLE LIFETIME REVENUE REQUIREMENTS FOR SLUDGE FIXATION ALTERNATIVE
(SLUDGE OPTION 4)
LIMESTONE SLURRY PROCESS — BASIS) 500 MM UNIT, 19|0 STARTUP
PROJECTED LIFETIME REVENUE REQUIREMENTS - BASE CASE EXAMPLE 500 MW
TOTAL CAPITAL JNVESTMENTi
CASE 007
41720000
ADJUSTED GRCSS
SULFUR BYPRODUCT ANNUAL REVENUE
REMOVED RATE, SLUDGE REQUIREMENT TOTAL NET ANNUAL CUMULATIVE
YEARS ANNUAL POWER UNIT POWER UNIT BY EQUIVALENT FIXATION FEE EXCLUDING ANNUAL INCREASE NET INCREASE
AFTER OPERA- HEAT FUEL POLLUTION TONS/YEAR I/TON SLUDGE SLUDGE IN TOTAL IN TOTAL
POWER TIQN, REQUIREMENT, CONSUMPTION, CONTROL FIXATION FIXATION REVJNUE REVENUE
UNIT KW-HR MILLION BTU TONS COAL PROCESS, DRY DRY COST/ COST, REQUIREMENT/ RlQUlREMENT,
START /KW /YEAR /YEAR TONS/YEAR SLUDGE SLUDGI I/YEAR »/YEAR * »
1 4312 io30*5o5 966900 2*100
2 4643 2Q89150Q 994900 25000
3 4775 21*87500 1023200 2JIOO
4 4906 22077000 1031300 26*00
5 5032 226665.00 10Z940Q- 21200
6 516? 23260500 1107600 27900
7 5300 23850000 11)5700 2B600
8 5432 2444*000 1164000 29100
9 5J63 25033500 1192100 30000
.10 . 5694 236,23000 - 122Q1QQ 3Q2QQ
11 5695 25627500 1220400 30700
12 5695 2J62750Q 1220400 10700
13 5695 25627500 1220400 30700
14 5695 25627500 1220400 JQ700
.15 3695 23622300 1220*00 _- -. 30200
16 5337 24916300 1186500 29900
17 5179 2*203500 1132600 29000
18 5221 21494500 1118800 28200
19 5064 22788000 1085100 27100
20 4906 22021000 1031300- 26SOO
21 4748 21366000 1017400 23600
22 4391 20659500 983800 24100
23 4433 19948500 949900 23900
24 4275 19237500 916100 21100
.25 411S 18531000 882400 22200
26 3960 17820000 8*8600 21*00
27 3102 17109000 014700 20100
28 3645 16402500 781100 19700
29 3*87 15691500 7*7200 18800
30 3323 14930300 213400 18000
118700 15,00 U769200 2060300 178*9700 178*9700
1*2800 15,00 156*7200 21*2000 17789200 3I61B9QO
1*6800 15,00 13525300 2202000 17727500 51366*00
130900 15,00 15*02000 2263500 17665500 71031900
13*300 13*00- _ 1322B30C .2323300 - 1I601BOO- - -88633200-
138900 15,00 1513*900 2383300 17318*00 10*172100
161000 15.00 13030200 2445000 17*75200 1216*7100
167000 15,00 1490370C 2505000 17*10700 U1058COO
171100 15,00 1477990C 2566500 17J*6*00 1584Q44QO
.--171100- 15,00__ 1*611300 2626300 - 12280000- --121684*00-
173100 15,00 1*399100 2626300 17Q23800 191710200
173100 15,00 1*1*410C 2626300 1677Q600 209*80800
171100 15.00 11889000 2626300 16513300 22I9963QO
171100 15.00 13611800 2626300 1626Q1QO 242256*00
121100 13*00 11)28200 2626300 - 16003200. 231261800.
17Q100 15.00 12968100 253*300 15322600 271784400
169*00 15.00 1253690C 2481000 15Q37900 288822300
160300 15.00 121*500C 2*07500 1*532300 301374000
153700 15,00 1173320C 23)5300 1*068700 117443300
.--130800 --15.00 1111920C 2263300 13383200 331026300.
1*6000 15.00 1090320C 2190000 1)095200 34*121*00
1*1200 15.00 10*91500 2118000 12609500 356731*00
136300 15.00 1007550C 20*4500 12120000 368851*00
111300 15.00 963B40C 1972500 1163Q9QO 3804821QO
.- 126600 13.00 S26120C 1899000- - 111*0200 291623000-
121800 13.00 I82260C 1827000 106*9600 *0{2726QO
116900 15.00 840270C 1733300 10156200 *1I42B800
112100 13.00 798230C 1681500 9664000 42.092600
107200 13,00 7339900 1608000 9167900 *3l260700
_ 102*00 15^00 _ 7.1361QC. -1316QQQ _ 8*22100 631932800.
TOT 146001 657004500 31286100 787700 4489300 372590300 673*2300 *199J2800
LIFETIME AVERAGE INCREASE IN UNIT REVENUE REQUIREMENT
DOLLARS PER TON OF COAL BURNfD 11.91 2;lS U.06
MILLS PER KILOWATT-HOUR 3.ic o.9» 6.03
CENTS PER MILLION BTU HEAT INPUT S6t7l 10. 2J 66, »6
DOLLARS PER TON OF SULFUR REMOVED *71. Ol 85. *» 538. So
REVENUE REQUIREMENT DISCOUNTED AT n.6x TO INITIAL YEAR, DOLLARS ii95639oc I93j6*oo 138900300
LEVELIZED INCREASE IN UNIT REVENUE REQUIREMENT EQUIVALENT TO DISCOUNTED REQUIREMENT OVER LIFE OF POWER UNIT
DOLLARS PER TON OF COAL BURNED 13.31 2.19 15.66
MJUS pf KILOHAJT-HOU* f.7C 0.91 6,*J
CENTS PER MILLION BTU HUT INPUT *J.Ji ic.tl fj.*j
OQLL.RS CEO TQM OF SL)l_fU* RIMQVED SXB.tl iS.St *1*.S?
-------
ISLUDG = 1
ISLUDG = 2
ISLUDG = 3 SDFEE = 15
ISLUDG = 4 SDFEE = 15
Pond Design Option
Line No . Input Data
10 1 0 500 3500 25 25 5280 1 12 2.5
4 4 ^
PSAMAX PDEPTH PMXEXC
Disposal pond size is calculated based on a square configuration with a
diverter dike three-fourths the length of one side. A pond construction
diagram is shown in Figure 1. The pond model is based on either unlined,
clay-lined, or synthetic-lined design and includes the following options in
running the program.
Fixed-depth pond
Optimum-depth pond based on minimum pond investment
Optimum-depth pond based on minimum pond investment with available
acreage and maximum excavation depth as overriding constraints.
The optimum-size pond is calculated to minimize the sum of construction
cost and land cost by using the optimum depth to area ratio. The input
variables are PSAMAX, PDEPTH, and PMXEXC. PSAMAX is the maximum available
area for construction of the pond. Pond depth, PDEPTH, is the ultimate depth
of the contained waste. Excavation depth, PMXEXC, is the depth of topsoil
and clay which is excavated over the entire area of the pond construction
site for construction of the enclosing dike. In calculating the amount of
excavation, it is assumed that the material excavated compacts to 85% of the
actual volume excavated. If PSAMAX is set to zero, pond depth (PDEPTH) is a
user-supplied input variable and excavation depth (PMXEXC) is calculated.
If the calculated excavation depth (PMXEXC) exceeds the input value, however,
excavation is set equal to PMXEXC and pond depth is calculated. If PXAMAX
is set to a nonzero value, the optimum size-versus-cost pond is designed
within the constraint of maximum available area (PSAMAX) for the pond.
In the event that the input value for PSAMAX is not large enough, the
pond printout will be incomplete. Because of this, values of sufficient
magnitude must be entered to allow the optimum pond size to be used. For
most cases, values of PSAMAX = 9999, PDEPTH = 25, and PMXEXC = 25 will allow
optimum pond calculation. The pond design results for the base case are
shown in Appendix C. Table 12 shows sample output for a fixed-depth pond
rather than an optimum pond.
27
-------
OUTER BOUNDARY
OF POND AREA
/ 20'
GROUND LEVEL
ho
oo
10% FREE BOARD
POND PERIMETER DIKE
TOPSOL EXCAM&TION
(I FT )
/ic^f-
/ V
DEPTH OF SLUDGE
_L TOTAL
EXCAVATION DEPTH
SUBSOIL EXCAVATION
TOPSOH. EXCAVATION
(I FT )
16'
ORGINAL GROUND LEVEL
SUBSOIL EXCAVATION
10% FREE BOARD
DEPTH OF SLUDGE
(TYP OTHER SIDE)
TOTAL
EXCAVATION DEPTH
POND DIVERTER DIKE
Figure 1. Pond dike construction details.
-------
TABLE 12. FIXED POND DEPTH EXAMPLE
POND DESIGNED FDR FIXED POND DEPTH
POND DIMENSIONS
DEPTH OF POND
DEPTH OF EXCAVATION
LENGTH OF PERIMETER
LENGTH OF DIVIDER
AREA Of BOTTOM
AREA OF INSIDE WALLS
AREA Of OUTSIDE WALLS
AREA OF POND
AREA OF POND SITE
AREA OF POND SITE
VOLUME OF EXCAVATION
VOLUME OF SLUDGE TO BE
DISPOSED OVER LIFE OF PLANT
Z3.00 FT
3.99 FT
13738. FT
2<.96, FT
157.
122.
1299.
305.
THOUSAND YD2
THOUSAND Y02
THOUSAND YDZ
THOUSAND YD2
THOUSAND YD2
ACRES
1637. THOUSAND Y03
10269, THOUSAND YD3
6365, ACRE FT
POND COSTS (THOUSANDS OF DOLLARS)
LABUR
MATERIAL TOTAL
CLEARING LAND
EXCAVATION
DIKE CONSTRUCTION
LINING< 12. IN. CLAY)
SODDING DIKE MAILS
ROAD CONSTRUCTION
POND CONSTRUCTION
LAND COST
POND SITE
OVERHEAD
453,
3053,
1222,
1092,
69.
8,
3899,
455,
3053.
1222.
1092.
56, 125.
17. 25,
74, 5973.
1066.
7039.
4061.
TOTAL
11100.
29
-------
Pond Liner Option
Line No. Input Data
10 1 0 500 3500 25 25 5280 1 12 2.5
/ X
ILINER XLINA XLINB
The pond liner option allows a choice of an unlined, clay-lined, or
synthetic-lined pond. The input variables are ILINER, XLINA, and XLINB.
ILINER specifies the type of lining in the pond as illustrated below.
1 = Clay liner
2 = Synthetic liner
3 = No liner
XLINA specifies the depth of clay in inches for a clay-lined pond. For
ILINER = 2, XLINA specifies the material unit cost in $/yd^ for a synthetic
liner. XLINB specifies either the clay cost (installed) in $/yd3 for the
clay-lined pond option or the labor unit cost in $/yd^ for installing the
synthetic liner.
Table 12 also shows the base case printout corresponding to a clay-lined
pond. An example of the synthetic-lined pond option is illustrated in
Table 13 for comparison.
For this synthetic-lined pond option example the values of the inputs
are as follows:
ILINER = 2 XLINA =0.50 XLINB =1.25
The unlined pond option requires input values of zero for XLINA and
XLINB.
Pond Capacity Option
Line No. Input Data
13 2 1 5 .8 2.0 3 65 1 2 1.10 1979 240.2
4-
PNDCAP
30
-------
TABLE 13. SYNTHETIC POND LINER EXAMPLE
POND DESIGN
OPTIMIZED TO MINIMIZE TOTAL COST PLUS OVERHEAD
POND DIMENSIONS
DEPTH OF PQND
DEPTH OF EXCAVATION
LENGTH OF PERIMETER
LENGTH OF DIVIDER
AREA OF
AREA OF
8QTTQM
INSIDE WALLS
AREA OF OUTSIDE WALLS
AREA OF POND
AREA OF POND SITE
AREA OF POND SITE
VOLUME OF EXCAVATION
VOLUME OF SLUD&E TO BE
DISPOSED QVIR LIFE OF PLANT
45.75 FT
11,34 FT
10575. FT
1846. FT
587.
195.
152.
765.
956.
198,
2388,
10269,
6365.
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
ACRES
THOUSAND YD3
THOUSAND YD3
ACRE FT
POND COSTS (THOUSANDS OF DOLLARS)
LABOR
MATERIAL TOTAL
CLEARING LAND
EXCAVATION
DIKE CONSTRUCTION
LINING(SYNTHETIC)
SODDING DIKE WALLS
ROAD CONSTRUCTION
POND CONSTRUCTION
LAND COST
POND SITE
OVERHEAD
295,
4455,
2197,
2346,
38,
*.
9337.
3911.
31.
13.
3955.
295,
4455.
2197.
6251.
69,
19.
13291.
691.
13983.
9038.
TUTAL
23021.
31
-------
The pond capacity option provides the capability to design the raw
material and scrubber areas based on maximum sulfur content of coal (high
sulfur content fluctuation) but, at the same time, to design the pond based
on an average sulfur content. For example, on a long-term basis, the coal
being used may be expected to average 2.0% sulfur. However, at times the
sulfur content may be as high as 3%. The raw material preparation area and
the scrubbers should be sized for the maximum coal sulfur content that is
expected to be encountered. In this case a value of 3% must be considered
for design of the feed preparation and scrubber units, but the model also
calculates the sludge production rate based on the input sulfur content and
sizes the pond based on that amount. The PNDCAP option is included in the model
to allow the projected waste disposal pond size to be modified to account for
the difference between average and maximum sulfur content (ordinarily PNDCAP
will be in the range of 0.5-1.0). In the example above, by inputting PNDCAP
equal to 0.67, the waste disposal pond would be sized based on a 2% sulfur
coal, whereas the other facilities would be designed for fluctuations in
sulfur content to 3% sulfur in the coal.
If the user wishes to specify an oversized pond to cover contingencies
in sulfur content, an appropriate PNDCAP factor, i.e., greater than 1.0, can
be specified.
Operating Profile Option
Line No. Input Data
13 2 1 5 .8 2.0 3 65 1 2 1.10 1979 240.2
^
IOPSCH
14 30
^
IYROP
One of the most important variables affecting the economics of a power
plant and an associated FGD system is the operating profile (number of years
of operation and the hours of operation per year) over the life of the unit.
The model provides three options for specifying this profile. The input
variable for these options is IOPSCH. If IOPSCH = 1 the program uses the
TVA-developed operating schedule shown in Figure 2 which is based on the
profile assumed in Detailed Cost Estimates for Advanced Effluent Desulfuriza-
tion Processes (5) . If IOPSCH = 2 the operating schedule is based on
historical Federal Energy Regulatory Comission (FERC, previously FPC) data
as shown in Figure 3. If IOPSCH = 3 the user must input the operating
profile (hr/yr, 7000 for example) beginning on line 15. The total number of
entries beginning on line 15 must equal the input variable IYROP located on
line 14, where IYROP indicates the years of life expected for the unit. The
number of entries per line must not exceed 10. A line with less than 10
entries is acceptable if it is the last line required to complete the number
of years required. An example is shown below.
32
-------
o
1*4
o
W
c?
30
60
40
20
^T
50
' > I
60
0 10 20 30 40
BOILER AGK - YEARS
Figure 2. Operating profile assumed for IOPSCH = 1.
I T
70
33
-------
30
60
40
50 +1.5 A
92-1. 8A
= AGE
20
&
1 I
10
20
' I
30
40
50
60
70
BOILER AGE - YEARS
Figure 3. Operating profile assumed for IOPSCH "* 2 based on
Federal Energy Regulatory Commission 1969-197.3 data.
34
-------
Line No. Input Data
13 3 1 5 .8 2.0 3 65 1 2 1.10 1979 240.2
14 25
15 5000 5000 6000 6000 7000 7000 7000 7000 7000 7000
16 7000 7000 7000 7000 7000 7000 7000 7000 6000 6000
17 6000 5000 5000 5000 4000
18 END
Sample output resulting from the Figure 1 operating profile (IOPSCH = 1)
is shown in Table 14. The sample base case printout in Appendix C illus-
trates the results of the Figure 2 FERC data operating profile (IOPSCH = 2).
Sample output resulting from a user-supplied operating profile (IOPSCH = 3)
is shown in Table 15.
USAGE OF THE MODEL
As previously discussed, a copy of the model can be made available for
independent user execution. As an alternative to obtaining the program, TVA,
under an information-exchange agreement with EPA, can make specific runs of
the model based on user-supplied input data. The remainder of this section
is provided for potential users who wish to obtain the model for independent
use.
The model was developed for, and is executed on, the TVA in-house IBM
computer system (370/165). The current model consists of two FORTRAN programs
that are compiled using either the IBM Gl or H extended compiler. The first
program is relatively large; it contains about 8000 lines of source code.
The second program contains about 2000 lines.
Core storage requirements for the first program are about 250,000 bytes;
the use of overlays can reduce this requirement to 150,000 bytes. The second
program executes within 150,000 bytes of core storage with no overlays.
Sample control cards for creating an overlay structure for the first program
are shown in Table 16. A conceptual map of the internal program is shown in
Figure 4. The map reflects the subroutine calling sequence in the order of
left to right and top to bottom.
In addition to the core storage required for program execution, tempo-
rary online storage (disk) is also required for intermediate files and the
transfer of data between the two programs. The only input data required
for model execution is the user input data; all other data for default
assumptions and option-related calculations are assigned the necessary values
internally within the program. Temporary online storage requirements depend
on the number of cases run but typically do not exceed 200,000 bytes.
35
-------
TABLE 14. SAMPLE OUTPUT USING THE DETAILED COST ESTIMATES OPERATING PROFILE
LIMESTONE SLURRY PROCESS — BASIS! 500 Hit UNIT, 1980 STARTUP
PROJECTED LIFETIME REVENUE REOU1REMENTS - BASE CASE EXAMPLE 500
CASE 010
TOTAL CAPITAL INVESTMENT! t 5*279000
SULFUR
REMOVED
YEARS ANNUAL POWER UNIT PDNER UNIT BY
AFTER OPERA- HEAT FUEL POLLUTION
POWER TJDN, REQJUMENT, CONSUMPTION/ CONTROL
UNIT KW-HR MILL'DN BTU TONS COAL PROCESS*
START /KM /YEAR /YEAR TONS/YEAR
1 7000
2 7000
3 7000
* 7000
— 5 7,000
6 7000
7 7000
8 7QOO
9 7000
-10 2000
11 5000
12 5000
13 5000
I* 5000
.15 5000
16 3500
17 3500
18 3500
19 3SOO
.20 3500
21 1500
22 1500
23 1500
24 1500
-25 ISOO
26 1500
27 1500
28 1500
29 1500
-30 1500
3150000Q
315QOOOO
31500000
31500000
--- .31500000 -
31500000
3150000Q
31500DOO
3150000Q
31500000
2250000Q
22500000
22500000
22500000
22500000
15750000
15750000
15750000
15750000
15250000
6750000
6750000
6750000
6750DOO
4250000
6750000
6750000
675000Q
6750000
625000Q
1500000
1500000
1500000
1500000
1500000 -
1500000
1500000
1500000
1500000
1300000
1071400
1071400
1071*00
1071*00
1021600
7JOOOO
750000
750000
750000
250000
321*00
321*00
321*00
321*00
321400
321*00
321*00
321*00
321*00
321400
37800
37800
37800
37800
32800
37800
37800
37800
37BOO
31800
27000
27000
27000
27000
22000
18900
18900
iB9oo
18»00
18800
8100
8100
8100
8100
aioo
8100
8100
8100
8100
8100
BYPRODUCT
RAT(,
EOUIVALENT
TONS/YEAR
DRY
SLuoce
ADJUSTED CRCSS
ANNUAL REVENUE
SLUDGE REOIJREMEKT TOTAL NET ANNUAL CUMULATIVE
FIXATION FEE EXCLUDING ANNUAL INCREASE NET INCREASE
»/TDN SLLDGE SLUDGE IN TOTAL IN TOTAL
FIXATION FIXATION REVENUE REVENUE
DRY CCST, COST, REQUIREMENT, REOUlREMENT,
SLUDCE $/YEAR J/YEAR » »
21»700 0.0
219700 0.0
219700 0.0
219700 0.0
218200 0.0
219700 0.0
219700 0.0
219700 0.0
21*700 0.0
213200 0.0
15*900 0.0
15*900 0.0
1S6900 0.0
156900 0.0
116800 0.0
10*900 0.0
109900 0.0
109900 0.0
109900 0.0
10SSOO -0.0-- .
*7100 0.0
*7100 0.0
*7100 0.0
*7100 0.0
42100 0.0
*7100 0.0
»7100 0.0
*7100 0.0
*7100 0.0
*2100 0.0
1992130C
1962330C
1932530C
1902720C
1822S20C- ...
1843120C
1813320C
17B3510C
1753710C
1323310C
1500030C
1470220C
1**0*20C
1*10620C
1380820C
1197590C
1167790C
1137990C
U08190C
1C283800
823*500
793650C
76385QC
73*0*OC
20*2*00
674440C
6*«6*OC
614830C
585030C
5SS230C
o o o o c
o o o o c
0
0
0
0
0
0
0
0
0
0
o o o o c
O 0 O O C
19921300
19623300
19325300
19027200
. 1822.3200--
18*31200
18133200
17835100
17537100
- 12233100-
15000300
1*702200
14*0*200
1*106200
. 13808200.
1197J900
11»77900
11379900
11081900
- 10283800.-
823*500
7936500
7638500
73*0*00
2042*00.
67***00
64*6*00
61*8300
5850300
. 3352300..
199213QO
395*4600
58669500
77897100
---36626300.
115057500
133190700
151025800
166562900
-_18Sa02COO_
200802300
21550*500
229908700
2*401*900
..25IB23100.
269799COO
2814769QO
292856800
303938700
.-11*222500.
322957COO
330893500
33853ZCOO
3*5872*00
-.352214800,
359659200
366105600
372253900
37810*200
-.383656500.
TOT 127500 573750000 27321000 688500 4002000
LIFETIME AVERASE INCREASE IN UNIT REVENUE REQUIREMENT
DOLLARS PER TON OF COAL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
REVENUE REOUIREME^T DISCOUNTED AT 11,6* TD INITIAL YEAR, DOLLARS
38365650C
1*.0*
6.02
66.87
557.24
13843320C
LEVELIZED INCREASE IN UNIT REVENUE REOUlREMENT EflUIVALENT TO DISCOUNTED RE9UIKEMENT OVER LIFE
DOLLARS PER TON OF COAL BURNED 13.00
MILLS PER KILOWATT-HOUR 5.57
CENTS PER MILLION BTU MEAT INPUT 6J.9C
DOLLARS P[R TON OF SULUJK KfHOVfD 519,77
0.0
0.0
0.0
0.0
0
OF POWER
0.0
0.0
0.0
0.0
383656500
U.04
6.02
66.87
357.2*
138*33200
UNIT
13.00
5.57
61.90
315.77
-------
TABLE 15. SAMPLE OUTPUT USING A USER-SUPPLIED OPERATING PROFILE
LIMESTONE SLURRY PROCESS •- BASIS: 500 MK UNIT/ I9jo STARTUP
PROJECTED LIFETIME REVENUE REQUIREMENTS - BASE CASE EXAMPLE 500 MM
TOTAL CAPITAL INVESTHENTi * 96523000
YEARS ANNUAL
AFTER OPERA-
POWER TIDN,
UNIT KW-HR
START /KM
POWER UNIT POWER UNIT
HEAT FUEL
REOJIREMENT, CONSUMPTION/
MILLION BTU TONS COAL
/YEA*
/YEAR
SULFUR
REMOVID
BY
POLLUTION
CONTROL
PROCESS/
TONS/YEAR
BYPRODUCT
RATE/
EQUIVALENT
TONS/YEAR
DRY
SLUDGE
SLUDGE
FIXATION PEE
»/TQN
DRY
SLUO&E
ADJUSTED GRCSS
ANNUAL REVENUE
REOLJREMENT
EXCLUDING
SLUDGE
FIXATION
COST,
I/YEAR
CASE Oil
TOTAL NET ANNUAL CUMULATIVE
ANNUAL INCREASE NET INCRE«SE
SLUDGE IN TOTAL IN TOTAL
FIXATION REVENUE REVENUE
COST, REOUIREMENT/ REOUIREMENT/
»/YEAR » *
1
2
3
4
—S.
6
7
8
9
-10.
11
12
13
1*
-15.
16
17
19
19
.20.
21
22
23
24
-25.
26
27
28
29
.30.
6QOO
6000
6000
6000
— 6.000.
6000
6000
6000
6000
—.6000.
6500
6SOO
6300
6SOO
—-6500-
6JOO
6500
6300
6500
...6.500-
5000
5000
5000
5000
_-_SOOO-
4000
3000
3000
3000
--.3,000-
27000000
27000000
27000000
27000000
22000000.
27000000
Z7000000
27000000
27000000
22000000-
29250000
29250000
29250000
29250000
29.250000-
29250000
29250DOO
29250300
29250300
--.2.9.250000-
22500300
22500000
22500000
22500300
22500000-
18000300
13500300
13500000
13500000
13500000-
1285700
1285700
1285700
1285700
.1215200.
1285700
1285700
1285700
1285700
.1285200-.
1392900
1392900
1392900
1392900
-13S2900-.
1392900
1392900
1392900
1392900
.1392900-.
1071*00
1071400
1071400
1071400
.1011*00-.
837100
6*2900
6*2900
6*2900
..6*2900-.
32*00
32*00
12*00
32*00
-32*00
J2*00
32*00
32*00
32*00
.32*00
33100
J5100
33100
33100
-3S100
33100
33100
33100
JS100
-35100
27000
27000
27000
27000
.21000
21*00
16200
16200
16200
-16200
188300
188300
168300
181300
1B8JOO-.
188300
188300
188300
188300
1B8300-.
20*000
20*000
20*000
20*000
20*000-.
20*000
20*000
20*000
20*000
20*000-.
13*900
156900
156900
136900
---13*900--
125300
9*200
9*200
9*200
9»2.00-_
5209800
o.o
o.o
o.o
0.0
-.0.0
0.0
o.o
0.0
0.0
— 0*0
0.0
o.o
o.o
o.o
..o.Q
0.0
o.o
o.o
o.o
.-0.0
o.o
o.o
o.o
o.o
.-0.0
o.o
o.o
o.o
o.o
-0.0
19*89500
1918000C
1887060C
1856120C
1823.1800-.
179*230C
1763290C
1732330C
1701*10C
1620460C-.
1687960C
1657020C
162607QC
1395130C
1J641SOC-.
U33230C
15Q2100C
147136QC
1«*0*20C
1409420C..
1231390C
1200*50C
116«510C
11JB360C
1107620C —
97*850C
837780C
8068*0c
773900C
2**860C--
4357208QC
0 19489500
0 1918QOOO
0 18870600
0 18361200
0 18231800.
0 179*2300
0 17&32900
0 17323300
0 1701*100
0--,.1620*600.
0 16879600
0 16570200
0 16260700
0 13951300
0 iS6*l90o.
0 15332500
0 1502)000
0 1*713*00
0 14*0*200
0-.,_140!»7.00-
0 12313*00
0 1200*500
0 11695100
0 11385600
0 11026200-
0 97*8500
0 8377800
0 8068*00
0 7739000
0 24*9600-
19489100
38669500
575*0100
76101300
9*353100-
112295<<00
129928300
1*7251600
16*263900
.-.180920500-
197850100
21*420300
230681COO
24*632)00
26227*200-
277606^00
292629700
30T3*3300
321747500
...3.333*2200.
3*8156100
360160(00
371B55100
383241300
...39*312500-
*0*066COO
*12443800
420512200
428271200
_--*31720IOO-
TOT 1<)6000 7*7000300 35571700 896*00 5209800 435720BQC 0 435720800
LIFETIME AVERAGE INCREASE IN UNIT REVENUE REOUIREMENT
DOLLARS PER TON OF COAL BURNED 12.25 0.0 12.23
MILLS PER KILOWATT-HOUR 5.25 o.o 5.23
CENTS PER MILLION BTU MEAT INPUT 58.33 o.o 38.33
03LLAR5 PER TON OF 5ULFL/R REMOVED *86,OB 0.0 *B6,08
REVENUE RETIREMENT DISCOUNTED AT u.e* TO INITIAL YEAR/ DOLLARS 1*2*73300 o i*2*7i30o
INCREASE IN UNIT REVENUE REQUIREMENT EQUIVALENT TO DISCOUNTED REOUIREMENT OVER LIFE OF POME* UNIT
BOLLlRS PER TON OF COAL BURNED 13.38 0.0 13.38
MILLS PER KILOWATT-HOUR 5.73 o.o 5.73
CENTS PER MILLION BTU HEAT INPUT 63.69 0.0 63.69
DOLLARS PER TON OF SULFUR REMOVED 530.82 o.o 530.82
-------
TABLE 16. LINKAGE-EDITOR CONTROL CARDS FOR THE SHAWNEE
LIME-LIMESTONE COMPUTER PROGRAM
00010 ENTRY MAIN
00020 OVERLAY ORG1
00030 INSERT PNDDEP.PNDCP
00040 OVERLAY ORG1
00050 INSERT ZERO
00060 OVERLAY ORG1
00070 INSERT READIN,RELDSP
00080 OVERLAY ORG1
00090 INSERT BECHTL
00100 OVERLAY ORG2
00110 INSERT DUST,PRIN,MBCON,HOTGAS
00120 OVERLAY ORG2
00130 INSERT S02ELM,MATBAL,PHIN,STOICH
00140 OVERLAY ORG2
00150 INSERT CLARIF,WETGAS,CSA,REHEAT,STMRHT,STKGAS.PDROP
00160 OVERLAY ORG2
00170 INSERT PNDSGN
00180 OVERLAY ORG2
00190 INSERT STREAM
00200 OVERLAY ORG2
00210 INSERT H20BAL,CSAFIL
00220 OVERLAY ORGl
00230 INSERT PROUT
00240 OVERLAY ORGl
00250 INSERT TVAIN
00260 OVERLAY ORG4
00270 INSERT EQUIP!
00280 OVERLAY ORG5
00290 INSERT VENTUR
00300 OVERLAY ORG5
00310 INSERT LSPREP
00320 OVERLAY ORG5
00330 INSERT LIMEPR
00340 OVERLAY ORG5
00350 INSERT THICK,FILTER,TANKS,SLPUMP.PREPSM
00360 OVERLAY ORG5
00370 INSERT MECOLL,FANS,SCRUBB,REHETR,SOOTBL,H20PMP,EQPSUM
00380 OVERLAY ORG5
00390 INSERT EQUIPR
00400 OVERLAY ORG4
00410 INSERT STRUCT,FOUNDT
00420 OVERLAY ORG4
00430 INSERT PIPES,DUCWRK.INSTRM,LAND
00440 OVERLAY ORG4
00450 INSERT ELECTR,TOTALS,WORKCP
00460 OVERLAY ORG4
00470 INSERT PRINTI
00480 OVERLAY ORG4
00490 INSERT SPRINT
(continued)
38
-------
TABLE 16 (continued)
00500 OVERLAY ORG4
00510 INSERT PARTIC
00520 OVERLAY ORG1
00530 INSERT WRITDS
00540 OVERLAY ORG11(REGION)
00550 INSERT EQCALL,BEQ
00560 OVERLAY ORG12
00570 INSERT TCON,KCALC
00580 OVERLAY ORG12
00590 INSERT CAS03,CAS04,CASOX
00600 OVERLAY ORG12
00610 INSERT BEQPRT
00620 OVERLAY ORG11
00630 *NSERT PNDOPT,PNDEXC,PNDCST,PNDSZE
00640 OVERLAY ORG11
00650 INSERT PNDPRT
00660 ALIAS PND
0060 NAME INV(R)
39
-------
C1.AR1F
WETGAS
CSA
REHEAT
STMRHT
STKliAS
PDROP
MECOLL
FANS
SCRVBB
RF.HETR
SOOTBI,
H20PMP
F.OPSUM
Figure 4. Conceptual map of the model Investment program
-------
The model is executed in both interactive and batch modes. The input
data can be provided in three different ways depending on the mode of execu-
tion. For batch execution (typically remote batch) the input data variables
are punched on cards and inserted in a model execution run deck. The second
method of providing data applies to interactive model execution. Input is
solicited at the terminal during actual model execution and the user must
respond with the appropriate values. The third method is used for both
interactive and batch execution. A data file is created interactively
(typically using text editor); all variable values (including the options
selected) are examined and corrected if necessary; then the model is executed
(either interactively or a batch run is submitted) and the input is processed
as a standard data file.
The third method of providing input data has been found to be preferable
in most cases. When separate but similar model runs are required, the data
file containing the input is copied to a second file, any variables and
options are modified as necessary, and a second model run is submitted. This
reduces both input preparation time and the number of input data errors
because only the variables and options that differ from a previous run must
be modified.
The job control language (JCL) required to execute the model in batch
mode is stored in a catalogued procedure file. A sample procedure file is
shown in Table 17. The catalogued procedure uses a system utility program,
IEBGENER, which can be replaced if necessary by a user program to copy from
input card data to disk storage and from disk storage to an output print
file. The overall procedure consists of four steps to (1) copy the input
data to a temporary online storage file (disk), (2) copy the input data to
an output print file, (3) execute the first program of the model, and (4)
execute the second model program. The programs are executed from load
modules to avoid recompiling each time they are executed.
The remaining JCL required to execute the model (batch mode) is shown
in Table 18. The catalogued procedure (Table 17) is executed and the
required input is read from a previously created data file. If the input
data have been prepared on cards, a card deck would be submitted (similar to
Table 18) with the data cards following the //LOAD.DATA DD * ... card. The
JCL example shown in Tables 17 and 18 generally applies whether the job is
submitted interactively or by a card deck.
In addition to interactively submitting a model run for batch execution,
the model can also be directly executed interactively. The input data can
either be entered directly during program execution or it can be provided
from a previously created data file. Table 19 shows two sample interactive
procedures for model execution. Example 1 in Table 19 shows a sample proce-
dure for directly entering the data during model execution. Example 2 shows
a sample procedure for interactive execution using a previously created data
file.
41
-------
TABLE 17. SAMPLE PROCEDURE FOR EXECUTING THE MODEL IN BATCH MODES
//SHAWNEE PROC PRTFMS=A 0000003.0
//LOAD EXEC PGM=IEBGENER 00000020
//SYSPRINT DD SYSOUT=A 00000030
//SYSIN DD DUMMY 00000040
//SYSUT1 DD DDNAME=DATA
//SYSUT2 DD UNIT=SYSCR,SPACE=(TRK,(1,1),RLSE),DISP=(NEW,PASS),
// DCB=(RECFM=FB,LRECL=80,BLKSIZE=400)
//LIST EXEC PGM=IEBGENER
//SYSPRINT DD SYSOUT=A
//SYSIN DD DUMMY
//SYSUT1 DD DSN=*.LOAD.SYSUT2,DISP=(OLD,PASS) 00000110
//SYSUT2 DD SYSOUT=&PRTFMS,DCB=(RECFM=F,LRECL=80,BLKSIZE=80) 00000120
//INVEST EXEC PGM=INV,REGION=150K 00000130
//STEPLIB DD DSN=CHM.SHAWNEE.LOAD,DISP=SHR 00000140
//FT02F001 DD UNIT=SYSCR,SPACE=(TRK,(1,1),RLSE),DISP=(NEW,PASS), 00000150
DCB=(LRECL=404,BLKSIZE=408,RECFM-VBS) 00000160
//FT03F001 DD SYSOUT=A 00000170
//FT05F001 DD DSN=*.LOAD.SYSUT2,DISP=(OLD,DELETE,DELETE) 00000180
//FT06F001 DD SYSOUT=&PRTFMS 00000190
//REVENUE EXEC PGM=REV,REGION=150K,COND=(COND=(0,LT,INVEST) 00000200
//STEPLIB DD DSN=CHM.SHAWNEE.LOAD,DISP=SHR 00000210
//FT02F001 DD DSN=*.INVEST.FT02F001,DISP=(OLD,DELETE,DELETE) 0000022«S
//FT06F001 DD SYSOUT=&PRTFMS 00000230
42
-------
TABLE 18. SAMPLE BATCH RUN TO EXECUTE THE MODEL USING A PROCEDURE FILE
//TXSHAWNE JOB 701009,SGROSS. T102NFDC.2513,MSGLEVEL=1,CLASS=K, 00000010
// NOTIFY=CHM 00000020
/*ROUTE PRINT REMOTES 00000030
//PROCLIB DD DSN=CHM.PROCLIB,DISP=SHR 00000040
//SHAWNEE EXEC SHAWNEE,PRTFMS=A 00000050
//LOAD.DATA DD * INPUT DATA CARDS FOLLOW THIS CARD
//TXSHAWNE JOB 701009,SGROSS.T102NFDC.2513,MSGLEVEL=1,CLASS=K, 00000010
// NOTIFY=CHM 00000020
/*ROUTE PRINT REMOTE3 00000030
//PROCLIB DD DSN=CHM.PROCLIB,DISP=SHR 00000040
//SHAWNEE EXEC SHAWNEE,PRTFMS=A 00000050
//LOAD.DATA DD DISP=SHR,DSN=CHM.PART2.DATA 00000060
// 00000070
43
-------
TABLE 19. SAMPLE PROCEDURE FOR EXECUTING THE MODEL INTERACTIVELY
00010 FREEALL
00020 TERM LINESIZE(132)
00030 FREE FILE (FT02F001,FT03F001,FT05F001,FT06F001)
00040 ALLOC FI(FT02F001) NEW BLOCK(13030) SPACE(10,5)
00050 ALLOC FI(FT03F001) DA(*)
00060 ALLOC FI(FT05F001) DA(*)
00070 ALLOC FI(FT06F001) DA(*)
CALL 'CHM.SHAWNEE.LOAD(INV)'
CALL 'CHM.SHAWNEE.LOAD(REV)'
00100 FREEALL
00010 FREEALL
00020 TERM LINESIZE(132)
00030 FREE DA('CHM.PART2.DATA')
00040 FREE FILE(FT02F001,FT03F001,FT05F001,FT06F001)
00050 ALLOC FI(FT02F001) NEW BLOCK(13030) SPACE(10,5)
00060 ALLOC FI(FT03F001) DA(*)
00070 ALLOC FI(FT05F001) DA(fCHM.PART2.DATA')
ALLOC FI(FT06F001) DA(*)
CALL 'CHM.SHAWNEE.LOAD(INV)1
00100 CALL 'CHM.SHAWNEE.LOAD(REV)'
00110 FREEALL
44
-------
The amount of computer time required for model execution is a function
of the number of cases of input data and the particular computer system. On
the TV A system (IBM 370/165) the average CPU time required per case is about
1 second but some cases have exceeded 5 seconds.
The model is usually distributed on magnetic tape for independent usage.
A fairly wide range of tape format options is available but typically the
tape is unlabeled, the density is 1600, the block size is 4000 characters
(50 records, 80 characters per record), and the tape contains 2 files, one
for each program.
45
-------
REFERENCES
1. Torstrick, R. L. Shawnee Limestone-Lime Scrubbing Process Computerized
Design Cost Estimates Program: Summary Description Report. Prepared
for presentation at Industry Briefing Conference, Raleigh, North Carolina
October 19-21, 1976. '
2. Stephenson, C. D., and R. L. Torstrick. Current Status of Development of
the Shawnee Lime-Limestone Computer Program. Prepared for presentation
at Industry Briefing Conference, Raleigh, North Carolina, August 29, 1978.
3. Torstrick, R. L., L. J. Henson, and S. V. Tomlinson. Economic Evaluation
Techniques, Results, and Computer Modeling for Flue Gas Desulfurization.
In: Proceedings, Symposium on Flue Gas Desulfurization, Hollywood, Florida
November 1977 (Volume I), F. A. Ayer, ed., EPA-600/7-78-058B, U.S. Environ-
mental Protection Agency, Washington, D.C., 1978 pp.
4. The program that sizes and costs particulate removal devices was provided
by Paul Farber of Argonne National Laboratory, Argonne, Illinois.
5. McGlamery, G. G., R. L. Torstrick, W. J. Broadfoot, J. P. Simpson, L. J.
Henson, S. V. Tomlinson, and J. F. Young. Detailed Cost Estimates for
Advanced Effluent Desulfurization Processes, Bulletin Y-90, Tennessee
Valley Authority, Muscle Shoals, Alabama; EPA-600/2-75-006, U.S. Environ-
mental Protection Agency, Research Triangle Park, North Carolina, 1975.
46
-------
APPENDIX A
PROCESS FLOWSHEETS AND LAYOUTS
47
-------
•e-
00
Figure A-l. Limestone scrubbing process utilizing TCA absorber.
-------
ENCLOSED CONVEYOR
STORAGE CONVEYOR
r£l
i * *
STORAGE
SILOS
SILO HOPPERS /
or or
RECLAIM CONVEYOR
FEED CONVEYOR
ELEVATOR NO. I
ELEVATOR NO. 2
SUMSY FEED
TO ABSORBER
SUPERNATE
Figure A-2. Lime handling and preparation area for lime scrubbing option.
-------
SCURRY RECIBCULATION
PLWPS
urruAUir&i
MECHANICAL.
ASH COLLECTORS
PLAN
ELEVATION
Figure A-3. Plan and elevation for limestone scrubbing area.
50
-------
SCTTUM WJNO
Waste Disposal Option 1
Onsite Ponding
Waste Disposal Option 2
Thickener Ponding
Figure A-4. Waste disposal options 1 and 2.
-------
Ul
FILTER CAKC
TO FIXATION/
DISPOSAL
Waste Disposal Option 4
Thickener-Filter-Fixation
TO SO, 7A
MSOMtll . 1
Waste Disposal Option 3
Thic kener-Fixa t ion
Figure A-5. Waste disposal options 3 and 4.
E^S^TO
-------
APPENDIX B
DETAILED DESCRIPTIONS OF MODEL INPUT VARIABLES
53
-------
TABLE B.-1. MODEL INPUTS - FORTRAN VARIABLE NAMES
Line
1 XINPUT XBC XALK XSSV XSRHT
2 OUTPUT XHGAS XWGAS XRAIR XRGAS XSRHO XSKGAS XSSO XDIS XSTR XGPM XIT
3 IRPT IEQPR IWTBAL
4 Case identification (up to 72 alphanumeric characters)
5 XESP MW BHR HVC EXSAIR THG XRH TSK TSTEAM HVS
6 WPC WPH WPO WPN WPSUL WPCL WPASH WPH20 SULO ASHO IASH ASHUPS ASHSCR
7 XLG VLG VTR V VRH IS02 XS02 TR XSR SRIN XIALK WPMGO XMGOAD WPI WPM ASHCAO ASHMGO
8 WPS PSD RS PSC OX PSF FILRAT PHLIME IVPD VPD DEPTAP
9 ISCRUB XNS XNG HS RAIN SEEPRT EVAPRT WINDEX HPTONW NSPREP NOTRAN NOREDN PCNTRN
10 ISLUDG SDFEE PSAMAX ACRE$ PDEPTH PMXEXC DISTPD ILINER XLINA XLINB
11 ENGIN FLDEXP FEES CONT START CONINT XINT PCTMNT PDMNTP PCTOVR PCTADM UNDCAP PCTINS
12 UC(1) - UC(7) MINDEX LINDEX YRINV YRREV
13 IOPSCH PNDCAP BAGDLP BAGRAT BGCOST BGLIFE EFFPS ESPDLP RESIST SCARAT ICEPYE CHPIOX
14 IYROP Lines 14-17 are required only if the IOPSCH option is set
15 IA(1) - IA(10) to 3. Lines 15-17 depend on the value of the IYROP
16 IA(11) - IA(20) variable; up to 10 entries per line are required, one
17 IA(21) - IA(30) entry for each of the years 1 - IYROP.
18 END or NEXT
-------
TABLE B-2. MODEL INPUT VARIABLE DEFINITIONS
Line No. Variable
Definition
Units or values
XINPUT
1
2
XBC
XALK
XSSV
XSRHT
OUTPUT
2
2
2
2
2
XHGAS
XWGAS
XRAIR
XRGAS
XSRHO
XSKGAS
Option to control the printing of input data
variables. If a value of zero is selected,
no input data variables are printed', the
options to individually control the printing
of input variables are ignored.
Controls the printing of alkali input
variables.
Controls the printing of scrubber system input
variables.
Controls the printing of steam reheater input
variables.
Option to control the printing of model output.
If a value of zero is selected, no output
listings are printed and the options to
individually control the printing of output
listings are ignored.
Controls the printing of calculated properties
of hot gas to scrubber.
Controls the printing of calculated properties
of wet gas from scrubber.
Controls the printing of calculated properties
of reheater air.
Controls the printing of calculated properties
of reheater gas (oil-fired).
Controls the printing of calculated properties
of inline steam reheater.
Controls the printing of calculated properties
of stack gas.
0 = No input
data printed
1 = Print input
variables accord-
ing to individual
input print option
Controls the printing of boiler characteristics 0 -
input variables. 1 =
No print
Print
No print
Print
0 = No print
1 = Print
0 = No print
1 = Print
0 = No output
printing
1 = Print output
listings according
to individual
output print option
0 = No print
1 = Print
0 = No print
1 = Print
0 = No print
1 = Print
0 « No print
1 = Print
0 = No fcrint
1 - Print
0 = No.print
1 « Print
(continued)
55
-------
TABLE B-2 (continued)
Line No.
2
2
2
2
2
3
3
3
A
5
5
5
5
5
5
Variable
XSSO
XDIS
XSTR
XGPM
KIT
IRPT
IEQPR
IWTBAL
CASEID
XESP
MW
BHR
HVC
EXSAIR
THG
Definition
Controls the printing of calculated scrubber
system parameters.
Controls the printing of calculated properties
of system discharge stream .
Controls the printing of calculated properties
of scrubber system internal streams (excluding
sludge discharge and makeup water) . This
option does not affect the printout of total
stream flow rate.
Controls printing of total flow rates (gpm
and Ib/hr) of internal streams (excluding
sludge discharge and makeup water).
For the interactive calculation of stoichiometry
this option controls the printing of the
iteration number and of the current and the
preceding stoichiometry values.
Option to select either a short -form printout
(totals only) or a long-form printout.
Controls the printing of the equipment list.
Controls the printing of calculated properties
of water balance.
Case identification - this field is free form
and may be up to 72 characters in length.
Particulate collection option
No mechanical collector available
Mechanical collector available
Particulate version
Electric power output
Boiler heat rate
Heating value of coal
Excess air
Temperature of hot gas to scrubber
Units or values
0 = No print
1 = Print
0 = No print
1 = Print
0 = No print
1 = Print
0 = No print
1 = Print
.0 = No print
1 = Print
0 = Short print
1 = Long print;
0 = No print
1 = Print
0 = No print
1 = Print
0 = No print
1 = Print
0
1
2
Megawatts
Btu/kWh
Btu/lb
Percent
oF
(continued)
56
-------
TABLE B-2 (continued)
Line No. Variable^
Definition
Units or values
6
6
6
6
6
6
6
6
XRH
TSK
TSTEAM
HVS
WPC
WPH
WPO
WPN
WPSUL
WPCL
WPASH
WPH20
SULO
ASHO
I ASH
ASHUPS
ASHSCR
XLG
VLG
Reheat option
Inline steam reheater (XRH value = 2)
is the only type of reheat available at
this time.
Temperature of stack gas
Temperature of reheater steam
Heat of vaporization of reheater steam
Amount of component (C, H, 0, N, S, Cl, ash,
H20) in coal
Sulfur to overhead as S02 gas (remainder goes
to bottom ash).
°F
OF
Btu/lb
Weight percent
Weight percent
Ash to overhead as part: dilates (remainder goes Weight percent
to bottom ash).
Unit of measure option for particulate removal
Default to model assumptions 0
Percent removal 1
Pounds particulates 2
Upstream removal (percent) with scrubber 3
default
(The actual values for particulate removal are
provided by the ASHUPS and ASHSCR variables that
immediately follow.)
Value for Particulate removal upstream from scrubber
(Unit of measure is indicated by the 1ASH option
above.)
Value for particulate removal within scrubber
(Unit of measure is indicated by the IASH option
above.)
L/G ratio in scrubber Gal/kft3
(Refer to the XSR option on the following
page.)
L/G ratio in venturi Gal/kft^
(continued)
57
-------
TABLE B-2 (continued)
Line No.
7
7
7
Variable
VTR
V
VRH
Definition
Venturi hold tank residence time
Scrubber gas velocity (superficial)
Superficial gas velocity through reheater
Units
Minute
Ft/sec
Ft/sec
—
or values
(face velocity)
7 IS02 Unit of measure option for S02 removal
S02 to be removed is a percent value
S02 emission concentration is a pounds SC>2/
MBtu value; S02 emission concentration is a
ppm value (The acutal value of the S02 to be
removed is provided by the XS02 variable that
immediately follows.)
7 XS02 Value for S02 to be removed. (Unit of
measure is indicated by the IS02 option above;
refer to the XSR option below for additional
requirements.)
7 TR EHT residence time
7 XSR Stoichiometry, L/G in scrubber, and S02
removal option. This option controls model
processing of the Stoichiometry value, SRIN,
below; the L/G ratio in the scrubber, XLG,
on the preceding page; and the S02 to be
removed, XS02, above (if XS02 is required
then IS02 is also required).
SRIN, XLG, and XS02 (also IS02) will be
processed as input variables.
XLG and XS02 (also IS02) will be processed
as input variables and SRIN will be calculated
by the model.
SRIN and XS02 (also IS02) will be processed
as input variables and XLG will be calculated
by the model.
SRIN and XLG will be processed as input
variables and XS02 will be calculated by
the model (all three units of measure will
be provided by the calculated results).
Minute
(continued)
53
-------
TABLE B-2 (continued)
— ' -' • - — —
Line No.
7
7
7
7
7
7
7
7
8
8
8
8
8
8
8
8
8
Variable
SRIN
XIALK
WPMGO
XMGOAD
WPI
WPM
ASHCAO
ASHMGO
WPS
PSD
RS
PSC
OX
PSF
FILRAT
PHLIME
IVPD
Definition
Value for stoichiometry (refer to the XSR
option above) .
Alkali addition option
Limestone
Lime
Soluble MgO in limestone-lime additive
Soluble MgO added to system (separate
from limestone-lime addition)
Insolubles in limes tone- lime additive
Moisture in limestone-lime additive
Soluble CaO in particulates
Soluble MgO in particulates
Solids in recycle slurry to scrubber
Solids in sludge discharge
Clarifier solids settling rate
Percent solids in clarifier underflow
Oxidation of sulfite in scrubber system
Percent solids in filter cake
Filtration rate
Recirculation liquor pH for lime system
(value is ignored for limestone system) .
Venturi AP option
AP is input in inches H20 Throat velocity
(ft/sec) is input and the corresponding
Units or values
Moles CaC03
added as limestone
per mole S02
absorbed
1
2
Weight percent
dry basis
Pound soluble MgO/
100 pound limestone
Weight percent dry
basis
Lb/100 pound dry
additive
Weight percent
Weight percent
Weight percent
Weight percent
Ft/hr
Weight percent
Mole percent
Percent
Tons/ft2 /day
0
1
VPD
VPD is calculated by corresponding
Value for either AP or throat velocity indicated
inches H20 by the IVPD option above
(continued)
59
-------
TABLE B-2 (continued)
Line No.
8
9
9
9
9
9
9
9
9
9
9
9
9
9
10
Variable
DELTAP
ISCRUB
XNS
XNG
HS
RAIN
SEEPRT
EVAPRT
WINDEX
HPTONW
NSPREP
NOTRAN
NOREDN
PCNTRN
ISLUDG
Definition
Override AP for entire system
TCA scrubbing option. TCA scrubbing
(ISCRUB value = 2) is the only type of
scrubbing available in the model at this time,
Number of TCA stages
Number of TCA grids
Height of spheres per stage
Annual rainfall
Seepage rate
Annual evaporation
Limestone hardness work index factor value
5-15.
Fineness of grind index factor (see Table B-3)
Number of redundant preparation units
Number of operating scrubber trains
Number of redundant scrubber trains
Entrainment level as percentage of wet gas
from scrubber
Sludge option
Onsite ponding
Thickener - ponding
Thickener - fixation (fee)
Thickener - filter - fixation (fee)
Units or values
Inch H20
Inch
In./yr
Cm/sec
In, /yr
Wi
hp/(ton) (wi)
(0-9)
Weight percent
1
2
3
4
10
10
SDFEE
PSAMAX
(For ISLUDG = 3 or 4, the SDFEE variable
immediately below must be provided.)
Sludge disposal fee. (Either an actual
value or a zero value must be provided;
refer to the ISLUDG option above.)
$/ton dry sludge
Total available land for construction of pond Acres
(continued)
60
-------
TABLE B-2 (continued)
Line No.
10
10
10
10
10
10
10
11
11
11
11
11
11
11
11
Variable
ACRE$
PDEPTH
PMXEXC
DISTPD
ILINER
XLINA
XLINB
ENGIN
FLDEXP
FEES
CONT
START
CONINT
XINT
PCTMNT
Definition
Land cost
Final depth of sludge in pond (ignored in
pond optimization model) .
Maximum excavation depth
Distance from scrubber area to pond
Pond lining option
Clay liner
Synthetic liner
No liner
(Refer to the XLINA and XLINB variables
that immediately follow. )
If ILINER = 1, XLINA = clay depth
If ILINER = 2, XLINA = material unit cost
If ILINER = 3, XLINA = 0
If ILINER = 1, XLINB = clay cost
If ILINER = 2, XLINB = labor unit cost
If ILINER = 3, XLINB = 0
Engineering design and supervision
Construction expenses
Contractor fees
Contingency
Indirect investment cost factors as percent of
subtotal fixed investment (See Tables B-4 and
B-5)
Allowance for startup and modifications
Interest during construction
Cost of capital (See Table B-6)
Maintenance rate, applied as percent of direct
Units or values
$/acre
Feet
Feet
Feet
1
2
3
Inch
$/yd2
$/yd3
$/yd2
Percent
Percent
Percent
Percent
Percent
Percent
Percent
Percent
investment excluding pond cost (See Table B-7)
11 PDMNTP Pond maintenance rate, applied as percent of
direct pond investment (See Table B-7)
(continued)
Percent
61
-------
TABLE B-2 (continued)
Line No.
Variable
Description
Units or valuta
11 PCTOVR Plant overhead rate, applied as percent of Percent
conversion costs less utilities
11 PCTADM Administrative research and service overhead Percent
rate, applied as percent of operating labor and
supervision
11 UNDCAP Annual capital charge basis for undepreciated Percent
investment (See Table B-6)
11 PCTINS Insurance and interim replacement as percent
of TCI total capital investment
(Refer to the IYROP and IA(n) options on the
following page.)
13 PNDCAP Expected pond capacity (controls pond design
capacity; if 100% of sludge is to be ponded
over the life of the unit, input 1.0; if 80%
of sludge is to be ponded, input 0.80.)
(continued)
62
Percent
12
12
12
12
12
12
12
12
12
12
12
13
UC (1)
UC (2)
UC (3)
UC (4)
UC (5)
UC (6)
UC (7)
MINDEX
LINK EX
YRINV
YRREV
IOPSCH
Limestone unit cost
Lime unit cost
Operating labor and supervision unit cost
Steam unit cost
Process water unit cost
Electricity unit cost
Analyses unit cost
Chemical Engineering material cost index
(See Table B-8)
Chemical Engineering labor cost index (See
Table B-8)
Investment year cost basis
Revenue requirement year cost basis
Operating profile option
TVA profile
FERC profile
Input profile
$/ton
$/ton
$/man-hr
$/klb
$/kgal
$/kWh
$/hr
Year
Year
1
2
3
-------
TABLE B-2 (continued)
Line No.
13
13
Variable
BAGDLP
BAGRAT
Definition
Baghouse pressure drop
Baghouse ratio (typically = 0.8)
Units or values
Inches H20
Open ft2
Actual ft2
13 BGCOST Bag cost
13 BGLIFE Bag life
13 EFFPS ESP rectification efficiency
13 ESPDLP ESP pressure drop
13 RESIST Resistivity option (high or low)a
Assume u = 20 ft/min
Assume u> = 30
13 SCARAT SCA ratio
Contingency or safety factor (fractional)
to apply to calculated collected area
13 ICEPYE Chemical Engineering plant index year
13 CHPIOX Chemical Engineering plant index (See
Table B-8)
14 IYROP Years remaining life (lines 14 through 17 are
needed only if the IOPSCH variable on the
preceding page is set to 3).
15 IA(1) - Operating hr/yr (input only 10 years per
IA(10) line)
16 IA(11) - Operating hr/yr (input only 10 years per
IA(20) line)
17 IA(21) - Operating hr/yr (input only 10 years per
IA(30) line)
18 END or "END" terminates further execution.
NEXT "NEXT" execution will continue with the next
group of input variables. (If variable IYROP
is not equal to 3, line 14 will be the "END"
or "NEXT" line.)
Year
Percent
Inches H20
Year
a. Required for sizing hot ESP. Drift velocity (w) is related to percent sulfur in the
cold ESP model, but is an input for the hot ESP model.
63
-------
TABLE B-3. LIMESTONE FINENESS OF GRIND INDEX FACTOR
Ground limestone product size distribution Index factor (HPTONW)
80%-% -200% -325 HP required
micron mesh mesh (ton) (wi)
129
113
98
85
74
62
58
51
44
40
37
31
24
60
65
70
75
80
85
86
90
93
95
70
75
80
85
90
95
1.11
1.22
1.35
1.51
1.72
2.04
2.19
2.54 Base
3.04
3.40
3.64
4.44
5.70
Data from KVS Rock Talk Manual, Kennedy Van Saun Corporation,
Danville, Pennsylvania, 1974.
64
-------
TABLE B-4. INDIRECT INVESTMENT AND ALLOWANCE COST FACTORS
Cost factor,
percentage of direct investment
Power unit size 200 MW 500 MW 1000 MW
Engineering design and
supervision 11 9 8
Construction expenses 18 16 15
Contractor 755
Contingency 11 10 9
Cost factor,
percentage of subtotal fixed investment
Allowance for startup
and modifications 888
Interest during construction 12 12 12
65
-------
TABLE R-5. INTEREST DURING CONSTRUCTION
Example 1 - 10% simple interest rate, 60:40 debta-equity ratio
Year
123 Total
Fraction of total expenditure
as borrowed funds
Simple interest at 10%/yr
as percent of total
expenditure
Year 1 debt
Year 2 debt
Year 3 debt
Accumulated interest as
percent of total expenditure
0.15
1.5
0.30
1.5
1.5
3.0
4.5
0.15
1.5
3.0
1.5
6.0
0.60
4.5
6.0
1.5
12.0
Example 2 -
simple interest rate, 50:50 debt-equity ratio
Year
Fraction of total expenditure
as borrowed funds
Simple interest at 8%/yr
as percent of total
expenditure
Year 1 debt
Year 2 debt
Year 3 debt
Accumulated interest as
percent of total expenditure
1.0
1.0
1.0
2.0
3.0
1.0
2.0
1.0
4.0
Total
0.125 0.250 0.125 0.50
3.0
4.0
1.0
8.0
Interest during construction is estimated as a percent of
subtotal fixed investment considering (1) simple interest
rate, (2) debt-equity ratio, arid (3) project construction
and expenditure schedule. Examples illustrate interest
during construction for two projects with 3-yr construc-
tion schedules but different simple interest rates and
debt-equity ratios.
66
-------
TABLE B-6. ANNUAL CAPITAL CHARGES FOR POWER INDUSTRY FINANCING
Percentage of total
depreciable capital
Investment
30-yr remaining life
Depreciation-straight line (based on years
remaining life of power unit) 3.3
Interia replacements (equipment having
less than 30-yr life) 0.7
Insurance 0.5
Property taxes 1.5
Total rate applied to original
investment 6.0
Percentage of
unrecovered
capital Investment8
60:40 debt-equity 50:50 debt-equity
ratio; 10% interest- ratio; 82 interest-
on bonds, 1M return on bonds, 12% return
on equity on equity
Cost of capital (capital structure)
Bonds 6.0 4.0
Equity13 5.6 6.0
Income taxes (Federal and State)c 5.6 6.0
Total rate applied to
depreciation based 17.2 16.0
a. Original investment yet to be recovered or "written off."
b. Contains retained earnings and dividends.
c. Since Income taxes are approximately 50% of gross return,
the amount of taxes Is the same as the return on equity.
d. Overall cost of capital (XIKT) = return on bonds » return on equity.
67
-------
TABLE B-7. MAINTENANCE RATE GUIDELINE
Power unit size 200 MW 500 MW 1000 MW
Plant maintenance (PCTMNT)3 9 8 7
Pond maintenance (PDMNTP)b
Unlined pond 333
Clay-lined pond 333
Synthetic-lined pond - - -
a. Percent of direct investment excluding pond
construction costs.
b. Percent of pond construction cost.
68
-------
TABLE B-8. COST INDEXES AND PROJECTIONS
Year
Plant
Material*1
Labor c
1974
165.4
171.2
163.3
1975
182.
194.
168.
4
7
6
1976
192.1
205.8
174.2
1977
204.1
220.9
178.2
1978a
221.4
240.8
194.2
1979a
240.2
262.5
209.7
19803
259.4
286.1
226.5
1981a
278.9
309.0
244.6
1982a
299.8
333.7
264.2
1983a
322.3
360.4
285.3
a. Projections.
b. Same as index
in Chemical Engineering
for "equipment,
machinery ,
supports. "
VO
c. Same as index in Chemical Engineering for "construction labor."
-------
APPENDIX C
BASE CASE INPUT AND PRINTOUT
70
-------
TABLE C-l
Line No. BASE CASE INPUT DATA SET
1 1, 1, 1, 1, 1
2 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 1
3 1, 1, 1
4 BASE CASE EXAMPLE 500 MW
5 2, 500, 9000, 10500, 33, 300, 2, 175, 470, 751
6 57.56, 4.14, 7.00, 1.29, 3.12, .1, 16.0, 10.74, 95, 80, 1, 98.5, 50
7 55, 0, 0, 12.5, 25, 1, 85, 12, 1, 0.0, 1, 0, 0, 2.85, 5, 0, 0
8 15, 40, .2, 40, 30, 65, 1.2, 7.0, 0, 12, 20
9 2, 3, 4, 5, 35, .0000001, 30, 10, 1.35, 1, 4, 1, .1
10 1, 0, 500, 3500, 25, 25, 5280, 1, 12, 2.5
11 9, 16, 5, 10, 8, 12, 11.6, 8, 3, 50, 10, 17.2, 1.17
12 8, 40, 12, 1.7, .12, .030, 17, 262.5, 209.7, 1979, 1980
13 2, 1, 5, .8, 2.0, 3, 65, 1, 2, 1.10, 1979, 240.2
14 END
-------
TABLE C-2. BASE CASE PRINTOUT
BASE CASE EXAMPLE 900 MW
*** INPUTS ***
BOILER CHARACTERISTICS
MEGAWATTS • 500.
BOILER HEAT RATE • 9000. &TU/KWH
EXCESS AIR • 93. PERCENT/ INCLUDING LEAKAGE
HOT GAS TEMPERATURE * 100. DEC F
COAL ANALYSIS/ WT X AS FIRED I
C H 0 N S CL ASH H20
97.56 «.l* 7,00 1.29 3.12 0,10 16.00 10.74
SULFUR OVERHEAD P 95.0 PERCENT
ASH OVERHEAD * 80,0 PERCENT
HEATING VALUE OF COAL • 10900. BTU/LB
FLYASH REMOVAL
CASE 001
EFFICIENCY,
X
98,5
50.0
EMISSION/
LBS/M BTU
0.16
0.09
UPSTREAM OF SCRUBBER
WITHIN SCRUBBER
ALKALI
LIMESTONE I
CACOI • 97.15 WT X DRY BASIS
SOLUBLE MGO • 0.0
HERTS - 2.85
MOISTURE CONTENT • 5.00 LB H2Q/100 LBS DRY LIMESTONE
LIMESTONE HARDNESS WORK INDEX FACTOR • 10,00
LIMESTONE DEGREE OF GRIND FACTOR " 1,35
FLY ASH I
SOLUBLE CAO * 0.0 WT X
SOLUBLE MGO • 0.0
HERTS • 100.00
RAW MATERIAL HANDLING AREA
NUMBER OF REDUNDANT ALKALI PREPARATION UNITS
(continued)
72
-------
TABLE C-2 (continued)
SCRUBBER SYSTEM VARIABLES
NUMBER OF OPERATING SCRUBBING TRAINS • 4
NUMBER OF REDUNDANT SCRUBBING TRAINS • I
NUMBER OP BEDS . 3
NUMBER OF GRIDS * 4
HEIGHT OF SPHERES PER BED • 5.0 INCHES
LIQUIO-TQ-GAS RATIO * 55. GAL/1000 ACF
SCRUBBER GAS VELOCITY • 12.5 FT/SEC
S02 REMOVAL • 85, PERCENT
STOICHJOMETRY RATIO TO BE CALCULATED
ENTRAINMENT LEVIL • 0.10 WT *
EHT RESIDENCE TIME » 12.0 MIN
S02 OXIDIZED IN SYSTEM • 90.0 PERCENT
SOLIDS IN RECIRCULATEO SLURRY « 15,0 WT X
SOLIDS DISPOSAL SYSTEM
COST OF LAND * 3500.00 DOLLARS/ACRE
SOLIDS IN SYSTEM SLUDGE DISCHARGE * 40,0 WT X
MAXIMUM POND ARfA • 500. ACRES
MAXIMUM EXCAVATION • 25,00 FT
DISTANCE TQ POND » 5280, FT
POND LINED WITH 12,0 INCHES CLAY
STEAM REHEATER (IN-LINE)
SATURATED STEAM TEMPERATURE • 470, DEC F
HEAT OF YAPORUATION OF STEAM • 751, BTU/LB
OUTLET FLUE GAS TEMPERATURE f 175, OEG F
SUPERFICIAL GAS VELOCITY (FACE VELOCITY) • 25,0 FT/SIC
IT SR SROLD
1 l.*l 1.50
2 LAI liftl
(continued)
73
-------
TABLE C-2 (continued)
FLUE GAS TQ STACK
C02
502
02
N2
H20
IOLI PERCENT
11.673
0.033
68.865
LB-MOLE/HR
0.2089E»03
0,59*3E»02
0,8000E*0*
0.1232E»06
0,2676E»03
LB/HR
0,9193E*06
0.3807E*0*
0.2560E+06
0.3452E+07
O.»820t»00
SPECIFIED 532 REMOVAL EFFICIENCY * 13,0 S
CALCULATED S02 EMISSION * 0.85 POUNDS PER MILLION
CALCULATED 532 CONCENTRATION IN STACK GAS . 332,
FLYASH EIISSION •
0.09 LBS/MULION BTU
0.0*2 GRA1NS/SCF (WET)
*H. IB/MR
STACK CAS FL3*« RATE • ,1130E»07 SCFM (»0 DEO ft 1 ATM]
• .13BOE+07 ACFM t;75, DEO f, \ ATM)
STEAM REPEATER (JN-LINE)
SUPERFICIAL GAS VELOCITY
O.U13E»0<.
0.2J97E*0*
NjMftfR OF
PIPES PE»
BANK PER
TRAIN
87
87
87
NUMBER OF
BANKS (ROMS)
PER TRAIN
3
*
7
(coi.t inued)
74
-------
TABLE C-2 (continued)
WATER BALANCE INPUTS
RAINFALUIN/VEAR) J3,
POND $EEPAGE(CM/SEC>*10**8 10.
POND EVAPORATIONUN/YEAR) 30.
WATER BALANCE OUTPUTS
WATER AVAILABLE
RAINFALL 36Z, GPM 211059. Ll/HR
ALKALI S. GPM 2453, Li/HR
T°T4l- 567, GPM 2IJ31Z. Ll/HR
WATER REQUIRED
HUMIDJPICATIQN 428, GPM 2UU9. Ll/HR
ENTRAINMENT 10. GPM 3102. Ll/HR
DISPOSAL WATER 117, CPM »I329. Ll/MR
MYORATJON WATER 11, GPM J724. L0/HR
CLARIFJER EVAPORATION 0, GpM 0. H/HR
POND EVAPORATION 322, GPM 260809. Ll/HR
SEEPAGE 20. GPM 9970. l*/HR
TOTAL WATIR REQUIRED 11T9, GPM 569075. Ll/HR
NET WATER RlaUJRED 611, GPM 90936). Ll/HR
(cone limed';
75
-------
TABLE C-2 (continued)
SCRUBBER SYSTEM
TOTAL NUMBER Of SCRUBBING TRAINS ( OPERAT ING+REDUNDANT ) » 5
S02 REMOVAL = 85.0 PERCENT
P4RTJCULATE REMOVAL IN SCRUBBER SYSTEM • 50,0 PERCENT
TCA PRESSURE DROP ACROSS 3 BEOS • 8.6 IN. H20
TOTAL SYSTEM PRESSURE DROP = 14.8 IN. H20
OVERRIDE TOTAL SYSTEM PRESSURE DROP • 20,0 IN. HEO
SPECIFIED LlQUJD-TO-GAS-RATIO « 55. GAL/1000 ACF
LIMESTONE ADDITION « 0.4906E+05 LB/HR 0*Y LIMESTONE
CALCULATED LIMESTONE STDICH IOMETRY • 1.41 MOLE CAC03 ADDED AS LIMESTONE
PER MOLE S02 ABSORBED
SOLUBLE CAD FROM FLY ASH = 0.0 MQLE PER MOLE S02 ABSORBED
TOTAL SOLUBLE MGO = 0.0 MOLE PER MOLE S02 ABSORBED
TOTAL ST3ICHIOMETRY * 1
MOLE SOLUBLE (CA+MG)
PER MOLE 502 ABSORBED
SCRUBBER 1MLET LIQUOR PH a 5.64
MAKE UP rfATER * 611. GPM
CROSS-SECTIONAL AREA PER SCRUBBER
SYSTEM SLUDGE DISCHARGE
425. SQ FT
SPECIES
CAS03 ,1/2 H20
CAS04 ,2H23
CAC03
H20
CA* +
MG* +
SU3 —
SU4--
CL-
LB-MOLE/HR
0.2356E+03
0.9996E+02
0.1333E+03
0.5180E+04
0,7219E*Ol
0,0
0.1539E+00
0, 1066E+01
0.1199E*02
LB/HR
0.3042E+05
0.1720E+05
0.1334E+05
oi9333E+OS
0.2893E+03
0,0
0.1233E+02
0,1024E*03
0.4250E+01
iUL 1U
WT *'
4B.43
27,41
21.26
20 u
.DO
L IUUJU
COMPj
PPM
3073.
0.
131.
1088,
4513,
TOTAL DISCHARGE FLOW RATE » 0.15&9E+06 LB/HR
« 237. GPM
TOTAL DISSOLVED SOLIDS IN DISCHARGE LIQUID « 8805. PPM
DISCHARGE LIQUID PH = 7,32
(continued)
76
-------
TABLE C-2 (continued)
SCRUBBER SLURRY BLEED
SPECIES
CAS03 ,1/2 H20
CAS04 ,2H2D
CAC03
T M ^ n 1 1 1 A 1 C ^
1 INOLJ^wQlvC^
HZO
CA + +
MG*+
503—
SO*—
CL-
TOTAL FLOW RATE
TOTAL SUPERNATE
SPECIES
HZO
CA*+
MG+ +
S03--
SO*--
CL-
TOTAL FLOW RATE
SUPERNATE TO WET
SPECIES
HZO
CA++
MG* +
503—
SO*—
CL-
TOTAL FLOW RATE
LB-MDLE/HR
0.2356E+03
0,99966+02
0.1333E+03
0.1957E+05
0.2727E+02
0,0
0.5816E+00
0.4028E+01
0.4529E+02
" 0.418SE+06
9 760.
RETURN
LB-MOLE/HR
0.1496E+05
0.2084E+02
0,0
0.4445E+00
0.3078E+01
0.3461E+02
s 0.2718E+06
• 544.
BALL MILL
LB-MOLI/HR
0.1689E+04
0.2354E+01
0,0
0.5021E-01
0.3478E+00
0.3910E+01
• 0.3071E+05
« 61.
LB/HR
0.3042E+09
Ot 1720E+05
0.1334E+03
n lAiof-^^^
v • lo^wC^y^
0 1 33266+06
0 1 1093E+04
0,0
0. 46366 + 02
0.3870E+0*
0.1603E+04
LB/HR
GPM
LB/HR
0.2694E+06
O.B353E+03
0.0
0.3558E+02
0,29576*03
0.1227E+04
LB/HR
GPM
LB/HR
0.3044E+05
0.9A36E+02
0.0
0.4020E+01
0.3341E+02
0.1386E+OJ
LB/HR
GPM
(continued)
77
-------
TABLE C-2 (continued)
LIMESTONE SLURRy
SPECIES
CAC03
SOLUBLE MGQ
INSOLUBIES
H20
CA++
MG*+
S03—
S04--
CL-
TOTAL FLOW RATE
LB-MOLE/HR LB/HR
0,476 IE+03
0,0
0.2508E+01
0,0
0.3348E-01
0,37046+00
0.4766E+03
OiO
0.3242E+05
0.1003E+OI
0.0
0.4281E+01
0.3358E+02
O.B177E+05 LB/HR
103. GPM
SUPERNATE
SPECIES
H20
CA+ +
MG*+
SOJ—
SO*—
CL-
RETURN TO SCRUBBER
LB-MOLE/HR
0.1327E+05
0.1849E4-02
0,0
0,3942E*00
0.2731E+01
0.3070E+02
OR EHT
LB/HR
0.2390E4-06
0.74Q9E+09
0.0
0.315^E*02
0.2623E4-01
0,1088E*04
TOTAL FLOW RATE
0.2411E+Q6 LB/HR
482. GPM
RECYCLE SLURRY TO SCRUBBER
SPECIES
CAS03 .1/2 H20
CAS04 ,2H20
CAC03
INSOLUBLES
H20
CA*+
MG*+
SO*—
CL-
TOTAL FLOW RATE •
LB-MOLE/HR
0,21721*05
0.9218E+04
0,1229E*05
0.1805E+07
0,2513E+04
0,0
0.3363E+02
0.3713E*03
0,4176E*04
LB/HR
0.2803E*07
0.1230E*07
0.1669E4.Q6
0.3251E*08
0.0
0.4294E*0*
0.3368E+05
0.1480E*06
0.3839E*08 LB/HR
70087. GPM
(continued)
78
-------
TABLE C-2 (continued)
FLUE GAS CQDIING SLURRY
SPSCIES
CAS03 ,1/2 H20
CA$Q4 ,2H20
CACOI
INSOLUBLES
H2Q
CA+*
MG**
S03—
504—
CL-
LB-MOLi/HR LB/HR
0,67046403
0.894QE+03
0,1829E-i-03
0,0
0,39006+01
0.2702E+OZ
0.2040E+Q6
0.1154E+06
0.69496*011
0.1214E+03
0,23656*07
0,73306*04
0.0
0.31236*03
0.25956*04
0.10776*05
TOTAL FLOW RAT6 • 0.2806E*07 LB/MR
* 5097. GPM
(continued)
79
-------
TABLE C-2 (continued)
POND DESIGN
OPTIMIZED TO MINIMIZE TOTAL COST PLUS OVERHEAD
POND DIMENSIONS
DEPTH OF POND
DEPTH OF EXCAVATION
LENGTH OF PERIMETER
LENGTH OP DIVIDER
AREA OF BOTTOM
AREA OF INSIDE WALLS
AREA OF OUTSIDE WALLS
AREA OF POND
AREA OF POND SITE
AREA OF POND SITE
VOLUME OF EXCAVATION
VOLUME OF SLUDGE TO BE
DISPOSED OVER LIFE OF PLANT
21,34 FT
9.U PT
14803, FT
2703, FT
1366
113.
1505,
1677,
3*6,
1526,
10269,
6365.
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
THOUSAND YD2
ACRES
THOUSAND YD3
THOUSAND YD3
ACRE FT
POND COSTS (THOUSANDS OF DOLLARS)
LABOR
MATERIAL TOTAL
CLEARING LAND
EXCAVATION
DIKE CONSTRUCTION
LINING( 12, IN, CLAY)
SODDING DIKE WALLS
ROAD CONSTRUCTION
POND CONSTRUCTION
LAND COST
POND SITE
OVERHEAD
TOTAL
517,
2846,
1034,
1263,
65,
9,
5734.
(continued)
80
517.
2846.
1034.
1263,
53. US,
19. 27.
72. 5806.
1213.
7019.
3948.
10967.
-------
TABLE C-2 (continued)
RAW MATERIAL HANDLING AND PREPARATION
INCLUDING 2 OPERATING AND 1 SPARE PREPARATION UNITS
ITEM
DESCRIPTION
NU, MATERIAL LABOR
CAR SHAKER AND HOIST
CAR PULLER
UNLOADING HOPPER
UNLOADING VIBRATING FEEDgR
UNLOADING BELT CQNvBYOR
UNLOADING INCLINE BELT
CONVEYOR
UNLOADING PIT DUST COLLECTOR
UNLOADING PIT SUMP PJMP
STORAGE BELT CONVEyOR
STORAGE CONVEYOR TRIPPER
MOBILE EQUIPMENT
RECLAIM HOPPER
RECLAIM VIBRATING F6EOER
RECLAIM BELT CONVEYOR
RECLAIM INCLINE BELT CONVEYOR
RECLAIM PIT OUST COLLECTOR
RECLAIM PIT SUMP PjMP
RECLAIM BUCKET ELEVATOR
FEED BELT CONVEYOR
FEED CONVEYOR TRIPPER
FEED BIN
BIN WEIGH FEEDER
GYRATORY CRUSHSRS
ZOHP SHAKER 7.5HP HOIST
23HP PULLER/ JHP RETURN
16FT DIA, 10FT STRAIGHT
SIDE HT, CS
3.5HP
ZOFT HORIZONTAL, JHP
310FT, 50HP
POLYPROPYLENE BAGTYPC,
2200 CFM/7.5HP
60GPM, 7QFT HEAD/ 5HP
200FT, 5HP
30FPM, 1HP
SCRAPPER TRACTOR
TFT WIDE, 4.23FT HT, 2FT
WIDE BOTTOM, CS
3.5HP
200FT, 3HP
193FT, 40HP
POLYPROPYLENE BAG TYPE
60GPM, 70FT HEAD, 5HP
90FT HIGH, 7SHP
60.FT HORIZONTAL 7.SHP 1
30 FPM, 1HP
13FT DIA, 21FT STRAIGHT
SIDE HT, CQVERED, cs
UFT PULLEY CENTERS/ 2HP
75HP
(continued)
1
I
1
1
1
1
1
1
1
1
I
2
2
1
1
1
1
1
1
I
3
3
3
Z858Z.
49345,
4180.
12134.
17527,
60670,
3258.
3371.
57974.
13482.
136171.
1079.
24268,
40447,
J7750.
5258.
3371.
80894.
20223.
13482.
16179.
54603,
1»9765.
1666.
1866.
7711.
1866.
0.
24875.
12438.
746,
16169.
2468.
0.
1741.
3731.
8706.
13930.
12438.
746,
1617,
1368.
2488.
29851,
3731.
13672.
81
-------
TABLE C-2 (continued)
BALL MILL DUST COLLICTQRS
BALL MILL
MILLS PRODUCT TANK
MILLS PRODUCT TANK AGITATOR 10HP
MILLS PRODUCT TANK SLURRY
PUMP
SLURRY FEED TANK
t
SLURRY FEED TANK AGITATOR
SLURRY FEED TANK PUMPS
TOTAL EQUIPMENT COST
POLYPROPYLENE BAG TYPE
2200 CFM, 7t5HP
12.3TPH,
166,HP
5500 GAL IOFT OIA; 10FT
FLAKEGLASS LINED cs
52.GPM, 60PT HEAD/
2,HP/ 2 OPERATING
AND 1 SPARES
54506.GAL/ 21,OFT DIA/
21.OFT HT, FLAKICLASS-
LINED CS
47,HP
26.GPM/ 60 FT MEAD/
l.HP, 4 OPERATING AND
4 SPARE
15774, 37313.
3
3
3
3
475996,
14561.
24673.
7810.
*39i2,
22761,
1119.
1493.
12189.
26122.
1
a
34432.
20063.
2541,
3980.
1451506. 905284,
(continued)
82
-------
TABLE C-2 (continued)
SCRUBBING
INCLUDING 4 OPERATING AND 1 SPARE SCRUBBING TRAINS
ITEM
DESCRIPTION
NO, MATERIAL LABOR
MECHANICAL ASH COLLECTOR
F.D. FANS
SHELL
RUBBER LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES
GRIDS
SPHERES
TOTAL TCA SCRJBBER COSTS
REHEATERS
SOOTBLDWERS
EFFLUENT HOLD TANK
EFFLUENT HOLD TASK AGITATOR
COOLING SPRAY PUMPS
ABSORBER RECYCLE PJMPS
MAKEUP WATER PUMPS
TOTAL EQUIPMENT COST
33x PARTICULATE REMOVAL
20.0IN H20/ WITH 1615.
HP MOTOR AND DRIVE
231287.GAL* 3*.OFT DIA/
3*.OFT HT, FLAKEGLASS-
LINED CS
63. HP
1274,GPM 100FT HEAD/
59,HP/ 4 OPERATING
AND 6 SPARE
8761.GPM/ 100FT HEAD/
406.HP, S OPERATING
AND 7 SPARE
1
5
5
5
60
5
5
10
424515.
1873839.
812283.
1199962.
368717.
313679.
471794.
175683.
3342115.
1046932.
404468.
181225.
345851.
117520.
78325.
113586,
278548.
43280.
298505.
354208.
127622.
173S2.
15 658657.
2549.GPM/ 200.FT HEAD/ 2
215,HP/ 1 OPERATING
AND 1 SPARE
19790.
51730.
1826.
8414911. 1364980.
(continued)
83
-------
TABLE C-2 (c.cinhJnued)
WASTE DISPOSAL
IT|M
DESCRIPTION
NO, MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATOR
POND FEID SLURRV PljMPS
POND SUPERNATE PUMPS
TOTAL EQUIPMENT COST
S7760.GAL, 17,OFT DJA,
34,OFT HT, PLAKGLASS-
LINED CS
36, HP
760.GPM, UO.FT HEAD
46,HP, 1 OPERATING
AND 1 SPARE
544.GPM, 192.FT HEAD,
44,HP/ 1 OPERATING
AND 1 SPARK
14S79.
10467.
14772.
1512.
31228,
1511.
2887.
765.
58331. 96411.
(continued)
84
-------
TABLE C-2 (continued)
LIMESTONE SLURRY PROCESS -- BASISl 500 M*
PROJSCTED CAPITAL INVESTMENT REQUIREMENTS
UNIT, 1980 STARTUP
• BASE CASE EXAMPLE 300 MW
INVESTMENT/ THOUSANDS OF 1979 DOLLARS
CASE 001
DISTRIBUTION
EQUIPMENT
MiTERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTWORK
MiTERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
POND CONSTRUCTION
00 STRUCTURAL
<~n MiTERIAL
LABOR
ELECTRICAL
MiTERIAL
LABOR
INSTRUMENTATION
MiTERIAL
LABOR
lUILDlNCS
MATERIAL
LABOR
SERVICES AND MISCELLANEOUS
SUBTOTAL DIRECT INVESTMENT
INGINEERING DESIGN AND SUPERVISION
CONSTRUCTION EXPENSES
CONTRACTOR FEES
CONTINGENT
SUBTOTiL FIXED INVESTMENT
ALLOWANCE FOR STARTJP AND MODIFICATIONS
INTEREST DURING CONSTRUCTION
SUBTOTiL CAPITAL INVESTMENT
LAND
WORKING CAPITAL
TOTAL CAPITAL INVESTMENT
RAW MATERIAL
HANDLING AND
PREPARATION
1*52.
305.
232.
93.
0.
0.
126.
525.
0.
270.
100.
172.
3*2.
105.
24.
36.
57.
130.
3969.
357.
635.
198.
J97.
5557.
4*5.
667.
6669.
7.
150.
6826.
SCRUBBING
7990.
1287.
2529.
7*1.
1982.
13*9.
92,
276.
0.
171.
380.
5*2.
875.
7*3.
122.
0.
0.
6*6.
19725.
1775.
3156.
986.
1972.
27615.
2209.
331*.
33138.
3.
74*.
3388*.
WASTE
DISPOSAL
58.
36.
936.
3*1.
0.
0.
12.
36.
5806.
1.
6.
100.
226.
1.
I.
0.
0.
256.
7826.
70*.
1252.
391.
781.
10956.
877.
131J.
131*1.
1221.
29J.
1*664.
TOTAL
9500.
1628.
3698.
1176.
1982.
1149.
229.
836.
58Q6.
442.
486.
814.
1*43.
856.
148.
36.
57.
1032.
31520.
2837.
5043.
1576.
3152.
44121.
3530.
5295.
52954.
1231.
1119.
5537*.
PERCENT
OF DIRECT
INVESTMENT
30.1
5.2
11.7
3.7
6.3
4.3
0.7
2.7
18.4
1.4
1.5
2.6
4.6
2.7
0.5
0.1
0.2
3.3
100.0
9.0
16.0
5.0
10. 0
140.0
11.2
16.8
161.0
3.9
3.8
175.7
(continued)
-------
TABLE C-2 (continued)
BASE CASE EXAMPLE 100 MM
CASE 001
PARTICULATE REMOVAL INVESTMENT AND OPERATIN6 COST
WPSUL CONTENT (X)|
ASH CONTENT (t)i
BTU RATING:
BOILER TYPE:
NO. OF SCRUBBERS)
SCRUBBER VELOCITY (FT/M)I
PLANT SIZE (Mrf) |
OPERATING HRS/YR:
PUMPING RATE (GAL/IOOO ACF>I
SCA RATIO:
(ACTUAL SQ.FT./CALC, SQ.FT.)
1.11
16,00
10900
DRY PULVERIZE!) COAL
4
207,0
500
OtO
1. 100
PARTICULAR EMISSION REGULATION ILI ASH/MILLION BTU): o.il
FLUE GAS TEMPERATURE (COLD) (F)!
FLUE CAS TEMPERATURE (HOT) (Ml
COST OF ELECTRICITY C»/IUH«>I
COST OF STfAM O/TCQUSANC L8)l
FIRST YEAR CAPITAL CHARGE FACTOR1
BAGHOUSE RATIO (OpER. SO. FT. /ACTUAL SQ.FT.Il
BAG COST t»/Sa.FT.)|
BAG LIFE(YBARS) t
FLUE GAS REHEAT TEMPERATURE ! 98.50
00 DRIFT VELOCITY (FT/M)l 25.78
^ SPECIFIC COLLECTION AREA (SQ.FT./ACFM)I 179.17
COLLECTION AREA (SQ.FT.Il 2759Q3.4
TOTAL CORONA POWER IKMH 3.4
AUXILIARY POWER (Kw): 226.4
FAN POWER UW) I 2*1,0
PUMP POrfER (KW)|
TOTAL POWER (Kw): *70.8
OPERATING AIR/CLOTH RATIOJ
INSTALLED AIR/CLOTH RATIOI
REQUIRED PRESSURE DROP (INCHES)! 1,0
DIAMETER (FEET)I
REQUIRED REHEAT (BTU/HR) :
STEAM SJPPLY/YR (THOUSAND LBll
INSTALLED COST (1979 DOLLARS): * 3724B87
FIRST YEAR CAPITALIZED COST: * 808*23
ANNUAL POWER CdSTl $ 63731
ANNUAL OPERATING AND
MAINTENANCE COST (J979 DOLLARS)! * 76227
REPLACEMENT COST (1979 DOLLARS))
ANNUAL REHEAT COST:
HOT
98.50
30,00
153.9*
361921,9
5,2
305,9
367.8
678,9
1.0
t
» 9971*2
» 91902
* 886*2
BACHCUSE FABRIC FILTERS
98,50
5715Z7.0
461,5
U0*.9
1666.3
3.*
2.7
5.0
10*59268
2270009
225557
6*150
45JQ72
SCRUBBERS
98.50
2633.2
0.0
2633.2
10.»
5J
5(660*16.0
29*08*,2
» 1909043J
» 41*125*
» 336421
908024
*999*|
TOTAL ANNJAL COST)
ANNUALIZED COST OF POWER(MILLS/KWHR)i
9*8383
0,42
» 1177686
0.52
3C12788
1,3*
» 5907654
(continued)
-------
TABLE C-2 (continued)
CXl
LIMESTuNE SLURRY PROCESS — BASIS: 500 MM UNIT, 1980 STARTUP
PROJECTED REVENUE REQUIREMENTS - BASE CASE EXAMPLE 100 MM
DISPLAY SHEET FOR YEAR- 1
ANNUAL OPERATION KW-HR/KW » 4512
31.39 TONS PER HOUR
TOTAL FIXED INVESTMENT 55373000
ANNUAL.SUAtJim
CASE 001
DRY
SLUDGE
TOTAL
ANNUAL
LIMESTONE
LIME
SUBTOTAL RAM MATERIAL
110.7 K TONS
0.0 K TONS
8.00/TUN
40.00/TON
885*00
0
885*00
OPERATING LABOR AND
SUPERVISION 2oe&o.o MAN-HR IZ.OO/MAN-HR
UTILITIES
STEAM 413*40.0 K L» 1.70/K LB
PR3CESS iJATER 165510.0 K GAL 0.1Z/K GAL
ELECTRICITY 38819120.0 KMH 0.030/KMH
MAINTENANCE
LABOR AND MATERIAL
ANALYSES 24ZO.O MR 17.00/HR
SJBTOTAL CONVEKSION COSTS
SJSTOTAL DIRECT COSTS
XMDmci.casis
DEPRECIATION
COST OF CAPITAL AND TAXES, 17.20X OF UNDEPREC I ATEU INVESTMENT
INSURANCE c INTERIM REPLACEMENTS, I.IT* OF TOTAL CAPITAL INVESTMENT
OVERHEAD
PLANT, 50.0* OF CONVERSION COSTS LESS UTILITIES
ADMINISTRATIVE, RESEARCH, AND SERVICE,
10. OX OF OPERATING LABOR AND SUPERVISION
SJBTDTAL INDIRECT COSTS
TJTAL ANNUAL REVENUE REOUJREMENT
E3UIVALENT UNIT REVENUE REQUIREMENT, MILLS/KWH
HEAT RATE 9000, BTU/KMH - HEAT VALUE UF COAL 10500 BTU/LB
250*00
702900
19900
1164600
1714400
-.-. 41200
3893400
4771800
1765100
9J24300
647900
1C03000
.... 23000
12965300
— 122*4100
7.87
CCAL RATE 966900 TONS/YR
(continued)
-------
TABLE C-2 (continued)
IIMESTONB SLURRY PROCESS — BASIS! 500 Mrf UNIT, 1980 STARTUP
PROJECTED LIFETIME REVENUE REQUIREMENTS • BASE CASE EXAMPLE 500 MW
TOTAL CAPITAL INVESTMENT!
CASE 001
5937*000
SULFUR BYPRODUCT
REMOVED RATI,
YEARS ANNUAL POWER USIT POWER UNIT BY EQUIVALENT
AFTER OPERA- HEAT FUEL POLLUTION TONS/YEAR
POWER TIONj REOJIRCMENT, CONSUMPTION, CONTROL
UNIT KW-HR MILLION BTU TONS COAL PROCESS, DRY
START /KW /YEA* /YEAR TONS/YEAR SLUOGt
ADJUSTED GRCSS
ANNUAL REVENUE
SLUDGE REQUIREMENT
FIXATION FEE EXCLUDING
»/TON SLLOGE
FIXATION
DRY COST/
SLUDGE I/YEAR
1 *512 2030*000 966900 2*300 1*1600 0.0 177**10C
2 *6*3 20893500 99*900 25000 1*5700 0,0 17571100
3 *775 21*87500 1023200 25800 1*9900 0.0 17*02600
* *9fl6 22077000 1051300 26JOO 15*000 0.0 1723060C
5 5032 226665.00 . 1012400. 27200 131100 - -0»0-- - 1703ZBOC--
6 51&9 23260500 1107600 27900 162200 0.0 1688560C
7 5300 23850000 1135700 28400 166300 0,0 167U80C
8 5*32 2**
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/7-79-210
2.
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Shawnee Lime/Limestone Scrubbing Computerized
Design/Cost-estimate Model Users Manual
5. REPORT DATE
August 1979
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
C. D. Stephenson and R. L. Torstrick
8. PERFORMING ORGANIZATION REPORT NO.
ECDP B-3
9 PERFORMING ORGANIZATION NAME AND ADDRESS
TVA, Office of Power
Emission Control Development Projects
Muscle Shoals, Alabama 35660
10. PROGRAM ELEMENT NO.
INE624A
11. CONTRACT/GRANT NO.
EPA Inter agency Agreement
D8-E721-BL
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Users Manual; 1/75 - 3/79
14. SPONSORING AGENCY CODE
EPA/600/13
is. SUPPLEMENTARY NOTES IERL-RTP project officer is John E. Williams, Mail Drop 61, 9T9/
541-2483.
16. ABSTRACT Tne manuai gives B. general description of the Shawnee lime/limestone
scrubbing computerized design/cost-estimate model and detailed procedures for
using it. It describes all inputs and outputs, along with available options. The model,
based on Shawnee Test Facility scrubbing data, includes a combination of material
balance models provided to TVA by Bechtel National, Inc., and capital-investment/
revenue requirement models developed by TVA. The model provides an estimate of
total capital investment, first year operating revenue requirements, and lifetime
revenue requirements for a lime or limestone scrubbing facility. Also included are
a material balance, an equipment list, and a breakdown of costs by processing areas.
The model should be used to project comparative economics of lime or limestone
flue gas desulfurization processes (on the same basis as the model) or to evaluate
system alternatives before developing a detailed design. The model is not intended
for use in projecting the final system design.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Pollution
Scrubbers
Sulfur Oxides
Calcium Oxides
Calcium Carbonates
Mathematical Models
Design
Cost Estimates
Desulfurization
b.lDENTIFIERS/OPEN ENDED TERMS
c. COS AT I Field/Group
Pollution Control
Stationary Sources
Material Balances
13B
07A,13I
07B
12A
14A
07D
ig. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
95
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
89
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