-------
TABLE A-2 (continued)
Item
No.
Description
4. Disk filter for
filtration of 56 tons/
hr clean coal from
froth flotation
5. Thickener receiving
2,360 gpm of refuse
slurry (tailings)
from froth flotation
and filtrate from
refuse filter
6. Disk filter for filtration
of 11 tons/hr refuse (under-
flow) from thickener
7
Pump fo* returning 2,280 gpm
of clarified water
+ 1 spare
Continuous rotary vacuum disk
filter, 12 feet, 6 inch diameter x
11 disk, 55 stainless steel wire
cloth; complete with vacuum pumps
and receiver, moisture trap, filtrate
pump, and blower; 580 hp
Single compartment bridge-supported
thickener with 80 feet diameter
reinforced-concrete tank; system
includes drive unit and lifting
device, rake mechanism, feed well,
overflow arrangement, underflow
arrangement, and instrumentation;
rotation drive 5 hp, lifting drive
1 hp
Continuous rotary vacuum disk
filter, 12 feet, 6 inch diameter x
6 disk , stainless steel wire
cloth; complete with vacuum pump
and receiver, moisture trap, filtrate
pump, and blower; 200 hp
Centrifugal pump, 1,140 gpm, 150 feet
total head; 75 hp
6—Refuse Disposal
Item
No.
Description
2.
Collecting conveyor for
128 tons/hr of 2 inch x
0 refuse
Refuse bin for truck
loading
(continued)
Horizontal and inclined belt conveyor,
400 feet long with 24-inch-wide belt,
carbon steel; 15 hp
Storage bin, 16 feet wide x 26 feet
long x 18 feet high on vertical sides,
13-feet-deep pyramidal bottom with
fast opening slides for truck loading;
3.5 hp
123
-------
TABLE A-2 (continued)
Item
No.
Description
3. Trucks for transporting
128 tons/hr of 2 inch x
0 refuse 1 mile from coal
cleaning plant to refuse
disposal site
4. Refuse disposal site for 30-
year operation
5. Bulldozer for spreading
refuse and earth in layers
at disposal site
Off-highway diesel-electric dump
truck, 100 ton payload, 100 yard^
capacity, dump body for 2 inch x 0
moist, sluggish, abrasive refuse
"Dry" storage site with 26,000 acre-
feet capacity for layered refuse and
earth ^~
Diesel bulldozer; 100 hp
Area 7—Clean Coa1 S torage
Item
No.
Description
1. Collecting conveyor for
679 tons/hr of 2 inch x
0 cleaned coal
2. Transfer conveyors
3. Stacking conveyors for
distributing coal along
the tops of 2 parallel and
adjacent wedge-shaped
open pile*, each of
150,000 ton*
4. Hopper* under stockpile
for recUi»i«8 cleaned
coal from stockpiles
5. P»n feeder, for with-
drawing 1,350 tons/hr,
2 inch X 0 cleaned coal
from reclaiming hoppers
20
20
(continued)
Horizontal conveyor, 300 feet lon»
with 36-inch-wide belt, carbon
20 hp
Inclined conveyor, 200 feet long
with 36-inch-wide belt, with belt
scale, carbon steel; 50 hp
Elevated horizontal conveyor, I Q/W\
feet long with 1 traveling tripper
36-inch-wide belt, carbon steel; 4Q
hp
Reclaiming hopper with 16 feet x
16 feet top opening, 4-feet-deep
pyramid, and 26 inch x 26 inch bott
opening, carbon steel
Vibrating pan feeder with 30 inch
x 48 inch long pan, carbon steel*
hp vibrator *
124
-------
TABLE A-2 (continued)
Item
No.
Description
6. Collecting conveyors for
1,350 tons/hr cleaned
coal from pan feeders
7. Tunnels for collecting
conveyors
g. Tunnel sump pump
9. Transfer conveyor
10. Tunnel for transfer
conveyor
11. Tunnel sump pump
12 Automatic sampling
" of coal from cleaning
plant to stockpile
Bulldozer for servicing
dean coal stockpile
2 Horizontal conveyor 1,000 feet long
with 36-inch-wide belt, carbon steel;
50 hp
2 Steel-reinforced concrete tunnel 8
feet wide x 6 feet deep x 1,000 feet
long
2 Centrifugal pump, 60 gpm, 30 feet
+ 1 spare head, carbon steel; 1 hp
1 Horizontal conveyor, 320 feet long
with 36-inch-wide belt, carbon steel;
15 hp
1 Steel-reinforced concrete tunnel 8
feet wide x 6 feet deep x 320 feet
long
1 Centrifugal pump, 60 gpm, 30 feet
•f 1 spare head, carbon steel; 1 hp
1 Automatic sampler of plate or
similar type conforming with ASTM
sampling requirements, primary
sampling from 339 tons/hr 2 inch x
0 coal from each of 2 transfer con-
veyors, combination of primary samples
to a single sample of cleaning plant
product
1 Diesel bulldozer; 100 hp
125
-------
TABLE A-'. PCC II PROCESS
(CLEANING AT INTERMEDIATE AITD FINE SIZES)
MATERIAL KALA/.CE - (M S COAL)
TABLE A-3 (continued)
Stream No.
Rescript ion
,
i
t
>.
>
•
,
•
*
I 9
1
,
,
1
1
1
,
1
1
3
1
2
3
1
i •>
t*
3 r
1 •
2 9
JO
3 1
i 2
J 1
35
9*
,7
3«
J "
»
Total stream, tons/hr
S treats components, tons/^
Coal , bone-dry
Water, total
C,al/min
Ash, tons/hr
Pyritic S, tons/hr
Total S, tons/hr
Btu/lb, bone-dry
1
Raw coal to
sizing
(3 in. x 0)
8S8.2
803.4
54.8
134.2
26.9
40.2
12,000
Coal to
crusher
(3 in. x 3/4 in.)
229.0
207.8
21.2
34.7
7.0
10. It
12,000
3
Coal from
raw coal
screen
(3/4 in. x 0)
760.7
595.6
165.1
99.5
19.9
29.8
12,000
i
3
*
S
7
a
«
1 0
i
i
i
i
i
i
i
i
i
2
2
2
2
2
2
29
2
2 •
2 9
£.°
9 1
3 2
S 3
)<•
2 9
I«
j r
?•
9ff
40
4
Coal to
fines screens
(3/4 in. x 0)
1,016.6
803.4
213.2
3,203.1
134.2
26.9
40.2
12,000
5
Oversize
from
fines screens
(3/4 in. x 28 m)
746.0
647.9
98.1
108.2
21.7
32.4
12,000
6
Undersize
from fines
screen
(28 m x 0)
478.7
155.5
323.2
26.0
5.2
7.8
12,000
7
Feed to low-
gravity cyclones
(3/4 in. x 28 m)
2.970.93
647.9
2.323.0
12.000.7
108.2
21.7
32.4
12,000
(continued)
a. Excluding 1,057.5 tonf/hr of mignttlte.
(continued)
-------
TABLE A-3 (continued)
8
Clean coal from
.ow-gravity cyclone
centrifuge
(3/4 in. x 28 m)
,
2
»
.
5
It
,
»
9
1 0
, i
1 3
1 3
1 *t
1 3
1 6
1 7
i e
1 9
3 O
1 i
2 2
a a
2fc
2 3
2 6
2 7
28
2 9
3°
31
32
39
1*
33
36
3 7
im
19
*• D
341.6
314.8
26.8
20.6
4.1
9.3
13,500
9
Feed to
high-gravity
cyclones
(3/4 in. x 28 m)
1 , J 1 0 . Ob
333.1
976.9
5.46T.5
87.6
17.6
23.1
10,700
10
Middling
from high-
gravity cyclone
centrifuge
(3/4 in. x 28 n)
249.2
229.7
19.5
30.9
6.2
10.0
12,500
11
Refuse
from high-
jravity cyclone
centrifuge
(3/4 in. x 28 m)
112.3
103.4
8.9
56.7
11.4
13.1
Excluding 1,726.0 tons/hr of magnetite.
(continued)
TABLE A-3 (continued)
12
Feed to
froth flotation
(28 m x 0)
i
2
3
4.
3
6
7
•
9
10
1 1
1 2
1 3
n.
1 3
1 6
1 7
i a
1 9
2 O
3 i
2 2
a 3
2 t.
2 3
2 6
2 7
2 a
2 9
3D
3 1
3 2
3 3
3*.
3 3
36
3 7
'i m
1 9
t O
1,611.0
155.5
1,455.5
6,276.9
26.0
5.2
7.8
12.000
13
Middling
from flotation
filter
(28 in x 0)
180.0
130.3
49.7
10.9
2.2
4.4
13.200
14
Refuse to
flotation
thickener
(28 m x 0)
1,371.6
25.2
1,346.4
5,459.3
15.1
3.0
3.4
15
Refuse from
flotation
filter
(28 m x 0)
34.8
25.2
9.6
15.1
3.0
3.4
(continued)
-------
TABLE A-'i (continued)
4
a
i
••
«
»
,
•
*
i*
t
t
,
i
i
,
i
,
1
1
a
i
a
a
2
a *
i
3 •
a «
2°
"
1 3
>»
)<•
t 9
1 t
37
jt
19
It 0
16
Clarit led
water
l.J^b.8
1,336.8
5..U7...'
17
Makeup
water
59.7
S9.7
iJ8.8
18
Refuse to
disposal pond
147.1
128.6
18.5
71.8
14.4
16.5
19
Middling to
stockpile
429.2
360.0
69.2
41.8
8.4
14.4
12,700
00
-------
TABLE A-4. PCC II PROCESS
(CLEANING AT INTERMEDIATE AND FINE SIZES)
EQUIPMENT LIST - BASE CASE (5% S COAL)
NOTE: Coal tonnages are listed as bone-dry coal excluding the
internal moisture of 3.5% in the base case coal. However,
equipment sizes include the handling of internal and of
surface moisture.
r.oal Receiving and Storage
Item
No.
Description
Inclined conveyor, 500 feet long,
with 1 fixed tripper, 48-inch-wide
belt, carbon steel, with tramp-iron
magnet; 125 hp
Elevated horizontal conveyor, 1,000
feet long with 1 traveling tripper,
48-inch-wide belt, telescoping chute,
carbon steel; 40 hp
Reclaiming hopper with 14 feet x 14
feet top opening, 3-1/2 feet deep
pyramid, and 24 inch x 24 inch bottom
opening, carbon steel
Vibratory pan feeder with 26 inch wide
x 48 inch long pan, carbon steel; 1.5
hp vibrator
Horizontal conveyor, 1,000 feet long
with 36-inch-wide belt, carbon steel;
35 hp
Steel-reinforced concrete tunnel 8
feet wide x 6 feet deep x 1,000 feet
long
Centrifugal pump, 60 gpm, 30 feet head,
carbon steel; 1 hp
2.
Unloading conveyors for
conveying 1,600 tons/hr,
3 inch x 0 raw coal from
unloading station to
s*:ocl'.piJes
Stacking conveyors for dis-
tributing coal along the tops
of 2 parallel and adjacent
wedge-shaped open piles, each
of 175,000 tons
Hoppers for reclaiming 803
tons/hr of 3 inch x 0 raw
coal from stockpiles
pan feeders for withdrawing
803 tons/hr of 3 inch x 0 raw
coal from reclaiming hoppers
Collecting conveyors for 803
ton*/hr of 3 inch x 0 raw coal
from pan feeders
Tunnels for collecting
conveyors
7. Tunnel sump pump
3.
A.
5.
20
20
+ 1 spare
(continued)
129
-------
TABLE A-4 (continued)
Item
8. Transfer conveyor
9. Tunnel for transfer
conveyor
10. Tunnel sump pump
11. Delivery conveyor for
803 tons/hr of 3 inch x
0 raw coal to raw coal
sizing area
12. Automatic sampling of coal
from stockpile to raw coal
sizing area
No.
Description
13. Bulldozer for servicing
raw coal storage piles
1 Horizontal conveyor, 320 feet long
with 36-inch-wide belt, carbon steel-
10 hp ei'
1 Steel-reinforced concrete tunnel, 7
feet wide x 6 feet deep x 320 feet
long
1 Centrifugal pump, 60 gpm, 30 feet h«ad,
+ 1 spare carbon steel; 1 hp
2 Inclined conveyor, enclosed, 600 fe«t
long, 36-inch-wide belt, with belt
scale, carbon steel; 75 hp
1 Automatic sampler of plate or similar
type conforming with ASTM sampli,^
requirements, primary sampling from
402 tons/hr of 3 inch x 0 coal froa
each of 2 delivery conveyors, combitu-
tion of primary samples to a sinal-
head sample ^
1 Diesel bulldozer; 100 hp
Area ?--Raw Coal Sizing
Item
No.
Description^
1. Raw coal screens for sizing
803 tons/hr of 3 inch x 0
coal to 208 tons/hr, 3 inch
x 3/4 inch, and 595 tons/hr,
3/4 inch x 0
(continued)
Horizontal vibrating screen, 6 feet
wide x 16 feet long, low-noise sus-
pension, standard positioning of v^ter
sprays, stainless steel flanged screw
plate for sizing at 3/4 inch.
steel body; 15 hp
130
-------
TABLE A-4 (continued)
No.
2.
3.
Crusher for reducing 208
tons/hr of 3 inch x 3/4
inch coal to 3/4 inch x 0
Crusher screen for sizing,
208 tons/hr of crushed coal
at 3/4 inch
Sieve bends for partial
dewatering and screening of
155 tons/hr of 28 mesh x 0
coal from 803 tons/hr of
3/4 inch x 0 coal
Fines screens for finish
5creening of 155 tons/hr
Of 28 mesh x 0 coal from
g03 tons/hr of 3/4 inch x
0 coal
Description
Single roll crusher with 24 inch x
48 inch roll and stationary breaker
plate, materials of construction
suited to secondary crushing of medium-
hard bituminous coal; 60 hp
Horizontal vibrating screen, 8 feet
wide x 16 feet long, low-noise sus-
pension, standard positioning of water
sprays, stainless steel screen plate
for sizing at 3/4 inch, carbon steel
body; 20 hp
Reversible sieve bend, 7 feet wide,
with deck of 1/8 inch Bixby-Zimmer
Iso-Rod spaced for 1.2 mm opening,
including feed box distributor, carbon
steel body; 0 hp
Horizontal vibrating screen, 8 feet
wide x 16 feet long, deck of 3/32 inch
Bixby-Zimmer Iso-Rod spaced for sizing
at 28 mesh, low-noise suspension,
standard positioning of water sprays,
carbon steel body; 20 hp
1.
Dense medium cyclone feed
8Ump for makeup of coal
-lurry comprising 648 tons/
£ coal at 3/4 inch x 28
£e8h and 3,360 tons/hr
enetite medium; nominal
Specific gravity of mag-
netite medium 1.34
No.
Description
(continued)
Cylindrical tank, 14 feet diameter x 2
feet high, with 60 degree cone bottom
and closed top, 7,000 gallon ground-
level installation, carbon steel
131
-------
TABLE A-4 (continued)
5.
6.
S.
Item
No.
2.
3.
4.
Pumps for feeding coal
slurry to dense medium
cyclones
Dense medium cyclones for
separation of 3/4 inch x
28 mesh coal at specific
gravity 1.34
Sieve bends for partial
drainage of medium from
315 tons/hr clean coal
tops (3/4 inch x 28 mesh)
from dense medium cyclones
Drain and rinse screens
for 315 tons/hr clean coal
tops at 3/4 inch x 28 mesh
+ 2 spare
12
Centrifuges for dewatering
315 tons/hr of 3/4 inch x
28 mesh clean coal from
drain and rinse screens
Sieve bends for partial
drainage of median from
333 tont/hr of 3/4 Inch
x 28 mesh bottom* from
low-gravity cyclone
Drain acreena for 333 tons/
hr of 3/4 inch x 28 mesh coal
Centrifugal pump, 4,000 gpm, 70
total head; 200 hp
Dense medium cyclone, 20 inch dia:
with tangential entry of feed and
exit of clean coal tops, cone anal-
about 20 degrees, hard nickel or
similarly abrasion-resistant iron
Reversible sieve bend, 6 feet wid.
deck of 3/32 inch Bixby-Zimmer '
so
spaced for 3/4 mm opening, including
feed box distributor; 0 hp 8
Horizontal vibrating screen, 7 fect
wide x 16 feet long, standard pO8l
tioning of water sprays in rinse
section, 2-compartment pan for
separate collections of medium and
rinse water, low-noise suspension
deck of 3/32 inch Bixby-Zimmer
Rod spaced for 1/2 mm opening,
steel frame; 18 hp
Vibrating basket centrifuge,
or vertical axis of baske? , ' e
basket of stainless steel screen-
individual motors and drives for'xm »~
rotation, for vibration along th.
of the basket, and if so designed *?*
oil pumping, carbon steel body Rn v
total ou *»
Reversible sieve bend, 6 feet wid.
deck of 3/32 inch Bixby-Zimmer I«o*
spaced for 3/4 mm opening, includl
feed box distributor; 0 hp UQln
Horizontal vibrating screen 7 f
wide x 16 feet long, low-noise su!'
pension, deck of 3/32 inch Blxby"
Zimmer Iso-Rod spaced for 1/2 um~
opening, carbon steel frame; 18 h
(continued)
132
-------
TABLE A-4 (continued)
Item
No.
Description
2.
3.
5.
Dense medium cyclone feed
sump for makeup of coal
slurry comprising 331 tons/
hr coal at 3/4 inch x 28 mesh
and 1,726 tons/hr magnetite
medium; nominal specific
gravity of magnetite medium
1.55
pumps for feeding coal slurry
to dense medium cyclones
Dense medium cyclones for
separation of 3/4 inch x 28
mesh coal at specific gravity
1.55
Sieve bends for partial
jrainage of medium from
230 tons/hr middling coal
tops (3M inch x 28 mesh)
from dense medium cyclones
m-ain and rinse screens for
,30 tons/hr middling coal
tops at 3/4 inch x 28 mesh
+ 1 spare
6.
rentrifuges for dewatering
£S tons/hr of 3/4 inch x
28 meflh coal from draln
rinsc screens
Cylindrical tank, 12-1/2 feet diameter
x 2 feet high, with 60 degree cone
bottom and closed top, 5,150 gallon,
ground-level installation, carbon steel
Centrifugal pump, 2,740 gpm, 70 feet
total head; 120 hp
Dense medium cyclone, 20 inch diameter
with tangential entry of feed and exit
of clean coal tops, cone angle about
20 degrees, hard nickel or similarly
abrasion-resistant iron
Reversible sieve bend, 5 feet wide,
with deck of 3/32 inch Bixby-Zimmer
Iso-Rod spaced for 3/4 mm opening,
including feed box distributor; 0 hp
Horizontal vibrating screen, 6 feet
wide x 16 feet long, standard posi-
tioning of water sprays in rinse sec-
tion, 2-compartment pan for separate
collections of medium and rinse water,
low-noise suspension, deck of 3/32
inch Bixby-Zimmer Iso-Rod spaced for
1/2 mm opening, carbon steel frame;
15 hp
Vibrating basket centrifuge, horizontal
or vertical axis of basket, cone-shaped
basket of stainless steel screen; indi-
vidual motors and drives for basket
rotation, for vibration along the axis
of the basket, and if so designed, for
oil pumping, carbon steel body; 60 hp
total
(continued)
133
-------
TABLE A-4 (continued)
Item
No.
Description
7. Sieve bends for partial
drainage of medium from
103 tons/hr of refuse
bottoms (3/4 inch x 28
mesh) from dense medium
cyclones
8.
9.
10.
Drain and rinse screens for
103 tons/hr of 3/4 inch x 28
mesh refuse
Centrifuge for dewatering
103 tons/hr of 3/4 inch x
28 mesh refuse from drain
and rinse screens
Dense medium recovery system for
dilute medium from rinse
screens in clean coal and
middling coal cleaning
sections
Reversible sieve bend, 5 feet wide
with deck of 3/32 inch Bixby-Zimmer
Iso-Rod spaced for 3/4 mm opening
including feed box distributor; 0 hp
Horizontal vibrating screen, 7 feet
wide x 16 feet long, standard posi-
tioning of water sprays in rinse
section, 2-compartment pan for
separate collections of medium and
rinse water, low-noise suspension
deck of 3/32 inch Bixby-Zimmer lso
Rod spaced for 1/2 mm opening,
steel frame; 18 hp 5
Vibrating basket centrifuge, horizontal
or vertical axis of basket, cone-shaL
basket of stainless steel screen
individual motors and drives for'b. t*t
rotation, for vibration along the
axis of the basket, and if so desiim-d
for oil pumping, carbon steel bodv.
60 hp total y>
Double-drum magnetite recovery unit
with permanent magnets in drums 30
inch diameter x 10 feet long dr^m •>
drums in series/unit; complete with'
dilute medium sump, magnetite scran»r
etc., installed at elevation above
dense medium separators; carbon steel-
Area 5—Fine Coal Cleaning
Item
No.
Description^
1. Froth flotation feed sump
for makeup of coal slurry
at 107. solids using 155 tons/
hr of 28 mesh x 0 coal
(continued)
Cylindrical tank, 13-1/2 feet
x 2 feet high with 60 degree cone
bottom and closed top, 6,300 gallo
ground-level installation, carbon
134
-------
TABLE A-4 (continued)
Item
2. Pump for feeding coal slurry
to froth flotation cells
No.
2
+ 1 spare
Description
Centrifugal pump, 3,140 gpm,
total head; 75 hp
60 feet
3.
Froth flotation cells for
treatment of 155 tons/hr of
28 mesh x 0 coal
4.
5.
6.
Disk filter for filtration
of 130 tons/hr middling coal
from froth flotation
Thickener receiving 5,800 gpm
refuse slurry (tailings) from
froth flotation and filtrate
from refuse filter
7.
Disk filter for filtration
of 25 tons/hr refuse (under-
flow) from thickener
Pump for returning 5,350 gpm
of clarified water
2 Bank of 5 froth flotation cells with
300 ft-Vcell; provisions for agitation,
aeration, and skimming of froth from
cell; each bank arranged with feed
box and tailings box; provisions for
reagent storage and reagent feeding;
carbon steel; 75 hp
3 Continuous rotary vacuum disk filter,
12 feet, 6 inch diameter x 10 disk,
stainless steel wire cloth; complete
with vacuum pumps and receiver, mois-
ture trap, filtrate pump, and blower;
525 hp
1 Single compartment bridge-supported
thickener with 120 feet diameter rein-
forced concrete tank; system includes
drive unit and lifting device, rake
mechanism, feed well, overflow arrange-
ment, underflow arrangement, and
instrumentation; rotation drive 5 hp,
lifting drive 1 hp
1 Continuous rotary vacuum disk filter,
12 feet, 6 inch diameter x 11 disk,
stainless steel wire cloth; complete
with vacuum pump and receiver, moisture
trap, filtrate pump, and blower, 580 hp
2 Centrifugal pump, 2,670 gpm, 150 feet
+ 1 spare total head; 175 hp
Area 6—Refuse Disposal^
Item
No.
Description
1. Collecting conveyor for
129 tons/hr of 3/4 inch x 0
refuse
Horizontal and inclined belt conveyor,
400 feet long with 24-inch-wide belt,
carbon steel, 15 hp
(continued)
135
-------
(cent Jnuei!)
4.
_ Item _
Refuse bin lor truck
loading
Trucks for transporting
129 tons/hr of 3/4 inch x
0 refuse 1 mile from coal
cleaning plant to refuse
disposal site
Refuse disposal site for
30-ycnr operation
- -iicl££I.iEt_i£n
Storage bin, 16 feet wide x 26 fMt.
lony x 18 feet high on vertical sid*«
13 feet deep pyramidal bottom with
fast opening slides for truck loading
f -highway dio.sel- electric dump
truck, 100 ton payload, 100 yd3 capa-
city, dump body for 3/4 inch x 0
racist, sluggish abrasive refuse
"Dry" storage site with 26,000 acre-
feet capacity for layered refuse
earth
Bulldozer for spreading
refuse and earth in layers
at disposal site
Diesel bulldozer; 100
Area 7— Clean Coal Storage
Item
1. Collecting conveyor for
315 tons/hr of 3/4 inch
x 28 mesh cleaned coal
2. Transfer conveyors
Stacking conveyors for
distributing coal along the
tope of 2 parallel and adja-
cent wedge-shaped open piles,
each of 75,000 tons
Hoppers under stockpile for
reclaiming cleaned coal from
stockpiles
No.
20
(continued)
Horizontal conveyor, 300 feet lOn»
with 36-inch-wide belt, carbon
10 hp
Inclined conveyor, 250 feet lona M-
36-inch-wide belt, with belt scale
carbon steel; 6C hp *
Elevated horizontal conveyor,
long with 1 traveling tripper,
wide belt, carbon steel; 25 hp
Reclaiming hopper with 14 feet x IA
feet top opening, 3-1/2 feet deei>
pyramid, and 24 inch x 24 inch hot
opening, carbon steel *'
136
-------
TABLE A-4 (continued)
Item
No.
Description
9.
feeders for withdrawing
TOO tons/hr, 3/4 inch x 28
esh cleaned coal from
hoppers
6 Collecting conveyors for
* 700 tons/hr cleaned coal
from pan feeders
7. Tonnel8 for collecting
conveyors
g. tunnel sump pump
conveyor
10. Tunnel for transfer
conveyor
11. Tunnel sump pump
12 Automatic sampling
12' rf coal from cleaning
plant
to stockpile
20 Vibrating pan feeder with 26 inch wide
x 48 inch long pan, carbon steel; 1.5
hp vibrator
2 Horizontal conveyor 500 feet long with
36-inch-wide belt, carbon steel, 20
hp
2 Steel-reinforced concrete tunnel 8 feet
wide x 6 feet deep x 500 feet long
2 Centrifugal pump, 60 gpm, 30 feet head,
+ 1 spare carbon steel; 1 hp
1 Horizontal conveyor, 250 feet long with
36-inch-wide belt, carbon steel; 10 hp
1 Steel-reinforced concrete tunnel 8 feet
wide x 6 feet deep x 250 feet long
1 Centrifugal pump, 60 gpm, 30 feet head,
+ 1 spare carbon steel; 1 hp
1 Automatic sampler of plate or similar
type conforming with ASTM sampling
requirements, primary sampling from
315 tons/hr 3/4 inch x 28 mesh coal
from transfer conveyor
2. Tr»n»fer conveyors
No.
Description
(continued)
Horizontal conveyor, 300 feet long with
36-inch-wide belt, carbon steel; 10
hp
Inclined conveyor, 250 feet long with
36-inch-wide belt, with belt scale,
carbon steel; 60 hp
137
-------
TABLE A-4 (continued)
Item
Description
3. Stacking conveyors for
distributing coal along
the tops of 2 parallel
and adjacent wedge-shaped
open piles, each of
75,000 tons
4. Hoppers under stockpile
for reclaiming middling
coal from stockpiles
5. Pan feeders for withdrawing
700 tons/hr, 3/4 inch x 0
middling coal from reclaiming
hoppers
6. Collecting conveyors for
700 tons/hr cleaned coal
from pan feeders
7. Tunnels for collecting
conveyors
8. Tunnel sump pump
9. Transfer conveyor
10. Tunnel for transfer
conveyor
11. Tunnel sump pump
12. Automatic sampling
of coal from cleaning
plant to stockpile
13. Bulldozer for servicing
stockpile
Elevated horizontal conveyor, 500
long with 1 traveling tripper, 36-mc
wide belt, carbon steel; 25 hp
20 Reclaiming hopper with 14 feet x I4
feet top opening, 3-1/2 feet deep
pyramid, and 24 inch x 24 inch bottom
opening, carbon steel
20 Vibrating pan feeder with 26 inch wide
x 48 inch long pan, carbon steel; 1.
hp vibrator
2 Horizontal conveyor 500 feet long
36- inch-wide belt, carbon steel, 20 np
2 Steel-reinforced concrete tunnel 8
feet wide x 6 feet deep x 500 feet long
2 Centrifugal pump, 60 gpm, 30 feet head,
+ 1 spare carbon steel; 1 hp
1 Horizontal conveyor, 250 feet long
with 36- inch-wide belt, carbon steel,
10 hp
1 Steel-reinforced concrete tunnel 8 feet
wide x 6 feet deep x 250 feet long
1 Centrifugal pump, 60 gpm, 30 feet bead,
+ 1 spare carbon steel; 1 hp
1 Automatic sampler of plate or similar
conforming with ASTM sampling require-
ments, primary sampling from 360 tons/hr
3/4 inch x 0 middling coal from transier
conveyor
1 Diesel bulldozer; 100 hp
138
-------
TABLE A-5. PCX 111 PROCESS
(CLEANING AT COARSE AND FINE SIZES)
MATERIAL BALANCE - BASE CASE (5% S COAL)
TABLE A-5 (continued)
1
1
1
1 3
1 (•
1 9
1 6
, 7
!•
»
0
1
2
3
I.
5
6
7
a
«
JO
3 1
2
,
1.
,
«
,
3 a
3 V
..0
Stream No.
Descri ntion
Stream components , tons/h
Coal, bone-dry
Water, total
Gal/nin
Ash. tons/hr
Pvritic S. tons/hr
Total S, tons/hr
Btu/lb. bone-dry
1
Raw coal to
sizing
(3 in. x 0)
809.2
55.2
135.1
27.1
40,5
12.000
2
Coal to
crusher
(3 in.x 3/4 In.)
209.3
21.4
34.°
7.0
10.5
12.000
3
Coal from
raw coal
screen
(3/4 In. x 0)
599.9
189.3
inn. 2
20.1
lo.n
12.000
/^
Coal to
fines screens
(1-1/2 in. x 0)
">
1,046.9
809.2
237.7
3.318.0
135.1
77.1
40.5
12,000
5
Oversize from
fines screens
(1-1/2 in.x 8 m
618.8
544.0
74.8
90.8
18.2
27.2
12,000
6
Oversize from
classifying
sieve bend
(8 m x 200 m)
432.3
250.3
182.0
41.8
8.4
12.5
12,000
7
Undersize from
classifying
sieve bend
(200 m x 0)
205.4
14.9
190.5
2.5
0.5
0.8
12,000
(continued)
(continued)
-------
TA.BLE *-5 (continued!
g
Feed to
DM cyclones
(1-1/2 In. x 8 •)
*o
2 119. la
544.0
1.595.3
8.929.0
90.8
18.2
27.2
12.000
9
Clean coal from
DM cyclone
centrifuge
(1-1/2 in.x 8 i»)
492.1
458.3
33.8
47.1
9.5
17.0
12.900
10
Refuse from
centrifuge
(1-1/2 in.x 8 m)
92.0
85.7
6.3
43.7
8.7
10.2
11
Feed to
table
(8 m x 200 m)
648.5
250.3
398.2
2,325.0
41.8
8.4
12.5
12.000
a. Excluding 1,243.0 tons/hi of magnetite.
(continued)
TABLE A-5 (continued)
12
Dressing water
to concentrating
table
i
3
7
•
9
10
1 1
1 3
1 3
1 *>
1 3
t 6
I 7
1>
1 »
2 0
a i
2 2
a 3
3 <•
a 3
2 6
2 7
a •
a 9
JO
9 1
»]
3 1
34
1 S
J*
9 7
3*
3*
4>O
129.7
129.7
518.8
13
Coal
concentrate
from table
(8 m x 200 m)
686.6
212.0
474.6
2,518.6
23.0
4.6
8.1
12.800
14
Clean coal
from table
centrifuge
(8 m x 200 m)
235.0
212.0
23.0
23.0
4.6
8.1
12.800
15
Clean coal
from table
filter
(200 m x 0)
20.5
14.9
5.6
2.5
0.5
0.8
12rOOO
(continued)
-------
TABLE A-5 (continued)
i
a
3
f
5
b
7
•
«
I 0
1 i
1 2
1 3
1 *
1 S
1 «
1 7
1 •
1 9
a O
2 1
22
a 3
2 *.
2 3
a 6
a 7
im
»
^
3
*
*
X
»
9
>
J
->
*>0
16
Total fine
clean coal
(& m x 0^
2SS.'i
226.9
28.6
25.5
5,1
8.9
12,800
17 '
Refuse from
table
centrifuge
(8 m x 200 tn)
42.6
38.3
4,3
18.8
3.8
4.4
16 1
Clarified
water
555.8
555.8
2,223.2
19
Makeup
water
17.8
17.8
71.2
(continued)
TABLE A-* (continued)
40
20
Refuse to
disposal pond
(8 m x 200 m)
134.fi
124.0
10.6
62.5
12.5
14.6
21
Clean coal
to stockpile
(1-1/2 in.x 0)
747.6
685.2
62.4
72.6
14.6
25.9
12,900
-------
TABLE A-6. PCC III PROCESS
(CLEANING AT COARSE AND FINE SIZES)
EQUIPMENT LIST - BASE CASE (5% S COAL)
NOTE:
Coal tonnages are listed as bone-dry coal excluding the inter
moisture of 3.5% in the base case coal. However, equipment s"
include the handling of internal and of surface moisture. 2SS
Area l_-^CpaJ_ Receiving and Storage
Item No
1. Unloading conveyors for 2
conveying 1,600 tons/hr,
3 in. x 0 raw coal from
unloading station to
stockpiles
2. Stacking conveyors for 2
distributing coal along
the tops of 2 parallel and
adjacent wedge-shaped open
piles, each of 175,000
tons
3. Hoppers for reclaiming 20
809 tons/hr of 3 in. x 0
raw coal from stockpiles
4. Pan feeders for with-
drawing 809 tons/hr of
3 in. x 0 raw coal from
reclaiming hoppers
5. Collecting conveyors for
809 tons/hr of 3 in. x 0
raw coal from pan feeders
6. Tunnels for collecting
conveyors
7. Tunnel sump pump
20
Inclined conveyor, 500 ft 1
with 1 fixed tripper, 48 in U8'
wide belt, carbon steel, wi^v
tramp iron magnet, 125 hp
Elevated horizontal convevnr-
1,000 ft long with 1 travel!!
tripper, 48 in. wide belt
telescoping chute, carbon'
steel, 40 hp
Reclaiming hopper with H ft
14 ft top opening, 3-1/2 ft *
deep pyramid, and 24 in . x 2L
in. bottom opening, carbon
steel
Vibratory pan feeder with 26 •
wide x 48 in. long pan> «
steel, 1.5 hp vibrator
Horizontal conveyor, 1,000 f
long with 36 in. wide beit
carbon steel, 35 hp *
Steel reinforced
Centrifugal pump, 60 gpm
head, carbon steel, 1 hp
(1 spare)
rt
(continued)
142
-------
TABLE A.-6 (continued)
11.
12.
Item
No,
8. Transfer conveyor
9. Tunnel for transfer
conveyor
10. Tunnel sump pump
Delivery conveyor for 809
tons/hr 3 in. x 0 raw coal
to raw coal sizing area
Automatic sampling of coal
from stockpile to raw coal
sizing area
Bulldozer for servicing
raw coal storage piles
Description
Horizontal conveyor, 320 ft
long with 36 in. wide belt,
carbon steel, 10 hp
Steel reinforced concrete
tunnel, 7 ft wide x 6 ft deep x
320 ft long
Centrifugal pump, 60 gpm, 30 ft
head, carbon steel, 1 hp
(1 spare)
Inclined conveyor, enclosed,
600 ft long, 36 in. wide belt,
with belt scale, carbon steel,
75 hp
Automatic samples of plate or
similar type conforming with
ASTM sampling requirements,
primary sampling from 405
tons/hr, 3 in. x 0 coal from
each of 2 delivery conveyors,
combination of primary samples
to a single head sample.
Diesel bulldozer, 100 hp
Area_2^Raw_J?oa_l jjizing
Item No.
1.
Raw coal screens for
sizing 809 tons/hr, 3 in. x
0 coal to 209 tons/hr, 3 in.
x 3/4 in. and 600 tons/hr,
3/4 in. x 0
Description
(continued)
Horizontal vibrating screen,
6 ft wide x 16 ft long, low-
noise suspension, standard
positioning of water sprays,
stainless steel flanged screen
plate for sizing at 3/4 in.,
carbon steel body, 15 hp
143
-------
TABLE A-6 (continued)
3.
6,
Item
No.
Crusher for reducing 209
tons/hr, 3 in. x 3/4 in.
coal to 1-1/2 in. x 0
Prewet screen for sizing,
209 tons/hr of crushed
coal at 1-1/2 in.
Sieve bends for dewatering
and screening, at 9 mesh,
of 209 tons/hr of coal at
1-1/2 in. x 0 and 600
tons/hr of coal at 3/4 in. x 0
Fines screens for finish
screening, at 8 mesh, of
oversize from sieve bends
receiving 209 tons/hr coal
at 1-1/2 in. x 0 and 600
tons/hr coal at 3/4 in. x 0
Sit-ve bends for screening
of 15 tons/hr of 200 mesh x
0 coal from 265 tons/hr of
8 mesh x 0 coal
Single roll crusher with 24 in.
x 36 in. roll and stationary
breaker plate, materials of
construction suited to
secondary crushing of medium
hard bituminous coal, 25 hp
Horizontal vibrating screen, 6
ft wide x 16 ft long, low-noise
suspension, standard positioning
of water sprays, stainless steel
screen plate for sizing at 1-1/2
in., carbon steel body, 15 hp
Reversible sieve bend, 7 ft wide
with deck of 1/8 in. Bixby-Zimnwr
Iso-Rod spaced for 2.0 mm opening
including feed box distributor
carbon steel body, 0 hp *
Horizontal vibrating screen 8
ft wide x 16 ft long, low-noise
suspension, standard positionin8
of water sprays, stainless steel
deck for sizing, l-l/2 in. x Q
and 3/4 in. x 0 coal at 8 mesh
carbon steel body, 20 hp *
Reversible sieve bend, 5 ft w^.
with deck of 3/32 in. Bixby-
Zimmer Iso-Rod spaced for Q.21 M
opening, including feed box'
distributor, carbon steel body,0 fc
Area 3--Coarse CojtL J^J^llPiL-^
Item
No.
1. Dense medium cyclone feed
sumps for makeup of coal
slurry comprising 544
tons/hr coal at 1-1/2 in. x
8 mesh and 2,819 tons/hr
magnetite medium, nominal
specific gravity of magentite
med ium 1.55
Cylindrical tank, 13 ft dia x '>
ft high, with 60 degree cone
bottom and closed top, 5,700 Ral
ground-level installation, '
carbon steel
(continued)
144
-------
TABLE A-6 (continued)
Item
No.
Pumps for feeding coal
slurry to dense medium
cyclones
Dense medium cyclones for
separation of 1-1/2 in. x
8 mesh coal at specific
gravity 1.55
4. Sieve bends for partial
drainage of medium from
clean coal tops from dense
medium cyclones
Drain and rinse screens for
458 tons/hr clean coal tops
at 1-1/2 in. x 8 mesh
Centrifuges for dewatering
458 tons/hr of 1-1/2 in. x
8 mesh clean coal from drain
and rinse screens
Sieve bends for partial
drainage of medium from 86
tons/hr of 1-1/2 in. x 8
mesh refuse
Description
Centrifugal pump, 3,000 gpm, 70
ft total head, 150 hp
Dense medium cyclone, 28 in.
dia, with tangential entry of
feed and exit of clean coal
tops, cone angle about 20
degrees, hard nickel or similarly
abrasion-resistant iron
Reversible sieve bend, 7 ft wide,
with deck of 3/32 in. Bixby-
Zimmer Iso-Rod spaced for 3/4 mm
opening, including feed box
distributor, carbon steel body,
0 hp
Horizontal vibrating screen
8 ft wide x 16 ft long, standard
positioning of water sprays in
rinse section, 2-compartment pan
for separate collections of
medium and rinse water, low-noise
suspension, deck of 3/32 in.
Bixby-Zimmer Iso-Rod spaced for
1/2 mm opening, carbon steel
frame, 20 hp
Vibrating basket centrifuge,
horizontal or vertical axis
of basket, cone-shaped basket
of stainless steel screen,
individual motors and drives for
basket rotation, for vibration
along the axis of the basket,
and if so designed, for oil
pumping, carbon steel body, 60
hp total
Reversible sieve bend, 5 ft
wide, with deck of 3/32 in.
Bixby-Zimmer Iso-Rod spaced for
3/4 mm opening, including feed
box distributor, carbon steel
body, 0 hp
(continued)
145
-------
TABLE A-6 (continued)
Item
No.
Description
8.
9.
10.
Drain and rinse screens for
86 tons/hr of 1-1/2 in. x 8
mesh refuse
Centrifuge for dewatering
86 tons/hr of 1-1/2 in. x 8
mesh refuse
Dense medium recovery system
for dilute medium from rinse
screens in coarse and inter-
mediate cleaning areas
Horizontal vibrating screen, 6
ft wide x 16 ft long, standard
positioning of water sprays in
rinse section, 2-compartment pan
for separate collections of
medium and rinse water, low-nois*
suspension, deck of 3/32 in.
Bixby-Zimmer Iso-Rod spaced for
1/2 mm opening, carbon steel
frame, 15 hp
Vibrating basket centrifuge,
horizontal or vertical axis of
basket, cone-shaped basket of
stainless steel screen,
individual motors and drives for
basket rotation, for vibration
along the axis of the basket
and if so designed, for oil
pumping, carbon steel body, 6Q
hp total
Double-drum magnetite recovery
unit with permanent magnets in
drums, 30 in. dia x 8 ft lone
drum, 2 drums in series/unit
complete with dilute medium
sump, magnetite scraper, etc.
installed at elevation above
dense medium separators, carbon
steel, 10 hp/unit
Area 4 — Flne__Cgal Cleaning
Item
No.
I.
Table feed sump for makeup
of coal slurry at water to
solids ratio of 1.5 using
250 tons/hr of
coal
8 x 200 mesh
(continued)
Cylindrical tank 8 ft dia x 2 ft
high with 60 degree cone bottom
and closed top, 1,620 gal,
ground-level installation,
carbon steel
146
-------
TABLE A-6 (continued)
Item
No.
Pump for feeding coal
slurry to concentrating
tables
Concentrating tables
receiving 250 tons/hr of
8 x 200 mesh feed
18
Sieve bends for partial
dewatering of 212 tons/hr
of 8 x 200 mesh clean coal
from tables
Centrifuges for dewatering
212 tons/hr of 8 x 200 mesh
clean coal from table sieve
bend
Thickener receiving about
1,800 gpm of slurry,
comprising 200 mesh x 0
slurry from raw coal sizing
section and underflow water
from table concentrate sieve
bend
Description
Centrifugal pump, 800 gpm, 20 ft
total head, 15 hp
(1 spare)
Double deck coal washing table
(36 decks, total) mounted 4
decks high, 134 ft2/deck, cable-
suspended, including "head
motion" oscillator for each
double deck unit, revolving feed
distributor servicing each 6
decks (6 distributors for total
system), 3 hp/double deck table,
1 hp/distributor
Reversible sieve bend, 7 ft wide,
with deck of 1/16 in. Bixby-
Zimmer Iso-Rod spaced for 0.15 mm
opening, including feed box
distributor, carbon steel body,
0 hp
Vibrating basket centrifuge,
horizontal or vertical axis of
basket, cone-shaped basket of
stainless steel screen for
dewatering 8 x 200 mesh feed,
individual motors and drives for
basket rotation, for vibration
along the axis of the basket, and
if so designed, for oil pumping,
carbon steel body, 85 hp total
Single compartment bridge
supported thickener with 70 ft
dia reinforced concrete tank,
system includes drive unit and
lifting device, rake mechanism,
feed well, overflow arrangement,
underflow arrangement, and
instrumentation, rotation drive,
5 hp, lifting device, 1 hp
(continued)
147
-------
TABLE A-6 (continued)
Item
Disk filter for filtration
of thickener underflow
containing 15 tons/hr coal
at 200 mesh x 0
Centrifuge for dewatering
38 tons/hr of 8 x 200 mesh
refuse from concentrating
table
___Descrlption
Continuous rotary vacuum disk
filter, 12 ft, 6 in. dia x 6 ft
disk stainless steel wire cloth
complete with vacuum pump and '
receiver, moisture trap, filtrate
pump, and blower, 200 hp
Vibrating basket centrifuge,
horizontal or vertical axis'of
basket, cone-shaped basket of
stainless steel for dewaterim>
8 x 200 mesh feed, individual
motors and drives for basket
rotation, for vibration alone the
axis of the basket, and if SQ
designed, for oil pumping, carbon
steel body, 60 hp total
Area 5j"Jl
1.
2.
3.
Item
Collecting conveyor for 124
tons/hr of 1-1/2 in. x 200
mesh refuse
Refuse bin for truck
1oading
Trucks for transporting
124 tons/hr of 1-1/2 in. x
200 mesh refuse 1 mile from
coa] cleaning plant to
disposal site
i on
Horizontal and inclined belt
conveyor, 400 ft long with 24 in.
wide belt, carbon steel, 15 _
Storage bin, 16 ft wide x 26 ft
long x 18 ft high on vertical
sides, 13 ft deep pyramidal
bottom with fast opening slides
for truck loading
Off highway diesel electric
dump truck, 100 ton payload
100 yd3 capacity, dump body'for
1-1/2 in. x 200 mesh moist
sluggish, abrasive refuse
(continued)
148
-------
TABLE A-6 (continued)
Item
Refuse disposal site for
30 yr operation
Bulldozer for spreading
refuse and earth in layers
at disposal site
No,
Description
"Dry" storage site with 25,000
acre capacity for layered refuse
and earth
Diesel bulldozer, 100 hp
Item
1. Collecting conveyor for 685
tons/hr of 1-1/2 in. x 0
cleaned coal
2. Transfer conveyors
Stacking conveyors for
distributing coal along
the tops of 2 parallel and
adjacent wedge-shaped open
piles, each of 150,000 tons
Hoppers under stockpile for
reclaiming cleaned coal from
stockpiles
Pan feeders for withdrawing
1,350 tons/hr, 1-1/2 in. x
0 cleaned coal from
reclaiming hoppers
Collecting conveyors for
1 350 tons/hr cleaned coal
from pan feeders
Jto.
1
20
20
Description
Horizontal conveyor, 300 ft long
with 48 in. wide belt, carbon
steel, 20 hp
Inclined conveyor, 200 ft long,
36 in. wide belt, with belt
scale, carbon steel, 50 hp
Elevated horizontal conveyor,
1,000 ft long with 1 traveling
tripper, 36 in. wide belt,
carbon steel, 40 hp
Reclaiming hopper with 16 ft x
16 ft top opening, 4 ft deep
pyramid, and 26 in. x 26 in.
bottom opening, carbon steel
Vibratory pan feeder with 30 in,
wide x 48 in. long pan, carbon
steel, 1.5 hp vibrator
Horizontal conveyor 1,000 ft
long with 42 in. wide belt,
carbon steel, 50 hp
(continued)
149
-------
TABLE A-6 (continued)
Item
7. Tunnels for collecting
conveyors
8. Tunnel sump pump
9. Transfer conveyor
10. Tunnel for transfer
conveyor
11. Tunnel sump pump
12. Automatic sampling of coal
from cleaning plant to
stockpile
13. Bulldozer for servicing
stockpile
Steel reinforced concrete
tunnel 8 ft wide x 6 ft deeo *
1,000 ft long P X
Centrifugal pump, 60 8pm> 30 f
head, carbon steel, 1 hp
(1 spare)
Horizontal conveyor, 320
with 42 in. wide belt,
steel, 15 hp
Steel reinforced concrete tunnel
8 ft wide x 6 ft deep x 32Q ft
long
Centrifugal pump, 60 gpm> 3Q f
head, carbon steel, I hp
(1 spare)
Automatic sampler of plate or
similar type conforming with
sampling requirements, primary
sampling from 343 tons/hr, l^
in. x 0 coal from each of 2
transfer conveyors, combination
of primary samples to a single
sample of cleaning plant product
Diesel bulldozer, 100 hp
150
-------
TABLE A-7. KVB COAL DESULF11R1/.ATION PROCESS
MATEP.1AL BALANCE - BASE CASE
t
-2
3
ft
7
«
9
1 0
1 1
1 3.
1 .
1*.
1 5
1 *
1 7
1«
1 9
^0
1 1
2 ^
a 3
3 t.
J 5
i e>
3 /
J H
3V
J 0
3 ,
t 2
j j
) i.
f ^
i n
'•*
^,,
Stream No.
Descript ion
Total stream, tons/hr
Stream component s ,tonR/h
Coal
Pyritic S
Sulfate S
Organic S
H20
NO 2
02
N'2
NO
S02
FeSO^, in coa]
Na2SO3
NaHSO3
Ca(OH)2
Ca(S03)
XaOH
FeSO4, in solution
Sulfate S,in solution
Na?S04
Fe(OH)3
Fe?(S04)-i
CaS04-2H20
CaSO3.2H20
Xa3Fe3(S04)2(OH)6
Binder
Natural gas
CaO
Tempera ture , °F
Pressure, psig
gpm
aft ^/min
1
Coal feed
to reactor
593.0
543.6
19.1
0.356
9.0
20.7
55
2
Recvcled
gas stream
1206.6
31.9
103.9
3.1
1065.4
2.1
' 302
3
Makeup
NOj
0.119
0.119
TABLE A-7 (continued)
••"
4
Makeup
02
32.7
32. -0
0.642
,
I
1
5
Oxidizing gas
to reactor
1238.8
31.9
104.0
34.5
1066.0
2.1
302
6
Coarse coal
from reactor
399.2
342.6
0.248
0.23(3
5.8
20.7
29.4
200
7
Reactor
off-gas
1433.0
186.9
0.135
0.126
3.2
31.9
104.0
3.1
1066.0
21.3
16. C
200
562,961
(ront inued)
(continued)
-------
TABLE A-7 (continued)
TABLE A-7 (continued)
N>
1
8
Water to
venturi
L/G - 10
i 1409.0
2
j
.
5
•
. 1407.0
10
, ,
,, 2.0
|*i
1 3
1 *
1,
!•
1*
a o
2 I
2 2
a 3
1 1.
1 9
z ft
7
•
O
*
9
* 86
7
• 5.638
,
9
Scrubber
slurry
outlet
1616.5
186.9
0.135
0.126
3.2
1406.9
3.0
16.0
86
6.468
10
Scrubber
off-gas
1225.5
31.9
104.0
3.1
1066.0
20.2
86
a Cm
11
Solution
to venturi
1519.5
1407.0
109.3
3.2
86
5,630
i
it
3
7
8
9
1 O
1
1
!<•
IS
1 *
1
11
I
2 O
2
2
2
2 I
2 3
2 6
2 7
2 •
2 9
? °
3 1
3 2
3 1
3 >.
3 9
36
3 7
3«
)«
t«
Scrubber
solution
outlet
15A2.0
1407.6
83.8
50.4
86
5,632
Scrubber
off-gas
1207.3
31.9
104.0
3.1
1066.0
2.1
86
atm
14A
Recycle gas
1206.6
31.9
103.9
3.1
1065.4
2.1
86
atm
1 ^^ 1
Bleed
to flair
0.783
0.019
0.119
0.002
0.642
0.001
86
(continued)
(continued)
-------
TABLE A-7 (continued)
1
a
3
<•
3
6
7
•
1 3
1 6
J 7
i a
1 9
3 O
2 1
2 a
2 >
34.
2 a
2 6
3 7
3 •
a 9
JO
?1
9 3
i a
»«.
J3
3*
3 7
>•
1 9
1.0
15
Thickener
underflow
560.3
186.9
0.135
0.126
3.2
353.6
0.225
16.0
86
1,415
16
Thickener
overflow
1056.1
1053.3
2.8
86
4,215
17
H20
recycle
1045.7
1045.7
55
4,184
20
Effluent
tank
outlet
2102.1
2099.0
3.0
8,399
(continued)
TABLE A-7 (continued)
•
a
3
i.
s
&
7
B
9
1 O
1 1
: 3
1 3
1 <.
1 3
1 6
1 7
ID
> V
a o
2 1
3 3
a i
a i.
2 5
a «
a 7
a e
a 9
30
3 1
3 2
3 3
It
1 3
3 6
3 ,
'!•
1 9
1.0
21
Affluent
bleed line
693.0
692.0
1.0
2j769
22
Ca(OH)2
feed
179.7
161.7
17.9
647.0
23
Neutralizer
tank
outlet
1713.0
1569.1.
114.4
29.1
6,279
24
Thickener
underflow
209.7
175.4
5.1
29.1
702
(continued)
-------
TABLE A-7 (continued)
,
i
.
,
.
(
,
,
i
,
i
!
1
1
,
,
3
2
2
a
2
2
2
2
2
2
^
3
3
3
3b
3 3
1 ft
3 7
•t»
If
40
25
Thickener
overflow
1503.2
1393.9
109.3
5,577
26
NaOH
feed
16.3
13.0
3.2
52
27
Cyclone
feed
942.0
186.9
0.135
3.2
721.5
0.246
13.6
16.1
0.138
200
60
2,887
28
Cyclone
overflow
640.9
0.218
14.6
0.123
200
2,564
(continued)
TABLE A-7 (continued)
1
*
3
4
3
*
7
B
s.
1 0
1 1
12
13
I *•
IS
I 6
1 7
i a
19
20
2 I
2 1
2 3
2 <.
2 3
2 6
a ?
2 •
2 4
?°
3 1
12
33
3 *•
33
3*
3 7
J*
1 *
40
29
Cyclone
underflow
286.1
186.9
0.135
3.2
80.5
0.028
13.6
1.5
0.013
200
322
30
Wash
water
feed
442.5
442.5
200
1,771
31
Cyclone
feed
728.6
18ft. 9
0.135
3.2
523.1
0.028
15.1
0.015
200
60
2,093
32
Cyclone
overflow
381.6
367.8
0.021
13.7
0.012
200
1,472
(continued)
-------
TABLE A-7 (continued)
TABLE A-7 (continued)
Ln
Ui
>
2
3
«
5
6
7
6
9
1 0
1 1
13
1 3
1 *•
1 5
1 t,
I 7
i a
1 9
30
2 i
3 3
2 3
2 <•
2 3
2 6
2 '
2 •
2 9
?°
3 t
i a
3 3
3 4-
1 3
3«
3 7
>•
1 »
4. O
33
Cyclone
underflow
266. A
186.9
0.135
3.2
74.7
0.007
1.4
0.003
200
299
34
Cyclone
overflow
677.3
677.3
200
2,710
35
Cyclone
feed
941.9
186.6
0.135
3.0
752.1
200
60
3,009
36
Cyclone
overflow
670.5
670.5
200
2,683
I
2
3
<•
3
*
7
&
9
I O
I 1
12
1 3
1 *•
1 5
1 6
1 7
i a
1 9
2 O
2 1
2 2
2 3
2 <•
2 5
2 6
2 7
2 0
2 9
3O
3 1
1 2
3 3
3U
11
3ft
3 7
t •
1 9
*. O
37
Cyclone
underflow
271.2
186.6
0.135
3,0
81.3
200
326
38
NaOH teed
to leach tank
6.2
3.1
3.1
55
13
39
Reaction
tank feed
272.0
185.1
0.135
2.2
84.5
200
338
40
Fines
Thickener
overflow
673.6
667.0
0.007
0.003
5.5
1.0
200
2,669
(cont inued)
(continued)
-------
TABLE A-7 (continued)
1
1
»
«
s
*
,
1
1
,
,
1
1
1
a
2
2
2
2
3
a
2
a
i°
9
3 2
S3
3".
3 3
J*
37
t*
39
4 0
41
Fines
thickener
underflow
3.5
3.5
200
14
42
Cyclone
feed
945.2
185.1
0.135
2.2
757.7 ^
200
60
3,032
43
Cyclone
underflow
267.8
185.1
0.135
2.2
80.3
200
322
tti>
Cyclone
feed
937.5
185.1
0.135
2.2
750.0
200
60
3,001
(continued)
TABLE A-7 (continued)
1
a
3
fc
S
4
7
B
9
1 O
I »
: a
1 3
L <•
13
1 6
1 1
i a
1 9
2 O
2 I
2 2
a 3
2 4.
2 3
2 6
2 7
2 •
2 9
JMS
3 1
3 2
3 3
31.
3 3
3 *
a 7
!•
39
4O
45
Cyclone
overflow
669.6
669.6
200
2,680
46
Cyclone
underflow
267.8
185.1
0.135
2.2
80.3
200
322
47
Cyclone
feed
937.5
185.1
0.135
2.2
750.0
200
60
3.001
48
Cyclone
overflow
669.6
669.6
!
200
2,680
(continued)
-------
TABLE A-7 (continued)
.
2
3
*•
3
fc
7
m
9
10
1 1
I 3
I 3
1 <•
1 9
1 6
1 7
1 8
1 9
2 O
2 1
2 2
a 3
24.
2 3
2 6
2 7
2 •
2 9
2°
*>
12
» 3
3*.
1 9
9 «
3 7
1 •
1 9
t.0
49
Cyclone
underflow
267.8
185.1
0.135
2.2
80.3
200
322
50
Wash
water feed
357.1
"iS7.1
200
1.429
51
Centrifuge
feed
625.0
185.1
.0.135
2.2
437.5
200
40
1,751
52
Centrifuge
wash water
252.9
252.9
200
1,012
(continued)
TABLE A-7 (continued)
,
2
J
<•
5
0
,
8
v
10
1 1
I 2
1 3
,..
I 3
1 6
, ,
1 8
t 9
3 0
2 1
2 2
a j
2 1.
2 3
2«
2 7
2 8
2 9
30
3 1
1 2
j a
3 <•
•j s
3 6
3 '
) •
,.
<•»
53
Recycled
centrate
669.6
669.6
200
2,680
54
Fine coal
product
208.3
185.1
0.135
2.2
20.8
55
Classifier
overflow
425.9
405.8
20.0
0.035
1,624
56
Classifier
overflow
366.8
346.7
19.9
0.215
1.387
(continued)
-------
TABLE A-7 (continued)
TABLE A-7 (continued)
00
57
Classifier
underflow
!
3
1
4.
1
&
,
1
1
1
1
1
,
1
1
1
1
t
2
3
a
a
a
a
a
a
2
2£.
3
33
99
34
33
}«
3 J
3«
3*
*C
433.2
342.6
0.248
5.8
79.8
4.5
0.049
319
58
Mash water
feed
405.8
405.8
1,624
59
Classifier
underflow
438.1
342.6
0.248
5.8
79.8
9.5
0.015
319
60
Coarse
thickener
feed
1328.3
342.4
0.248
5.6
980.0
3.921
61
i
2
3
4>
9
7
0
»
1 O
1 1
t a
1 3
1 d
15
1 •
,7
1 •
19
2 0
2 1
2 2
a s
21*
2 5
26
3 7
2 •
3 •
i°
3 I
3 3
ss
3<*
33
J«
S7
3B
>f
«»
Coarse
thickener
overflow
362.1
338.6
0.015
16.7
6.6
1,355
62
Coarse
thickener
underflow
989.6
342.4
0.248
5.6
641.3
2,566
63
NaOH
feed
18.8
9.4
9.4
55
38
64
Reactior. tank
overflow
996.1
341.0
0.248 ' '
4.1
650.8
200
2,604
(continued)
(continued)
-------
TABLE A-7 (continued)
TABLE A-7 (continued)
Ui
»
2
3
"
9
6
7
•
9
1 0
1 1
1 2
1 J
1*
1 9
1*
i r
!•
1 »
a o
2 I
2 2
2 3
2fc
2 9
2«
2 7
2 •
2«
££.
1 1
12
SI
><•
l»
36
3 7
1 •
IS,
i. O
65
Classifier
overf low
335.7
335.7
200
1,343
66
Classifier
overflow
900.2
900.2
200
3,602
67
Classifier
underflow
431.7
341.0
0.248
4.1
86.3
200
345
68
Classifier
overflow
335.7
335.7
200
1.343
1
2
3
t.
»
6
7
•
9
10
1 1
1 2
1 3
1 if
1 9
1 6
1 7
1 0
1 t
20
2 1
2 2
2 3
a <.
2 3
26
J 7
26
2 9
30
3 1
1 2
] 3
3*.
-) ^
3 6
3 7
J«
IV
1*0
69
Classifier
underflow
431.7
341,0
0.248
4.1
86.3
200
345
70
Classifier
underflow
431.7
341.0
0.248
4.1
86.3
200
345
71
Wash
water feed
143.9
143.9
200
576
72 1
Coarse coal
centrifuge feed
S7S.f>
341.0
0.2iS
4 1
230 '
i
i
*
921 ]
1
(continued)
(continued)
-------
TABLE A-7 (continued)
3
J
31
40
73
Centrifuge
wash water
feed
* 143.9
a
i 143.9
1 0
13
1 3
1 9
1 7
1 •
1 9
a o
2 1
2 2
a 3
2<.
3 S
2 «
» 7
1 •
»
0
1
9
• 200
7
« 576
74
Recycle
centrate
335.7
335.7
200
1.343
75
Coarse coal
product
383.7
341.0
0.2iS
4.1
38.3
76
Combined
leachate
feed
2268.2
2160.1
0.225
5.1
34.5
0.356
22.2
7.6
37.8
200
8,643
(continued)
TAB1E A-7 (continued)
77
i
3
"
9
6
7
a
9
I 0
1
u
1 3
!<•
1 9
»
1
IB
1 9
20
2
2 2
2
2 >.
3 3
2 6
2 7
2 fl
2 »
30
a i
1 2
9 9
14.
3 9
1«
3 7
3*
39
fcO
50% NaOH
feed
0
0
0
38 ,
78
207. lime
feed
15.5
12.4
3.1
50
'
79
02 feed
4.5
4.4
0.092
80
Neutralizer
effluent
2990.3
2869.1
7.5
22.6
7.9
5.0
49.0
29.0
200
11,480
(continued)
-------
TABLt A-7 (continued)
,
2
3
"
5
6
7
e
9
1 0
1 1
V 2
1 3
1 <•
1 3
i 6
] ?
i a
» 9
2 0
7 I
2 2
a j
3*.
a,
3 6
2 7
a a
2 9
1C
31
•»2
> S
9 *
-J 1
» »
) '
1 •
19
b O
81
Pond
settled
solids
202.0
80.8
7.5
22.6
7.9
5.0
A9.0
29.0
82
Pond
water
recycle
2788.3
2788.3
55
11,136
83
Fine coal
wash water
610.1
610. 1
55
2,441
84
Coarse coal
wash water
287.8
287.8
55
1,152
(continued)
TABLK A-7 (continued)
1
2
3
"
3
*
7
8
«
1 O
1 1
1 2
1 3
1*.
1 5
1 6
1 7
i a
i *
2 O
2 1
22
2 3
2 tt
2 5
2 f>
27
2 a
a 9
30
3 ,
1 2
3 3
3 *.
1 3
3 ft
1 T
J •
T 9
*. O
85
Water to
NaOH
preparation
9.7
9. J
55
39
86
Water to
lime
slaker
179.3
179.3
55
697
87
Raw water
makeup
192.9
192.9
55
752
88
Slaked
lime
105.4
B4.3
21.0
338
(cont inued)
-------
TABLE A-7 (continued)
2
i.
I
I
1
1
1
I
I
I
1
I
4
3
1
a
a
3.
2
a
2
a
J_
3
33
S3
!<•
33
A
3 r
3t
jt
i
89
Raw
lime
15.9
15.9
90
NaOH feed
to mix
tank
6.5
1.2
1.?
13
91
NaOH
31. A
15.7
15.7
92
92
°2
37.3
36.5
0.734
(continued)
TABLE A-7 (continued)
1
2
3
*•
5
6
7
fl
9
1 O
1 1
12
13
!*•
IS
16
17
1 8
19
2 D
2 L
a 2
a a
2 <.
a 3
2 6
2 7
2 •
a 9
9 O
32
a s
3*.
39
3*
3 7
39
3*
46
93
Binder
solution
9.4
4.7
4.7
20
94
Coarse coal
bleed
57.5
51.1
0.038
0.615
5.7
95
Feed to
agglomeration
265.9
236.2
0.173
2.8
26.5
96
Steam from
dryer
18.4
18.4
(continued)
-------
TABLE A-7 (continued)
t
2
J
t.
9
*
7
•
9
I C
1 1
1 2
1 3
1 *•
1 3
1 *
i r
i*
i »
30
2 I
23
3 3
2*.
2 9
a *
3 7
34
2 *
J°
3 1
3 3
3 1
1*
t J
? *
3 »
*•
t •
40
97
Pellet
product
256.8
236.2
0.173
0.236
2.8
12.8
'-* . 5
98
Coarse coal
product
U2.2
294. i
0.286
3.".
44, 1
99
Clean coal
product
598.9
530.6
0.459
0.236
6.3
56.9
4.5
100
Natural
gas
0.067
0.067
50
(cont inued)
TABLE A-7 (continued)
I
]
1
*•
5
*
7
a
9
t 0
1 1
1 2
1 3
I <•
1 3
1 6
1 7
1 •
1 9
2 O
2 1
2 2
2 3
2 <.
2 3
2 *
a 7
2 •
a *
30
3 1
3 2
3 3
3*
1 9
36
3 7
i •
1 9
«• 0
101
Cooling
H20
0.30
0.30
1.2
102
Gas reheat
steam
45.5
45.5
434
345
103
Water heater
steam
81.0
81.0
434
345
104
Water heater
steam
65.4
65.4
434
345
(continued)
-------
TABLE A-7 (continued)
105
Water
heater
steam
t
2
)
%
3
*
7
•
•
1
1
I
1
!
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
£
3
9
S3
34
3 3
3 6
J7
^m
39
40
^^,
46.3
46.3
106
Water
heater
steam
74.3
74.3
434 434
345 345
1
107
Steam
6.5
6.5
434
345
108
Steam
6.5
6.5
434
345
-------
TABLE A-8. KVB COAL DESULFURIZATION PROCESS
EQUIPMENT LIST - BASE CASE (5% S COAL)
Area 1—Raw Material Handling and Preparation
Item
1. Conveyor, coal
No.
Description
unloading
2. Conveyor, coal
stacker
1 1000 tons/hr, 42-in. belt, 500 ft
long, 100-hp motor, 2 fixed trippers,
CS
2 1000 tons/hr, 42-in. belt, 968 ft
long, 40-hp motor, 1 traveling
tripper, CS
3. Hopper, pile reclaim 20 13-ft x 13-ft top opening, 3-ft-deep
pyramid, with 22-in. x 22-in. bottom
opening, CS
4. Feeders, vibrating
pan
5. Conveyor, coal
transfer
6. Tunnel, conveyor
7. Pump, tunnel sump
8. Conveyor, coal
transfer
9. Tunnel, conveyor
10. Pump, tunnel sump
11. Conveyor, crusher
feed
12. Sampler, coal
13. Bin, coal surge
20 120 tons/hr, 24 in. wide, 42-in.-long
pan, with 1.5-hp vibrator, CS
2 593 tons/hr, 42-in. belt, 970 ft long,
25-hp motor, CS
2 7 ft wide, 6 ft deep, 970 ft long,
steel reinforced concrete
2 60-gpm, 30-ft head, centrifugal, 1-hp
motor, CS
1 593 tons/hr, 42-ln. belt, 320 ft long,
5-hp motor, CS
1 7 ft wide, 6 ft deep, 320 ft long,
steel reinforced concrete
1 60-gpm, 30-ft head, centrifugal, 1-hp
motor, CS
1 593 tons/hr, 42-in. belt, 565 ft long,
100-hp motor, totally enclosed, CS
1 Automatic coal sampler
2 3600 ft3, 15 ft wide, 15 ft long, 16 ft
high, 13-ft-deep pyramid bottom, closed
top, CS
(continued)
165
-------
TABLE A-8 (continued)
Item
14. Feeder, weigh belt
15. Crusher, coal
16. Screen, coal
17. Crusher, coal
18. Conveyor, reactor
area feed
19. Pump, NC>2 unloading
20. Tank, N02 storage
Pump, binder
unloading
Pump, binder
storage
22.
23. Pump, binder feed
JVescrlption
__ __ _i_-^^.
297 tons/hr, 42-in. belt,
2-hp motor, CS
2 297 tons/hr, double roll type, 36-in.~
diameter rolls, 2 each 25-hp motors
totally enclosed, CS
2 297 tons/hr, 119 ft2 area, 7 ft x 17
ft, flip flow vibrating screen deck,
40-hp motor, CS
2 173 tons/hr, double roll type, 30-in.~
diameter rolls, 2 each 20-hp motors
totally enclosed, CS
1 593 tons/hr, 42-in. belt, 560 ft lortg
100 _hp motor, with 4 fixed trippers
totally enclosed, CS
2 70-gpm, 415-ft head, positive displace-
ment, 15-hp motor, 316 SS
17,600 gal, 10-ft-diameter, 30 ft
horizontal type, 150-psig operating
pressure, 316 SS
2 40-gptn, 50-ft head, centrifugal, 2-hp
motor, CS
1 887,000 gal, 55-f t-diameter , 50 ft ht«h
flat bottom, closed top, CS *
2 20-gpm, 200-ft head, centrifugal, 5_hp
motor, CS
24. Pump, NaOH unloading 2 55-gpm, 40-ft head, centrifugal,
25. Tank, NaOH storage
26. Pump, NaOH feed
motor, neoprene lined CS
994,000 gal, 59-f t-diameter , 50 ft
flat bottom closed top, neoprene
CS
2 13-gpm, 100-ft head, centrifugal, i^
motor, neoprene lined CS
(continued)
166
-------
TABLE A-8 (continued)
Item
27. Pump, NaOH feed
28. Pump, NaOH feed
29. Pump, NaOH transfer
30. Tank, 20% NaOH mix
31. Agitator, NaOH mix
tank
32. Pump, 20% NaOH feed
33. Hoist, car shaker
34. Shaker, car
35. Puller, car
36. Hopper, lime
unloading
37. Feeder, lime
vibrating
38. Conveyor, lime
unloading
39. Conveyor, lime
unloading
40. Tunnel, conveyor
41. Pump, tunnel sump
No.
2~
Description
1
1
1
38-gpm, 100-ft head, centrifugal, 3-
hp motor, neoprene lined CS
28_gpm, 100_ft head, centrifugal, 3-
hp motor, neoprene lined CS
13-gpm, 100-ft head, centrifugal, 1-
hp motor, neoprene lined CS
25,470 gal, 17-ft-diaraeter, 15 ft
high, flat bottom, closed top,
neoprene lined CS
15-hp, neoprene coated CS
52-gpm, 100-ft head, centrifugal, 3-
hp motor, neoprene lined CS
2,000 lb capacity, 15-hp motor
Railroad, trackside vibrator, 20-hp
Railroad car puller with base, wire
rope, 25~hp motor, 5-hp return motor
1 94 ft3, 8-ft 4-in. x 8-ft 4-in. top
opening, 3-ft-deep pyramid, with 2-ft
4-in. x 2-ft 4-in. bottom opening
1 210 tons/hr, 42 in. wide, 5 ft long
pan, 2.5-hp vibrator, CS
1 210 tons/hr, 24-in. belt, 10 ft long,
2.5-hp motor, CS
1 210 tons/hr, 24-in. belt, 381 ft long,
25-hp motor, totally enclosed, CS
1 6 ft wide, 6 ft high, 70 ft long, steel
reinforced concrete
1 20-gpm, 20-ft head, centrifugal, 0.5-hp
motor, CS
(continued)
167
-------
TABLE A-8 (continued)
_ rtem
4T. Silo, lime storage
43. Feeder, weigh belt
44. Conveyor, slaker
feed
45. Slaker, lime
46. Pump, lime slaker
product
47. Tank, 20% lime feed
48. Agitator, 20% lime
feed tank
49. Pump, 20% lime feed
50. Tank, 10% lime feed
No.
l"
Description
430,000 ft3, 74-ft-diameter, 100 ft—
high, cone bottom, closed top, CS
22 tons/hr, 12-in. belt, 10 ft long,
0.5-hp motor, CS
22 tons/hr, 12-in. belt, 40 ft long,
0.75-hp motor, CS
105.5 tons/hr of 20% slaked slurry
product, 20 ft x 43 ft x 9.5 ft high 2-
hp motor on rake drive, 30-hp mixer
338-gpm, 100-ft head, centrifugal, 20-
hp motor, neoprene lined CS
25,470 gal, 17-ft-diameter, 15 ft hiRh,
flat bottom, closed top, neoprene lined
CS
1 10 -hp, neoprene coated CS
50-gpm, 100-ft head, centrifugal, 3^v
motor, neoprene lined CS
322,400 gal, 38- f t-diameter, 38 ft hi h
flat bottom, closed top, neoprene li fj*
51. Agitator, 10% lime
feed tank
1 20-hp, neoprene coated CS
52. Pump, 10% lime feed 2 647-gpm, 100-ft head, centrifugal, 30->»
motor, neoprene lined CS » up
Area 2—Sulfur Oxidation
Item
1. Bin, reactor feed
No.
_pcj3crj.ption
4 5670 ft3, 19-ft-diameter, 20 f"t~hi»h~'
cone bottom, closed top, CS *
(continued)
168
-------
TABLE A-8 (continued)
Item
5. Fan, recirculating
6. Heater, oxidizing
gas
No.
~2. Feeder, weigh belt
3. Reactor, fluidized
bed
4. Fan, scrubber forced 4
draft
7. "Scrubber", vent gas 1
combustion
Description
149 tons/hr, 24-in. belt, 15 ft long,
1-hp motor, CS
22.3-ft-diameter, 51-ft high side,
cone bottom, cone top, 1 atmosphere
operating pressure, 316 SS
140,740 aft3/min at 200°F, AP 15-in.
H20, 450-hp motor, 316 SS
140,740 aft3/min at 200°F, AP 15-in.
P.20, 450-hp motor, 316 SS
4 8,080 ft2 area, 316 SS
10-ft x 10-ft natural gas fired
NOxiniZER, 10-hp blower, 35-ft of
stack, CS
Item
Cl ean ing_ __
No.
Scrubber, particulate
Thickener, fine coal
3. Pump, thickener
underflow
4. Tank, thickener
overflow
5. Pump, venturi feed
Description
Venturi, 14.8-ft-diameter, 52 ft high,
with mist eliminator, 316 SS
13 ft wide, 22 ft long, 21 ft high,
inclined pi ate gravity settler-
thickener with increased volume sludge
compartment, 1-hp picket-fence rake
354-gpm, 160-ft head, centrifugal, 40-
hp motor, neoprene lined CS
6600 gal, 7.5-ft-diameter, 20 ft high,
flat bottom, neoprene lined CS
2100-gpm, 100-ft head, centrifugal, 100-
hp motor, neoprene lined CS
(continued)
169
-------
TABLE A-8 (continued)
Item
No.
6. Absorber, SC>2
7. Tank, effluent surge 4
8. Agitator, effluent 4
surge tank
9. Pump, effluent 6
10. Thickener, absorber
11. Pump, thickener under-
flow
12. Tank, thickener over-
flow neutralizes
13. Agitator, thickener
14. Pump, thickener
underflow
15. Fan, absorber forced
draft
4
6
Description
Venturi, 14.8-ft-diameter, 52 ft' high
with mist eliminator, 316 SS '
16,100 gal, 14-ft-diameter, 14 ft
high, cone bottom, neoprene lined CS
10-hp, neoprene coated CS
1570-gpm, 100-ft head, centrifugal,
75-hp motor, neoprene lined CS
13 ft wide, 22 ft long, 21 ft high,
inclined plate gravity settler-
thickener with increased volume
sludge compartment, 1-hp picket-
fence rake
176-gpm, 100-ft head, centrifugal,
10-hp motor, neoprene lined CS
4280 gal, 9-ft-diameter, 9 ft high
cone bottom, neoprene lined CS *
5-hp, neoprene coated CS
1408-gpm, 100-ft head, centrifugal
75-hp motor, neoprene lined CS *
140,740 aft3/min at 200°F, AP 15-in
H?0, 450-hp motor, 316 SS
Area 4—Fine Coal Leaching
Item No.
1. Tank, water leach
2. Agitator, water leach
tank
Description
4 3600 gal, 8.5-ft-diameter, S.TTt
high, cone bottom, closed
lined CS
4 IC-hp, neoprene coated CS
(continued)
170
-------
TABLE A-8 (continued)
__ ^
3. Pump, cyclone feed
A. Cyclone, water leach
6. Agitator, cyclone
underflow tank
7. Heater, process water
8. Pump, cyclone feed
9. Cyclone, water leach
10. Tank, cyclone
underflow
11. Agitator, cyclone
underflow tank
12. Pump, cyclone feed
13. Cyclone, caustic
leach
14. Tank, cyclone
underflow
15. Agitator, cyclone
underflow tank
No.
5. Tank, cyclone underflow A
Description
722-gpm, 260-ft head, centrifugal,
125-hp motor, CS
36 90-gpm, 6-in. -diameter, heavy duty
cyclone, 100 psig operating pressure,
high density gum rubber-lined cast
iron and steel
1614 gal, 6.5-ft-diameter, 6.5 ft
high, cone bottom, closed top, neoprene
lined CS
5-hp, neoprene coated CS
4 178 ft2 area, CS
6 523-gpm, 260-ft head, centrifugal,
100-hp motor, CS
24 90-gpm, 6-in.-diameter,heavy duty
cyclone, 100 psig operating pressure,
high density gum rubber-lined cast
iron and steel
4 3600 gal, 8.5-ft-diameter, 8.5 ft high,
flat bottom, closed top, neoprene lined
CS
4 10-hp, neoprene coated CS
6 752-gpm, 260-ft head, centrifugal, 125-
hp motor, CS
36 90-gpm, 6-in.-diameter, heavy duty cyclone
100 psig operating pressure, high density
gum rubber-lined cast iron and steel
4 850 gal, 5.25-ft-diaraeter, 5.25 ft high,
flat bottom, closed top, neoprene lined CS
4 10-hp, neoprene coated CS
(continued)
171
-------
TABLE A-8 (continued)
Item
16. Pump, slurry
transfer
17. Thickener, fine coal
18. Pump, thickener
underflow
19. Tank, thickener
overflow
20. Pump, thickener
overflow
21. Tank, leach mix
22. Agitator, leach mix
tank
23. Pump, cyclone feed
24. Cyclone, water wash
25. Tank, cyclone
underflow
26. Agitator» cyclone
underflow tank
27. pump, cyclone feed
No.
6
Description
6
4
85-gpm, 100-ft head, centrifugal^
15-hp motor, neoprene lined CS
10 ft wide, 19 ft long, 21 ft high,
inclined plate gravity settler-
thickener with increased volume
sludge compartment, 1-hp picket-
fence rake
3.5-gpm, 100-ft head, centrifugal,
0.25-hp motor, neoprene lined CS
2000 gal, 7-ft-diameter, 7 ft high,
flat bottom, neoprene lined CS
667-gpm, 100_ft head, centrifugal,
30-hp motor, neoprene lined CS
7800 gal, 11-ft-diameter, 11 ft
high, cone bottom, closed top,
neoprene lined CS
4 5-hp, neoprene coated CS
6 758-gpm, 260-ft head, centrifugal,
125-hp motor, CS
36 90-gpm, 6-in.-diameter, heavy duty
cyclone, 100 psig operating pressure
high density gum rubber-lined cast
iron and steel
4 3800 gal, 8.5-ft-diameter, 9 ft high
cone bottom, closed top, neoprene
lined CS
4 10-hp, neoprene coated CS
6 758-gpm, 260-ft head, centrifugal,
125-hp motor, CS
(continued)
172
-------
TABLE A-8 (continued)
Item
Cyclone, water wash
29. Tank, cyclone
underflow
30. Agitator, cyclone
underflow tank
31. Pump, cyclone feed
32. Cyclone, wash water
33. Tank, cyclone
underflow
34. Agitator, cyclone
underflow tank
35. Pump, centrifuge feed
36. 'Heater, process water
37. Heater, process water
38. Centrifuge, fine coal
39. Tank, centrate
40. Pump, centrate
return
41. Conveyor, centrifuge
product
No.
~36~
Description
90-gpm, 6-in.-diameter, heavy duty
cyclone, 100 psig operating pressure,
high density gum rubber-lined cast iron
and steel
3SOO gal, 8.5-ft-diameter, 9 ft high,
cone bottom, closed top, neoprene
lined CS
10-hp, neoprene coated CS
6 758-gpm, 260-ft head, centrifugal,
125-hp motor, CS
36 90-gpm, 6-in.-diameter, heavy duty
cyclone, 100 psig operating pressure,
high density gum rubber-lined cast
iron and steel
4 1270 gal, 6-ft-diameter, 6 ft high,
cone bottom, closed top, neoprene
lined CS
4 10-hp, neoprene coated CS
6 437-gpm, 100-ft head, centrifugal, 30-
hp motor, neoprene lined CS
4 144 ft2 area, CS
4 102 ft2 area, CS
4 44-in.-diameter, 132 in. long, continuous
screen bowl type, 200-hp motor
4 2000 gal, 7-ft-diameter, 7 ft high, cone
bottom, closed top, CS
6 670-gpm, 100-ft head, centrifugal, 30-hp
motor, CS
1 209 tons/hr, 30-in. belt, 160 ft long,
5-hp motor, CS
(continued)
173
-------
TABLF, A-8 (continued)
Item
42. Conveyor, centrifuge
product
43. Sampler, coal
44. Elevator, bucket
No.
Area 5—Coarse Coal Leaching
Description
209 tons/hr, 30-in. belt, 180
long, 5-hp motor, CS
Automatic coal sampler
105 tons/hr, 40 ft high, 16-in. x
8-in. x 11-3/4-in, continuous buckets
J:. _lHlY.e-»-_L' 5-hp mo tor_, CS
Item
No.
1. Dewaterer, water
leach
2. Pump, overflow
3. Dewaterer, water leach
4. Pump, dewaterer
overflow
5. Heater, process water
6. Tank, caustic leach
7. Agitator, caustic
leach tank
8. Pump, thickener feed
9. Thickener, coarse coal
4
4
100 tons/hr, single screw spiraT"
dewaterer, 54-in.-diameter flights
34-ft tube length, 40-hp motor, *
closed top, CS
347-gpm, 100-ft head, centrifugal, 20-
hp motor, neoprene lined CS
100 tons/hr, single screw spiral
dewaterer, 54-in.-diameter flights
34-ft tube length, 40-hp motor,' "'
closed top, CS
406-gpm, 100-ft head, centrifugal
20_hp motor, neoprene lined CS
163 ft2 area, CS
10,000 gal, 12-ft-diameter, 1? ft
high, cone bottom, closed top, neon*-
lined. CS P^ene
4 10-hp, neoprene coated CS
6 980-gpm, 100-ft head, centrifugal 6O-
hp motor, neoprene lined CS '
4 10 ft wide, 19 ft long, 21 ft high
inclined plate gravity settler-thi *V
with increased volume sludge en*r
1-hp picket-fence rake
(continued)
174
-------
TABLE A-8 (continued)
Item
10. Pump, thickener
underflow
11. Tank, thickener
overflow
12. Pump, thickener
overflow
13. Tank, caustic leach
14. Agitator, caustic
leach tank
15. Dewaterer, water wash
16. Pump, dewaterer
overflow
17. Dewaterer, water wash
18. Pump, dewaterer
overflow
19. Dewaterer, water wash
20. Pump, dewaterer
overflow
21. Tank, water wash
22. Agitator, water wash
tank
No.
Description
641-gpm, 100-ft head, centrifugal,
50-hp motor, neoprene lined CS
975 gal, 5.5-ft-diameter, 5.5 ft high,
flat bottom, closed top, neoprene lined
CS
339-gpm, 100-ft head, centrifugal, 20-
hp motor, neoprene lined CS
6460 gal, 10-ft-diameter, 11 ft high,
flat bottom, closed top, neoprene lined
CS
5-hp, neoprene coated CS
100 tons/hr, single screw spiral
dewaterer, 54-in.-diameter flights,
34-ft tube length, 40-hp motor, closed
top, CS
900-gpm, 100-ft head, centrifugal, 40-
hp motor, neoprene lined CS
100 tons/hr, single screw spiral
dewaterer, 54-in.-diameter flights,
34-ft tube length, 40-hp motor, closed
top, CS
336-gpm, 100-ft head, centrifugal, 15-hp
motor, neoprene lined CS
1.00 tons/hr, single screw spiral, dewaterer,
54-in.-diameter flights, 34-ft tube length,
40-hp motor, closed top, CS
336-gpm, 100-ft head, centrifugal, 15-hp
motor, neoprene lined CS
1070 gal, 5.5-ft-diameter, 6 ft high,
cone bottom, closed top, neoprene lined CS
10-hp, neoprene coated CS
(continued)
175
-------
TABLE A-8 (continued)
Item
No.
23. Heater, process water 4
24. Pump, centrifuge feed 6
25. Heater, process water 4
26. Centrifuge, coarse coal 4
27. Tank, centrate 4
28. Pump, centrate
return
29. Conveyor, centrifuge
product
Description
30. Sampler, coal
31. Conveyor, coarse coal
bleed
32. Conveyor, stacker feed
33. Elevator, coal dryer
feed
34 Elevator, coal mix
bin feed
1
1
58"ft2" area, CS
230-gpm, 100-ft head, centrifugal, 25-
hp motor, neoprene lined CS
58 ft2 area, CS
230-gpm, continuous oscilating bowl
25-hp motor and 5-hp motor
1070 gal, 5.5-ft-diameter, 6 ft high
flat bottom, closed top, CS
336-gpm, 100-ft head, centrifugal, 15_
hp motor, CS
384 tons/hr, 30-in. belt, 160 ft long
5-hp motor, CS *
Automatic coal sampler
56 tons/hr, 18-in. belt, 50 ft long
5-hp motor, CS
596 tons/hr, 42-in. belt, 715 ft lone
50-hp motor, CS
100 tons/hr, 96 ft high, 24-in. x 8-in x
11-3/4-in. continuous buckets, double
chain drive, 20-hp motor, CS
134 tons/hr, 40 ft high, 20-in. x 8-in
11-3/4-in. continuous buckets, belt
drive, 7.5-hp motor, CS
Area
Agglomeration and Handling
Item
No.
~TBln7 coal mix
Description
1 1725 ft3, 13-ft-diameter, 13~ft~"hi£ip
cone bottom, CS '
(continued)
176
-------
TABLE A-8 (continued)
Item
No.
11
2. Feeder, coal
3. Conveyor, coal
transfer
U. Pelletizing plants
5. Conveyor, pelletizer
product
6. Conveyor, pelletizer
product
7. Conveyor, s ta eke r
8. Hopper, pile reclaim 20
9. Feeders, vibrating pan 20
10. Conveyor, coal
transfer
II, Tunnel, conveyor
Tunnel, conveyor
13. Pump, tunnel sump
266 tons/hr, 30-i.n. belt, 5 ft long,
1.5-hp motor, CS
266 tons/hr, 30~in. belt, 200 ft long,
40-hp motor, 11 fixed trippers, CS
25 tons/hr package pelletizing plants
including 23-ft-diameter pan pelletizer,
dryers and all support systems
125 tons/hr, 24-in. belt, 185 ft long,
2-hp motor, CS
125 tons/hr, 24-in. belt, 130 ft long,
2-hp motor, CS
596 tons/hr, 42-in. belt, 968 ft long,
25-hp motor, traveling tripper, CS
13-ft x 13-ft top opening, 3~ft~deep
pyramid, with 22-in. x 22-in. bottom
opening, CS
120 tons/hr, 24 in. wide, 42-in. long
pan, 1.5-hp vibrator, CS
1000 tons/hr, 42-in. belt, 970 ft long,
40-hp motor, CS
7 ft wide, 6 ft deep, 970 ft long, steel
reinforced concrete
7 ft wide, 6 ft deep, 320 ft long, steel
reinforced concrete
60-gpm, 30-ft head, centrifugal, 1-hp
motor, CS
(contineud)
177
-------
TABLE A-8 (continued)
7 Leach Solution Neutralization and Water Handling
No.
Item
Description
1. Tank, neutralizer
stage 1
2. Agitator, neutralizer
stage 1 tank
3. Tank, neutralizer,
stage 2
4. Agitator, neutralizer
stage 2 tank
5. Tank, neutralizer
stage 3
6. Agitator, neutralizer
stage 3 tank
7. Tank, neutralizer
stage 4
g. Agitator, neutralizer
stage 4 tank
9. Pump, pond feed
10. Pipeline, pond feed
Pump, pond return
12. Pipeline, pond
return
25,600 gal, 16-ft-diameter, 17 ft
high, flat bottom, closed top,
neoprene lined CS
10-hp, neoprene coated CS
8500 gal, 11-ft-diameter, 12 ft high,
flat bottom, closed top, neoprene
lined CS
10-hp, neoprene coated CS
8500 gal, 11-ft-diameter, 12 ft high
flat bottom, closed top, neoprene
lined CS
10-hp, neoprene coated CS
8500 gal, 11-ft-diameter, 12 ft high
flat bottom, closed top, neoprene
lined CS
10-hp, neoprene coated CS
2 11,480-gpm, 300-ft head, centrifugal
1750-hp motor, neoprene lined CS *
2 30-in.-diameter, 5280 ft long, rubber
lined CS
2 11,156-gpm, 300-ft head, centrifugal
1500-hp motor, CS '
1 30-in.-diameter, 5280 ft long, CS
(continued)
178
-------
TABLE A-8 (continued)
__ Item ____________
^ tank, recycle water
Description
14. Pump, water feed
15. Pump, water feed
16. Pump, water feed
17. Pump, water feed
18. Pump, water feed
19. Pump, water feed
20. Pump, water feed
21. Pump, makeup water
5,400,000 pal, 150-ft-diameter, 41 ft
high, flat bottom, CS
4184-gpm, 100-ft head, centrifugal,
200-hp motor, CS
697-gpm, 100-ft head, centrifugal,
30-hp motor, CS
39-gpm, 100-ft-head, centrifugal, 2-
hp motor, CS
1152-gpm, 100-ft head, centrifugal,
50-hp motor, CS
2441-gpm, 100-ft head, centrifugal,
12,5-hp motor, CS
1624-gpm, 100-ft head, centrifugal,
75-hp motor, CS
1771-gpm, 100-ft head, centrifugal,
75-hp motor, CS
752-gpm, 100-ft head, centrifugal,
40-hp motor, CS
Area 8--SjBttUng_Pond_
Pond
No_. Description
1 932 acres, 25.58 ft deep, with clay
179
-------
TABLE A-9. TRW GRAVICHEM COAL DESULFURIZATION PROCESS
MATERIAL BALANCE - BASE CASE
I
2
]
»
>
t
•
•
1
1
1
I
1
1
1
1
1
,
2
1
2
2
2
t
2
2
'
2 t
to
J
1 2
If
J»
39
)«
] 7
)•
t
Stream No.
Description
Total stream, tons/hr
S t ream conponen t s , tons /
Coal
Pyrltej S
Sulfate, S (In coal)
Organic, S
Ash
H?0
Sulfate. S (In solutio
FeSOi
Fe2(SOi)-,
H2SOi
S
07
Ca(OH)9
CaSOi'2HjO
Acetone (llauld)
Acetone (BBS)
Fe(OH)?
CaO
Temperature, °F
.Pressure, pslf
Aft3/mln
1
Crushed
coal
593.0
r
448. 1
19.1
O.i56
9.0
95.4
20.7
)
55
2
Heated
coal feed
629.0
448.1
19.1
0.356
9.C
95.4
56.8
215
3
Leach solution
feed
1736.6
1182.6
38.2
442.8
72.9
215
4,891
TABLE A-9 (continued)
fcO
4
Mixed
coal
slurry
2-m.fi
448.1
14.7
9.
93.4
1236.3
0.156
95.1
365.2
90.2
0.943
215
5jl44
5
Slurry to
heavy media
cyclones
7Ti-( A
448.1
14.7
9.0
93.4
1236.3
0.356
95.1
365.2
90.2
0.943
164
5.144
6
Sink
coal
slurry
1151 .6
266.0
14.fi
8.5
89.8
533.7
0.153
41.1
157.6
38.9
0.941
164
2.221
7
Float
coal
slurry
1 202 r,
182 1
0.10Q
0.554
3.5
702.5
0.203
54. n
207.fi
51.2
n
164
2.921
(continued)
(continued)
-------
TABLE A-9 (continued)
TABU A-4 (continued)
00
8
Leach
solution
filtrate
923.9
639.1
0.185
49.1
188.8
46.6
160
2.650
9
Wash
solution
feed
183.5
160
% 744
in
Wash
solution
filtrate
211.8
183. 5
0.018
4.8
IK. 7
•4.fi
160
*: 744
11
Filtered
coal
182.1
0.100
0.5S4
3.5
91 .7
160
1
2
3
"
3
ft
7
•
9
1 0
1 1
1 2
1 3
1 <•
1 5
1 6
I 7
1 9
IV
20
3 1
a 3
2 3
2 <.
2 3
2 «
2 7
2 6
2 9
d?°
3 1
3 2
3 S
3 h
3 3
3 «
3 7
J •
1 9
*. 0
12
Wash
solution
feed
183.5
160
^744
15
Coal slurry
feed to
filter
182.1
0.100
0.554
3.5
275.2
160
-53,112
14
Wash
solution
feed
183.5
160
*744
1 ^
Filtered
coal
182.1
0.100
0.554
3.5
91.7
160
(contInued)
(continued)
-------
TABLE A-9 (continued)
TABLE A-9 (continued)
00
N>
1
1
,
1
1
1
,
,
1
,
a
3
1
1
3
i
1
i
2
2
3
J
1
»
1 l.
>J
1 ft
J7
)•
J 9
t
If
Wash
solution
feed
183.5
160
%744
17
Coal slurry
feed to
filter
182.1
0.100
0.554
3.3
275.2
160
%1.J12
IB
Wash
water
feed
183.5
183.5
160
734
19
Float
coal
product
278.0
182.1
0.100
0.554
3.5
91.7
0.007
0.018
0.006
160
20
.
2
3
«•
3
*
7
8
9
1 0
1 1
12
1 3
i <>
i!
i «
1 7
t 8
1 9
2 O
2 1
2 2
3 I
2 <.
j,
2 6
2 7
2 0
2 9
? °
3 '
1 2
) 9
a i.
1 9
9«
3 7
J>
1 •
fcO
Reactor
gas feed
5.9
5.9
50
21
Reactor
vent gas
Nil
Nil
Nil
22
Reacted
coal
slurry
1173.1
266.0
0.383
8.5
83.2
547.4
0.153
4.6
236.7
21.8
4.0
250
50
2,238
23
Flash
steam
29.9
29.9
219
2.3
(continued)
(continued)
-------
TKM.E K-9
00
1
2
3
«.
5
6
7
a
9
ID
1 1
1 2
1 3
1*.
1 9
i *
1 7
L «
1 9
2 0
2 1
2 2
3 3
2 <.
2 5
2 6
3 7
2 8
29
30
•J i
) 2
3 S
3 4
3 3
J 6
3 7
J •
,«
1. 0
2t
Coal slurry
to cooler
1143. 2
266.0
0.383
8.S
83.2
517. 5
nrt ST
i.fi
?•*£ 7
71. ft .
i.n
219 J
2.11* j
1
3S
Compressed
oxygen feed
7.0
7.0
50
26
Reactor
oxygen feed
5.9
5.9
SO
n
Regenerator
oxygen feed
1.0
1.0
Yi
<•"
28
Regenerator
vent gas to
reactor
Nil
2q
High pressure
steam to
reactor
10.6
10.6
422
300
31
Coal slurry
feed to
filter
1143.2
266. C
0.383
8.5
83.2
517.5
0.153
4.6
236.7
21.8
4.0
160
2,119
32
Leach solution
filtrate
602.6
inn.i
0.118
-\ '.
181.9
16.8
160
1,638
(continued)
(cont inued)
-------
TABLE A-9 (continued)
TABLE A-9 (continued)
00
1
,
,
,
,
1
1
I
,
2
2
2
2
2
2
2
2
2
2
^_
3
1
9
Jt
11
J f
J 7
•1»
1 f
49
33
Wash water
feed
252.4
252.4
160
1.010
34
Wash solution
filtrate
252.4
200.6
0.030
0.916
46.5
4.3
160
812
31
Filtered
coal
540.5
266.0
0.383
8.5
83.2
169.2
0.005
0.162
8.2
0.761
4.0
160
36
Acetone feed
to wash
t.ink
364.8
364.8
85
1,846
37
Acetone/coal
slurry to cooler
i
a
3
(4
5
*
7
a
y
I 0
1 1
1 2
1 3
I*.
13
1 6
1 7
i a
i ?
2 O
2 1
23
a 3
a *.
2 3
2 6
2 7
3 •
2 9
?°
3 1
)2
9 3
J <•
) 9
»»
J 7
J*
3 *
*O
905.3
266.0
0.383
8.5
83.2
169.2
0.005
0.162
8.2
0.761
4.0
364.8
130
2,525
38
Acetone/coal
slurrv to
filter No. 5
905.3
266.0
0.383
8.5
83.2
169.2
. 0.005
0.162
8.2
0.7M
4.0
364.8
85
2,525
39
Acetone wash
feed
153.1
153.1
85
775
40
Filtered coal
to dryer
553.5
266.0
0.383
8.5
83.2
60.3
0.001
0.065
0.006
0.724
134.2
85
(continued)
(continued)
-------
TABU 1-9 (continued)
tU.1l A-9 (continued)
oo
41
Acetone solution
filtrate
,
2
3
<4
3
«
7
•
9
1 0
1 1
n
1 3
1 <•
1 3
1 6
1 7
1 •
1 9
ao
2 I
4 2
a j
24
23
2 «
2 7
2 •
2 9
i°
11
12
»»
1*
IS
!•
> 7
!•
1«
«0
504.9
108. 8
0.005
0.161
8.1
0.755
3.2
383.7
85
2,379
42
Wash solution
to evaporator
464.3
38*. 2
0.048
5.7
65.3
8.9
160
1,557
43
Leachate to
regenerator
preheater
841.5
3BZ . 1
44 . 8
172.0
42.5
160
2,422
44
Leachate to
regenerator
841.5
3ti^ . i
44 .0
172.0
42.5
244
2.422
45
i
a
3
*
3
6
7
6
9
1 0
1 1
1 2
1 3
1 fc
1 3
1 6
1 7
i a
19
ao
a i
2 2
a 3
2<.
a 3
a «
a 7
2 0
a «
30
31
1 2
S 9
3<*
3,
3B
3 ,
j«
3 9
1. O
Regenerated
leaehate to
recycle tank
842.4
583.1
26.9
195.6
36.7
250
2,414
46
Sulfuric acid
makeup
10.4
10.4
55
21
47
Leach solution
from evaporator
271.7
191.6
0.048
5.7
65.3
8.9
181
786
48
Dilution water
to leaehate
recycle tank
6.1
6.1
55
25
(continued)
(continued)
-------
TABLE A-9 (continued)
49
Leachate bleed to
neutralize!
,
i
,
*
i
»
7
•
w
1 0
, ,
1 2
i 1
I*.
1 3
1*
, 7
1 •
1«
1Q
2 1
2 J
I 3
2 i.
2 3
a t
3 7
2 •
2 t
30
-, ,
3 J
3 3
3 J.
3*
9 A
,?
it
1 9
« 0
82.3
57.0
0.055
4.3
16.8
4.1
160
237
50
Makeup
FeS04-7H20
(copperas)
3.5
1.5
1.9
55
51
Leach solution
feed
1736.6
1182.6
38.2
442.8
72.9
215
4.891
52
Cleaned
coal
product
419.6
266.0
0.383
. 8,5
83.2
60.3
0.001
0.065
0.006
0.724
0.359
133
(continued)
TABLE A-9 (continued)
i
3
3
'
3
•
7
>
9
1 0
1 1
1 2
1 3
1*.
1 3
><.
I 7
1 8
1 «
3 O
2 L
a 2
a 3
a <.
a 3
a 6
a 7
2 •
2 9
3O
3 1
32
9 9
3*.
33
]&
3 7
31
3 «
<>0
53
Coal dryer
off-gas
133.8
133.8
133
30,018
54
Cooled
off-gas
133.8
133.8
85
677
55
Off-gas
recycle to
coal dryer
Nil
56
Acetone to
recycle tank
133.8
133.8
85
677
(continued)
-------
TAHIU A-9 (continued)
TABLE A-9 (continued)
00
1
3
3
>.
3
fc
7
a
v
1 0
i i
I 2
13
1*.
1 5
16
1 7
i a
i *
2 O
2 1
2 J
2 3
2 *.
2 •,
3 6
2 7
2 a
a »
30
3 ]
1 2
3 J
1 *.
,,
J & 1
1 ' '
1 1 *
57
fash solution
evaporator
464.3
384.2
0.048
5.7
6i.3
8.9
1MB
),V;f>
S9
Process steam
evaporator
192.5
192.5
290
^
60
bottoms
271.7
191.6
0.048
5.7 _
fi.5.1.
8.q
,'90
'i5
7«ft
61
feed
504.9
108.8
0.005
0.161
R ^
0.753
3.2
383.7
85
15
2,384
i
2
1
t.
5
«
7
e
»
10
i i
! i
1 3
It
1 3
1 6
1 I
i a
i s
2 O
2 1
2 2
2 1
2 t.
2 3
2 6
2 7
J«
a »
30
3 ]
1 2
) 3
3 >.
, ,
J A
»
1 •
,»
4 O
62
Stripped
acetone
383.7
381 7
174
15
63
Stripper
bottoms
121.2
108.8
0.005
0.161
8.1_
0.755
•i.2
.250.
442
64
Sulfur
product
3.2
3.2
250
7
65
Stripper
bottoms to
process cooler
117.9
108.8
0.005
0.161
8.1
0.755
250
435
(< uni i nu
(cont inued)
-------
TABLF A-9 (continued)
H-*
oo
oo
i
**
Stripper bottoms
to surge tank
,
4
•
•
117.9
108.8
0.005
0.161
8.1
0.755
160
435
i
*7
itrtpper bottoms
to
neutraliier
117.9
108.8
0.005
0.161
8.1
0.755
160
435
,
68
Slaked lime
feed to
neutral Izer
98,8
79.0
19.7
316
69
Pond
feed
m,9
229.2
0.600
45.9
2.6
13.3
1,015
(continued)
TABLE A-9 (continued)
i»
70
Pond
settled
solids
88.5
25.9
0.600
45.9
2.6
13.3
55
202
71
Pond return
water
203.3
2m, 1
55
845
72
Condensed
acetone from
stripper to
recycle tank
383.7
383.7
85
1.942
73
Acetone
make-up
0.359
0.359
55
1.4
(continued)
-------
TAKJE X-9 (continued)
TABLE A-9 (continued)
00
74
Acetone feed to
sulfur removal
system
,
2
3
(.
3
6
7
a
»
t o
i i
1 2
1 3
1*
1 9
1 A
1 7
!•
1 9
2 O
2 1
2 2
3 3
24.
1 3
2 *
2 7
2«
2 »
10
J 1
1 2
1 >
»<.
1 S
I 4
1 J
i •
1»
<• O
518.0
518-C
85
2,621
75
Sulfur to
product storage
3.2
3.2
250
7
76
Cleaned coal to
briquet ting
plant
335.0
Z12.3
0.306
6.8
66.4
48.2
0.0008
0.052
0.005
0.578
0.285
225
77
Cleaned coal to
briquetting
bypass
84.6
53.6
0.077
1.7
16.7
12.1
0.0002
0.013
0.001
0.146
0.074
225
78
Brlquetted coal
product
i
2
3
*
S
6
7
•
*,
I 0
1 1
1 2
1 3
1 <•
1 5
1 t>
7
8
<
O
1
2
]
<4
3
6
7
a
9
o
!
2
3
4
a
«
7
j«
i «
-.0
335.0
212.3
0.306
6.8
66. A
48.2
0.0008
0.052
0.005
0.578
0.285
79
Cleaned coal
product to
storage
419.6
266.0
0.3B3
8.5
83.2
60.3
0.001
0.065
0.006
0.724
0.359
80
Combined coal
product to
storage
697.7
448.1
0.483
9.0
86.7
152.1
0.008
0.083
0.012
0.724
0.359
81
Makeup
water
383.1
383.1
55
1,291
(continued)
(continued)
-------
TABLE A-9 (continued)
TABLE A-9 (continued)
vo
O
,
J
t
.
1
*
J
a
,
1
,
,
,
!
!
1
JO
2
2 1
t
3 -
J 3
2ft
37
2 •
a 9
30
3 1
12
S 3
3 ".
3 3
3*
3 7
i •
3 «
1. O
82
Lime to
slaker
U.">
14.9
55
83
Water to
slaker
83.8
S3..8
55
316
84
Slaked lime
to surge tank
9.8.8
79. n
19.7
316
85
Low pressure
steam to
coal heat
6.1
6.1
281
35
t
»
2
3
14
5
*
7
8
y
1 0
i i
1 2
1 3
1-
13
1 6
1 7
1 8
19
20
2 1
2 2
3 ^
3 >.
2 9
2 6
a 7
a s
2 9
30
3 1
13
33
3 *•
3 3
3 6
3 7
J •
39
J.O
85A
Total steam
o coal heat
36.0
36.0
219
2.3
86
Cooling water
feed to E-l
2353.0
2353.0
55
9.415
87
Water to
cooling tower
surge tank
2353.0
2353. C
89
9,415
88
Ccoling water
feed to E-3
1133.0
1133.0
55
4,533
(continued)
(continued)
-------
TABLE A-9 (continued)
1
2
3
<•
a
«
,
8
9
1
:
i
i
i
i
i «
i
1 8
11
2 0
1 1
1 3
1 1
1 1,
13
I 6
2 7
2 •
J •
O
,
2
1
1
,
,
»q
Water to
cooling tower
surge tank
1133.0
1133.0
93
4.533
on
Low pressure
steam to E-4
28.6
28.6
281
35
91
Low pressure
condensate
from E-4
28.6
28.6
281
35
115
92
Cooling water
feed to E-5
905.0
905.0
55
3,621
(continued)
TAILE A-9 (continued)
1
2
3
*.
3
6
7
e
9
1 0
1 1
1 2
1 3
1 <•
1 3
16
1 7
1 0
19
2 0
2 1
2 2
2 3
2 *.
2 9
2 6
2 7
2 0
2 «
J0
3 1
1 2
3 3
3 <•
1 5
36
,,
J •
»*
<. O
93
Water to
cooling tower
surge tank
905.0
905.0
80
3,621
94
Low pressure
steam to E-6
60.4
60.4
281
35
95
Low pressure
condensate £ron
E-6
60.4
60.4
281
35
242
96
Low pressure
steam to E-7
20.8
20. ft
281
35
(continued)
-------
TABLE A-9 (continued)
TABLE A-9 (continued)
to
1
2
t.
9
•
•
,
1
1
1
1
1
1
,
1
1
1
2
2
2
2
2
2
3
2
2
2
i°
3
32
> 9
3fa
3 9
3 «
S 7
3»
1*
40
97
Low pressure
condensate froa
E-7
20.8
20.8
281
35
83
,
100
High pressure
steam to
evaporator
254.5
254.5
422
300
101
High pressure
condensate
from evaporator
254.5
254.5
422
300
939
102
Process steam
to stripper
192,5
192.5
290
35
(
1
2
3
t.
3
*
7
a
9
1 1
1
12
1 3
I *•
13
16
1
1 6
1 «
2 0
2
2 3
2 3
2*
2 5
2 6
2 7
2 8
2 9
?°
3 1
32
» 3
3 fa
3 9
36
3 7
J«
.19
40
101
Process steam
:ondensate from
stripper
192.5
192.5
281
35
563
104
Cooling water
feed to E-10
422.4
422.4
55
1,690
101
Water to
cooling tower
surge tank
1335.4
1335.4
139
5,343
ins
Cooling water
feed to E-ll
118 0
nfi.n
55
472
(continued)
(continued)
-------
TABLE A-9 (continued)
TABL? A-9 (continued)
u>
1
a
3
4.
3
A
,
•
9
1 0
1
12
1 3
I *•
1 3
1 *
1 7
1 1
1 9
2 0
2 I
2 2
2 3
a *.
2 3
2*
a 7
a •
a •
2°
j i
i a
* *
>*
J 5
J«
I >
J*
) »
4 O
107
Water to
cooling tower
surge tank
118.0
118.0
142
472
ioe
High pressure
steam to
coal dryer
123.3
123.3
422
300
109
High pressure
condensate from
dryer
123.3
123.3
422
300
479
110
Cooling water
feed to E-12
801.3
801.3
55
3,206
1
2
)
4
5
6
7
•
9
10
1 1
1 2
13
1 *•
IS
1 A
1 7
1 8
1 9
2 0
2 1
2 3
2 3
2 4
2 3
2 6
a 7
2 •
2 »
?°
3 1
3 3
a i
3 *
3 3
1 ft
3 7
J«
1 »
•. O
111
Water to
cooling water
surge tank
801.3
801.3
100
3,206
112
Low pressure
steam to
sulfur storage
0.004
0.004
281
35
113
Low pressure
condensate fron
sulfur storage
0.004
0.004
281
35
0.016
114
Cooling tower
feed
5732.8
5732.8
104
22.937
(continued)
(continued)
-------
vO
TAE1.F. A-9 (continued)
Cooling tower
discharge to
river
6645. 7
65
26,590_
-------
TABLE A-10. TRW GRAVICHEM COAL DESULFURIZATTON PROCESS
EQUIPMENT LIST - BASE CASE (5% S COAL)
Area 1—Baw_Ma_teri£l Kandling
Item No.
1. Conveyor, coal 1
unloading
2. Conveyor, coal 2
stocker
3. Hopper, pile reclaim 20
i. Feeders, vibrating 20
pan
Description
5. Conveyor, coal
transfer
6. Tunnel, conveyor
7. Pump, tunnel sump
g. Conveyor, coal
transfer
9. Tunnel, conveyor
10. Pump, tunnel sump
11.
12.
n.
Conveyor, crusher
feed
Sampler, coal
Bin, coal surge
2
2
1
1
1000 ton/hr, 42-in. belt, 500 ft long, 100-
hp motor, 2 fixed trippers, CS
1000 ton/hr, 42-in. belt, 968 ft long, 40-
hp motor, 1 traveling tripper, CS
13-ft x 13-ft top opening, 3-ft-deep pyra-
mid, with 22-in. x 22-in. bottom opening,
CS
120 ton/hr, 24 in. wide, 42-in. long pan,
with 1.5-hp vibrator, CS
593 ton/hr, 42-in. belt, 970 ft long, 25-hp
motor, CS
7 ft wide, 6 ft deep, 970 ft long, steel
reinforced concrete
60 gpm, 30-ft head, centrifugal, 1-hp motor,
CS
593 ton/hr, 42-in. belt, 320 ft long, 5-hp
motor, CS
7 ft wide, 6 ft deep, 320 ft long, steel
reinforced concrete
60 gpm, 30-ft head, centrifugal, 1-hp motor,
CS
593 ton/hr, 42-in. belt, 565 ft long, 100-hp
motor, totally enclosed, CS
Automatic coal sampler
7200 ft3, 19 ft wide, 19 ft. long, 20 ft high,
10-ft-deep pyramid bottom, closed top, CS
(continued)
195
-------
TABLE A-10 (continued)
Item
No.
Description
14. Feeder, weigh belt
15. Crusher, coal
16. Pulverizer, coal
17. Elevator, coal
18. Conveyor, coal
transfer
19. Pump, acid unloading
20. Tank, acid storage
21- Pump, acid feed
22. Pump, acetone
unloading
23. Tank, acetone
storage
24. Pump, acetone feed
25. Hoist, car shaker
26. Shaker, car
27. Puller, car
1 593 ton/hr, 42-in. belt, 10 ft long, 5-hp
motor, CS
2 300 ton/hr, ring-type granulator, 150-hp
motor, totally enclosed, CS
2 300 ton/hr, reversible impactor, 400-hp
motor, totally enclosed, CS
8 148 ton/hr, 70 ft high, 24-in. x 8-in. x
11-3/4-in. continuous buckets, belt drive
15-hp motor, CS '
1 593 ton/hr, 42-in. belt, 140 ft long, 25-hp
motor, 4 fixed trippers, totally enclosed
CS
2 44 gpm, 100-ft head, centrifugal, 5-h.p motor,
neoprene lined, CS
1 988,000 gal, 58-ft-diameter, 50 ft high, flat
bottom, closed top, neoprene lined, CS
2 23 gpm, 100-ft head, centrifugal, 2-hp motor.
neoprene lined, CS
2 102 gpm, 100-ft head, centrifugal, 5-hp motor.
CS
1 71,500 gal, 23-ft-diameter, 23 ft high, flat
bottom, closed top, CS
2 1-1/2 gpm, 100-ft head, centrifugal, l/8-np
motor, CS
1 2,000-lb capacity, 1.5-hp motor
1 Railroad track side vibrator, 20 hp
1 Railroad, car puller with base, wire ro
25-hp motor, 5-hp return motor *
(continued)
196
-------
TABLE A-10 (continued)
Item
No.
Description
28.
29.
30.
31.
32.
33.
34.
35 -
36 .
Hopper, railcar
unloading
Feeder, lime
vibrating
Conveyor, lime
unloading
Conveyor, lime
unloading
Tunnel, conveyor
Pump, tunnel sump
Silo, lime storage 1
Feeder, weigh belt 1
Conveyor, slaker feed 1
37 . Slaker, lime
3B-
39.
40.
41-
Pump, slaked lime 2
product
Tank, 20% lime feed 1
Agitator, 20% lime 1
feed tank
Pump, lime feed 2
94 ft-*, 8 ft 4 in. x 8 ft 4 in. top opening,
3-ft-deep pyramid, with 2 ft 4 in. x 2 ft
4 in. bottom opening
210 ton/hr, 42 in. wide, 5-ft-long pan,
2.5-hp vibrator, CS
210 ton/hr, 24-in. belt, 10 ft long, 2.5-hp
motor, CS
210 ton/hr, 24-in. belt, 436 ft long, 30-hp
motor, totally enclosed, CS
7 ft wide, 6 ft deep, 70 ft long, steel
reinforced concrete
20 gpm, 20-ft head, centrifugal, 0.5-hp motor,
CS
407,000 ft3, 72-ft-diameter, 100 ft high, cone
bottom, closed top, CS
20 ton/hr, 12-in. belt, 10 ft long, 0.5-hp
motor, CS
20 ton/hr, 12-in. belt, 40 ft long, 0,75-hp
motor, CS
100 ton/hr of 20% slaked slurry product,
20 ft x 43 ft x 9.5 ft high, 2-hp motor,
on rake drive, 30-hp mixer
316 gpm, 100-ft head, centrifugal, 20-hp motor,
neoprene lined, CS
159,000 gal, 30-ft-diaineter, 30 ft side, flat
bottom, closed top, neoprene lined, CS
15 hp, neoprene coated, CS
316 gpm, 100-ft head, centrifugal, 20-hp
motor, neoprene lined, CS
(continued)
197
-------
TABLE A-10 (continued)
Item
No.
42. Conveyor, copperas
unloading
43. Tunnel, conveyor
44. Pump, tunnel sump
45. Tank, copperas
storage
46. Feeder, weigh belt
210 ton/hr, 24-in. belt, 252 ft long, 25-hp
motor, totally enclosed, CS
7 ft wide, 6 ft deep, 70 ft long, steel
reinforced concrete
20 gpm, 20-ft head, centrifugal, 0.5-hp
motor, CS
43,000 ft3, 38-f t-diameter , 38 ft high,
cone bottom, closed top, 316 SS
3.5 ton/hr, 18-in. belt, 10 ft long, 0.75-hn
motor, CS
Area 2-_-"Grayi_ch_em" Separation
I tern
No.
1. Bin, coal feed
2. Tank, slurry mix
3. Agitators, slurry
mix tank
4. Drum, knockout
5. Pump, cyclone feed
Description^
4 47,100 ft, 35-f t-diameter , 49 ft high, cone
bottom, closed top, CS
2 367,200 gal, 25-f t-diameter, 100 ft long
horizontal, operating at 215°F and atmos-
pheric pressure, 316L SS
6 25 hp, 316L SS
2 10,100 gal, 8-f t-diameter, 27 ft long dish
head ends, 316L SS
3 2,672 gpm, 125-ft head, centrifugal 250-ho
motor, 316L SS
6. Cooler, coal slurry 13 2,080 ft area, Hastelloy C
7. Cyclone, heavy media 54 10.49 ton/hr solids, 6-in. -diameter he
medium cyclone, operating at 40 psie
8. Tank, cyclone
underflow
2 3,400 gal, 8-f t-diameter , 9 ft high, co
bottom, closed top, neoprene lined CS
(continued)
198
-------
TABLE A-10 (continued)
Item
9. Agitator, underflow
tank
10. Pump, reactor feed
11. Feeder, coal weigh
No.
Description
2 10 hp, neoprene coated, CS
1,111 gpm, 100-ft head, centrifugal, 100-hp
motor, neoprene lined, CS
296.5 ton/hr, 30-in. belt, 10 ft long, 1.5-hp
motor, CS
—Float Coal Washing
Item No.
Description
1. Filter, coal 3
2. Pump, vacuum 6
3. Tank, filtrate 6
4. Pump, filtrate 5
5. Pump, filtrate 5
6. Tank, coal wash 1
7. Agitator, wash tank 1
8. Pump, filter feed 2
Filter, coal
Pump, vacuum
62 ton/hr, 12-ft-diameter, 24 ft long, 912
ft area, rotary drum type, 5-hp motor drive,
3-hp agitator, 316L SS
200-hp system, 316L SS
750 gal, 4-ft-diameter, 8 ft long, vacuum
receiver, 316L SS
887 gpm, 100-ft head, centrifugal, 60-hp
motor, neoprene lined, CS
248 gpm, 100-ft head, centrifugal, 15-hp
motor, neoprene lined, CS
11,000 gal, 12-ft-diameter, 13 ft high,
cone bottom, neoprene lined, CS
7.5 hp, neoprene coated, CS
1,111 gpm, 100-ft head, centrifugal, 80-hp
motor, neoprene lined, CS
3 62 ton/hr, 12-ft-diameter, 24 ft long, 912
ft area, rotary drum type, 5-hp motor
drive, 3-hp agitator, 316L SS
6 200-hp system, 316L SS
(continued)
199
-------
TABLE A-10 (continued)
Item
No.
Description^
11. Tank, filtrate
12. Pump, filtrate
13. Tank, coal wash
14. Agitator, wash tank
15. Pump, filter feed
16. Filter, coal
17. Pump, vacuum
18. Tank, filtrate
19. Pump, filtrate
6 750 gal, 4-ft-diameter, 8 ft long, vacuum
receiver, 316L SS
10
10
248 gpm, 100-ft head, centrifugal, 15-hp
motor, neoprene lined, CS
1 11,000 gal, 12-ft-diameter, 13 ft high,
cone bottom, neoprene lined, CS
1 7.5 hp, neoprene coated, CS
2 111 gpm, 100-ft head, centrifugal, 80-hp
motor, neoprene lined, CS
3 62 ton/hr, 12-ft-diameter, 24 ft long, 912
ft2 area, rotary drum type, 5-hp motor drive,
3-hp agitator, 316L SS
6 200-hp system, 316L SS
6 750 gal, 4-ft-diameter, 8 ft long, vacuum
receiver, 316L SS
248 gpm, 100-ft head, centrifugal, 15-hp
motor, neoprene lined, CS
20. Heater, wash water 1 1,151 ft2 area, CS
21. Conveyor, coal
product
22. Sampler, coal
1 638 ton/hr, 42-in. belt, 1,120 ft long,
motor, 2 fixed trippers, totally enclosed CS
1 Automatic coal sampler
Area_4--Rgactor j^ Regenerator
No.
Item
1. Reactor, leach
2. Agitators, reactor
Description^
3 270,300 gal, 21-ft-diameter, 115 ft
horizontal, 50 psig operating pressure
4 Hastelloy C dividers, 85 mill polypronvler.
liner, 6-in. acid brick liner, 10 aeit-V
openings, Shell is CS acor
30 200 hp, Hastelloy C
(continued)
200
-------
TABLE A-10 (continued)
No.
Item
3. Drum, knockout 3
4. Pump, leachate feed 5
5. Drum, flash 3
6. Compressor, oxygen 1
Description
7.
8.
9.
10.
11-
12.
13.
14.
15.
16.
Pump, filtrate feed 5
12,900 gal, 9-ft-diameter, 27 ft long, dish
head ends, 316L SS
1,631 gpm, 100-ft head, centrifugal, 100-hp
motor, 316L SS
7,500 gal, 8-ft-diameter, 20 ft long, dish
head ends, 316L SS
2,500 ft3/min, at 110 psig, centrifugal,
600-hp motor, CS
706 gpm, 100-ft head, centrifugal, 75-hp
motor, 316L SS
Cooler, reactor
slurry
Filter, coal
Pump, vacuum
Tank, filtrate
pump, filtrate
Pump, filtrate
8 1,877 ft2 area, Hastelloy C
72.4 ton/hr, 12-ft-diameter, 24 ft long,
912 ft^ area, rotary drum type, 5-hp motor
drive, 3-hp agitator, 316L SS
10
10
8
8
Heater, wash water 1
Heater, leachate 6
Regenerator, leachate 1
200-hp system, 316L SS
750 gal, 4-ft-diameter, 8 ft long, vacuum
receiver, 316L SS
328 gpm, 100-ft head, centrifugal, 25-hp
motor, neoprene lined, CS
163 gpm, 100-ft head, centrifugal, 10-hp
motor, neoprene lined, CS
1,583 ft2 area, CS
2,314 ft2 area, Hastelloy C
70,000 gal, 11-ft-diameter, 119 ft long,
horizontal, 35 psig operating pressure,
4 Hastelloy C dividers, 85 mill polypropyl-
ene liner, 6-in. acid brick liner, 10
agitator openings, Shell is CS
(continued)
201
-------
TABLE A-10 (continued)
Item
No.
Description
17. Agitators, 10 100 hp, Hastelloy C
regenerator
18. Pump, filtrate return 2 2,414 gpm, 100-ft head, centrifugal, 150-h
motor, 316L SS ' P
19. Tank, leachate return 1 49,300 gal, 20-ft-diameter, 21 ft high flat
bottom, closed top, 316L SS '
20. Agitator, leachate 1 15 hp, Hastelloy C
return tank
21. Pump,leachate feed 5 1,631 gpm, 100-ft head, centrifugal, 100-ho
motor, 316L SS
Area 5—Acetone Leaching
Item ____
1. Tank, acetone mix
2. Agitators, acetone
mix tank
3. Pump, acetone
slurry
4. Cooler, acetone
slurry
5. Filter, coal
6. Pump,vacuum
7. Tank, filtrate
8. Pump, filtrate
No.
Description
5 5,000 gal, 9.5-ft-diameter, 9.5 ft high,
cone bottom, closed top, neoprene lined CS
5 10 hp, neoprene coated, CS
8 507 gpm, 100-ft head, centrifugal, 30-hp
motor, neoprene lined, CS
27 1,295 ft2 area, 316L SS
12 30.2 ton/hr, 24-ft-diameter, 445 ft2 area
horizontal rotary pan type, 5-hp motor **
316L SS
12 150-hp system, 316L SS
12 750 gal, 4-ft-diameter, 8 ft long>
receiver, 316L SS
18 211 gpm, 100-ft head, centrifugal 7 <; ^
motor, CS * ' 5~hP
(continued)
202
-------
TABLE A-10 (continued)
6—Acetone Recovery
Item
and Coal Drying __
_ __Nj°j; Description
1. Tank, stripper feed
2. Pump, stripper feed
3. Preheater, stripper
4. Stripper, acetone
5. Reboiler, stripper
6. Condenser, acetone
7. Drum, reflux
8. Pump, reflux
Cooler, acetone
pump, bottoms
Drum, bottoms
receiver
Cooler, bottoms
Tank, bottoms
surge
Pump, neutralizer
feed
15. Tank, sulfur surge
9.
10-
11.
12.
13.
1 7,100 gal, 10-ft-diameter, 12 ft high,
cone bottom, closed top, 316L SS
2 2,384 gpm, 250-ft head, centrifugal, 180-
hp motor, 316L SS
2 3,100 ft2 area, 316L SS and Hastelloy C
1 16-ft-diameter, 90 ft high, 33 valve trays,
45 psig design pressure, 316L SS
2 13,500 ft2 area, 316L SS and Hastelloy C
6 5,500 ft2 area, 316L SS
1 25,400 gal, 12-ft-diameter, 30 ft long,
horizontal, 45 psig design pressure,
316L SS
2 1,620 gpm, 325-ft head, centrifugal, 160-hp
motor, 3L6L SS
1 1,900 ft2 area, 316L SS
2 442 gpm, 100-ft head, centrifugal, 25-hp
motor, 316L SS
1 1,500 gal, 6-ft-diameter, 7 ft long,
horizontal, operating pressure 15 psig,
316L SS
4 4,000 ft2 area, 316L SS and Hastelloy C
1 1,500 gal, 6-ft-diameter, 7 ft high, cone
cottom, closed top, neoprene lined, CS
2 437 gpm, 100-ft head, centrifugal, 20-hp
motor, neoprene lined, CS
1 25 gal, 1-ft-diameter, 4 Ct high, cone
bottom, closed top, 316L SS
(continued)
203
-------
TABLE A-10 (continued)
Item
No.
Description
16. Pump, sulfur
7 gpm, 100-ft head, centrifugal, 0.75-hn
motor, 316L SS
17. Tank, acetone recycle 1
18. Pump, acetone recycle 2
19. Bin, dryer feed 12
20. Dryer, coal 12
21. Condenser, acetone 5
22. Tank, acetone 12
receiver
23. Fan, induced draft 12
24. Conveyor, dryed
coal
8,200 gal, 10-ft-diameter, 14 ft high,
cone bottom, closed top, CS
2,621 gpm, 100-ft head, centrifugal, 100-hp
motor, CS
15,700 ft3, 20-ft-diameter, 50 ft high,
cone bottom, closed top, CS
8-ft-diameter, 80 ft long, 8,480 ft2 area
rotary steam tube type, 60-hp motor, sealed
for solvent recovery
972 ft2 area, 316L SS
212 gal, 3-ft-diameter, 4 ft high, dish head
ends, 316L SS
3,000 aftVmin at 85°F, AP, 10 in. H20, io-hp
motor, CS
420 ton/hr, 30-in. belt, 280 ft long, 7.5_hp
motor, totally enclosed, CS
25. Sampler, coal
1 Automatic coal sampler
Area 7—-Leach. Solution Concentration
Item
No.
Description^
1. Tank, evaporator
feed
2. Pump, evaporator
feed
1 7,600 gal, 10-ft-diameter, 13 ft high fi
bottom, closed top, neoprene lined, CS
2 2,379 gpm, 100-ft head, centrifugal 12.5 ..
motor, neoprene lined, CS ' *«>-ftp
3. Preheater, evaporator 4 1,757 ft2 area, Hastelloy C
4. Evaporator 1 26-ft-diameter, long tube natural
type, 42-in.-diameter c
17,000 ft2 area heating
construction
(continued)
204
-------
TABLE A-10 (continued)
Item
No.
Description
5. Pump, leachate
return
786 gpm, 100-ft head, centrifugal, 40-hp
motor, 316L SS
g Neutralization and Pond Water Handling
Item No. Des cr ip t ion
1. Tank, neutralizer
1 10,200 gal, 12-ft-diameter, 12 ft high,
cone bottom, closed top, neoprene lined,
CS
2.
3.
Agitator, neutralizer 1 5 hp, neoprene coated, CS
tank
Pump, pond feed
4. Pipeline, pond
feed
5. Pump, pond return
Pipeline, pond
return
2 917 gpm, 300-ft head, centrifugal, 150-hp
motor, neoprene lined, CS
2 5,280 ft long, 10-in.-diameter, rubber lined,
CS
2 845 gpm, 300-ft head, centrifugal, 125-hp
motor, CS
1 5,280 ft long, 10-in.-diameter, CS
7.
8.
9.
10.
11.
12.
Tank, recycle water 1 34,500 gal, 14-ft-diameter, 30 ft high, flat
bottom, closed top, CS
Pump, wash water
Pump, wash water
Pump, leachate
recycle tank feed
Pump, slaker feed
Pump, makeup water
2 744 gpm, 100-ft head, centrifugal, 40-hp
motor, CS
2 1,010 gpm, 100-ft head, centrifugal, 50-hp
motor, CS
2 25 gpm, 100-ft head, centrifugal, 1.5-hp
motor, CS
2 316 gpm, 100-ft head, centrifugal, 15-hp
motor, CS
2 1,250 gpm, 100-ft head, centrifugal, 60-hp
motor, CS
(continued)
205
-------
TABLE A-10 (continued)
Area 9—Product Agglomeration and Handling^
Item No.
Description
1. Conveyor, coal
2. Elevator, coal
3. Conveyor, coal
4. Briquetting plants 12
5. Conveyor, briquett 1
6. Conveyor, coal 1
bypass
7. Conveyor, transfer 1
8. Conveyor, stacking 2
9. Hopper, pile reclaim 20
10. Feeders, vibrating 20
pan
11. Conveyor, coal 2
transfer
12. Tunnel, conveyor 2
287 ton/hr, 30-ln. belt, 100 ft long, 3-hp
motor, totally enclosed, CS
144 ton/hr, 40 ft high, 24 in. x 8 in. x
11-3/4 in. continuous buckets, belt drive
15-hp motor, CS
287 ton/hr, 30-in. belt, 190 ft long, 40-hp
motor, totally enclosed, 12 fixed trippers
CS
25 ton/hr package briquetting plants,
including hot briquetter and all support
systems
144 ton/hr, 24-in. belt, 185 ft long, 2-hp
motor, totally enclosed, CS
73 ton/hr, 18-in. belt, 210 ft long, 1.5-.np
motor, totally enclosed, CS
217 ton/hr, 24-in. belt, 180 ft long, 3-hp
motor, totally enclosed, CS
638 ton/hr, 42-in. belt, 968 ft long, 30-hp
motor, traveling tripper, CS
13 ft x 13 ft top opening, 3-ft-deep pyramid
with 22 in. x 22 in. bottom opening, CS
120 ton/hr, 24 in. wide, 42-in.-long pan,
1.5-hp vibrator, CS
1,000 ton/hr, 42-in. belt, 970 ft long, 40-hp
motor, CS
7 ft wide, 6 ft deep, 970 ft long, steel
reinforced concrete
13. Tunnel, conveyor
7 ft wide, 6 ft deep, 320 ft long, steel
reinforced concrete
14. Pump, tunnel sump 3 60 gpm, 30-ft head, centrifugal, l-hp
(continued)
206
-------
TABLE A-10 (continued)
Item
Description
15. Tank, sulfur
storage
16. Pump, sulfur
5,200 gal, 9-ft-inside-diameter, 11-ft-
inside-height, flat bottom, closed top,
totally underground, 10-in.-thick steel
reinforced concrete construction
40 gpm, 100-ft head, centrifugal, 5 hp,
316L SS
10 — U t i .lj£L JJfLfLgT- .Hand 1 ing
Item
No.
____ Description
1. Pump, makeup water 2 1,250 gpm, 100-ft head, centrifugal, 60-hp
motor, CS
2. Pump, cooling water 2 9,415 gpm, 100-ft head, centrifugal, 400-hp
motor, CS
3. Pump, cooling water 2 4,533 gpm, 100-ft head, centrifugal, 200-hp
motor, CS
/,. Pump, cooling water 2 3,621 gpm, 100-ft head, centrifugal, 175-hp
motor, CS
5. Pump, cooling water
2 1,690 gpm, 245-ft head, centrifugal, 155-hp
motor, CS
6. Pump, cooling water 2 472 gpm, 100-ft head, centrifugal, 20-hp
« -lor, CS
7. Pump, cooling water 2 3,206 gpm, 100-ft head, centrifugal, 150-hp
motor, CS
8. Tank, cooling tower
feed
9. Pump, cooling tower
feed
10. Tower, cooling
1 81,200 gal, 24-ft-diameter, 24 ft high, flat
bottom, open top, CS
6 5,734 gpm, 100-ft head, centrifugal, 250-hp
motor, CS
1 26,590 gpm, mechanical draft, crossflow type
510 total hp
(continued)
207
-------
TABLE A-10 (continued)
Item __JL°<__ _ ___ Description
2
11. Basin, cooling 1 6,000 ft area basin, steel reinforced
tower concrete
12. Pump, cooling tower 2 26,590 gpm, 30-ft head, centrifugal, 350-hp
motor, CS
Ar ea_n--^ettling_P£nd_
Item No. Description
__ poncj 1 468 acres, 21.73 ft deep, with clay lining
208
-------
TABLE A-ll. KENNECOTT COAL DESULFURIZATION PROCESS
MATERIAL BALANCE - BASE CASE
N5
O
,
2
3
«
5
6
7
•
9
O
3
J
1.
5
*
I !•
)•
«
O
1
I
1
t.
4
»
;
•
*
19
1 t
ta
t,
j*
tt
!•
, ,
t •
t «
•. (l
Stream Number
Description
Total, tons/hr
Stream components, tons
Coal
Pyritic S
Sulfate S
Oreanic S
H?0
02
CO
C02
FeS04
FefOH)2
FejO}
H7S04
02 Coal uptake
Sulfate in solution
Oi In molution
C»0
(la COH1 7
CafSO/,V?H20
Binder
tmpcrature, °T
Pre»»ur«^ p»lg
tra
1
Coal to
hall rains
680.0
ir
623.4
21.9
0.41
10.4
23.6
T5.o -'
2
Water to
ball mill
259R.O
2296.0
55.0
9194,0
3
Slurry to
suree tanlr
7a77 o
623.4
21.9
10.4
2321.8
0.41
65.0
9289.0
TABLE A-ll (continued)
4
Slurry to
preheater
2977.9
623.4
21.9
10.4
2321.8
0.41
65
20
9289
5
Slurry to
flash-gas
scrubber
2977.9
623.4
21.9
10.4
2321.8
0.41
150
15
9289
6
Slurry to
scrubber
catch tank
3280.9
623.4
21.9
10.4
2624.8
0.41
250 _
15
10,502
7
Slurry to
reactor
preheater
3280.9
623.4
21.9
10.4
2624.8
0.41
250
10,502
(continued)
-------
TABLE A-ll (continued)
TABLE A-ll (continued)
to
f—4
o
8
Slurry to
reactor
t
a
3
4
»
6
r
ft
9
!
1
1
I
1
1
!
1
1
1
2
2
2
2
2
2
3
2
2 0
2
i°
3
3 2
9 9
3 <•
3 3
9 «
37
}•
19
40
3280.9
623.4
21.9
10.4
2624.8
0.41
350
315
10.502
9
02 to
reactor
129.3
129.3
315
10
Reactor
off-gas
71.8
10.6
30.6
1.6
29.0
350
315
11
Slurry to
flash tank
3338.3
597.9
2.6
8.9
2604.6
11.4
18.3
56.2
36.7
0.41
1.29
350
315
10.544
12
Flash steam
p.. scrubber
1
*
3
*
S
»
7
8
9
10
1 1
12
J 3
I *•
1 3
1 6
1 7
i a
i<»
2 O
2 I
a 2
2 3
2 <*
2 3
2 6
2 7
2 a
2 9
3O
3 1
i a
39
3*.
35
36
3 7
J«
3 9
<« D
304.29
303
1.29
250
15
13
Flash tank
slurry outlet
3034.0
597.9
2.6
8.9
2301.6
11.4
18.3
56.2
36.7
0.41
250
15
9332
14
Slurry to
preheater
3034.0
597.9
2.6
8.9
2301.6
11.4
18.3
56.2
36.7
0.41
250
9332
15
Slurry to
3034.0
597.9
2.6
8.9
2301.6
11.4
18.3
56.2
36.7
0.41
166
9332
(continued)
(continued)
-------
TABLE A-ll (.continued)
1
1
1
1
1
(
!
1
I
1
2
2
2
2
3
2
2 t>
2 r
2 •
2 *
i°
J 1
1 2
1 •
>v
) *
*
,,
It
"
16
Thickener
overflov
1135.4
1102.9
5.4
26.9
0.20
!(,(,
4472
17
Slurry feed
to filter
1898.6
597.9
2.6
8.9
1198.7
5.94
18.3
29.2
36.7
0.21
166
4860
18
Cake to
reslurry tank
1022.2
597.9
2.6
8.9
354.4
0.57
18.3
2.8
36.7
0.02
166
19
Slurry feed
to filter
1898.4
597.9
2.6
8.9
1230.6
0.57
18.3
2.8
36.7
0.02
166
5004
(ront i nuc-cl;
TABLE A-ll (continued)
1
3
3
(.
S
6
7
»
9
I 0
1 1
1 2
1 3
1 <•
,3
1 &
I r
1 8
t »
2 O
2 1
2 2
2 3
2 *.
2 S
2 6
2 7
2 •
2 «
1 2
9 9
3 <•
J 5
1 ft
, ,
1 •
1,
1,0
20
Filter solids
1022.3
597.9
2.6
8.9
357.4
0.085
18.3
0.41
36.7
144
21
Pelletizing
bypass
197.6
115.7
0.51
1.7
69.1
1.5
7.1
144
22
Coal feed
to pelletizlng
824.2
482.1
2.1
7.2
288.2
li.7
0.33
29.6
144
23
Wash water
feed to
filter
357.9
157.9
55
1432
(continued)
-------
TABLE A-ll (continued)
fc
24
H20 to
r««lurry tank
876.2
876.2
1
2
3
1.
166
3506
25
Wash water
to filter
715.7
715.7
166
2864
26
Filtrate to
neutralize!
1234.1
1231.2
0.485
2.4
0.015
144
4931
?7
Filtrate to
neutralizer
1591.9
1560.0
5.3
26.4
0.19
166
6299
N)
(continued)
TABLE A-ll (continued)
10
:2
1 3
I'-
ll
]«,
19
1»
3 O
22
,
2-.
25
2 fr
,
a
«
o
28
Lime to
s laker
36.31
36.31
55
2q
Slaked lime
to neutralizer
239.8
191.9
47.9
768
31
Slurry to
pond
4201,8
4083.2
7.08
111.5
16.337
31a
Pond settled
solids
164.0
52.2
111.5
55
(continued)
-------
TABLE A-U (continued)
-
«
32
Pond water
recycle
4031.0
4031.0
___JL . ...
n+m
33
Makeup
water to
recycle tank
420.1
420.1
55,. . . -
1681
34
Scrubber
off-gas
1.29
1.29
2J£
. _. 15
35
Binder solution
to pelletizing
21.4
10.7
10.7
L5
43
front ini
TABUS A-H (continued)
i
V
1 3
, 3
1-
15
1 6
7
9
,
O
i
3
3
,.
3
6
7
a
,
3 1
1 2
*»
]<.
,,
J«
, r
I*
T -,
^0
36
Steam from
pellet dryer
271.1
271.1
2J2
37
Pelletized
product
574.6
482.1
2.1
7.2
27.8
0.07
14.7
0.33
29.6
10.7
212
38
Clean coal
product to
storage
772.2
597.9
2.6
8.9
96.9
0.09
18.3
0.41
36.7
10.7
39
H20 to
s laker
203.2
203.2
-S5
813
(continued)
-------
TAFLE A-ll (continued)
a
2
2
3
2
2
2
2
1
2
9
J
T
3
3
J
3t
3 7
39
y 9
40
40
Steam to
reactor
preheater
i 355.3
3
3
*
9
•
,
355.3
9
1 0
i a
1 3
<.
3
*
7
8
9
0
1
2
3
t.
3
6
7
i
9
112
300
41
Steam to
water heater
98.4
98.4
422
300
42
Steam to
water heater
120.5
120.5
422
300
-------
TABLE A-12. KENNECOTT COAL DESULFURIZATION PROCESS
EQUIPMENT LIST - BASE CASE (5% S COAL)
Area
1—Raw Material Handling and Preparation
Item
No.
1. Conveyor, coal
unloading transfer
2. Conveyor, stacker
3. Hoppers, pile reclaim
4. Feeders, vibrating
pan
5. Tunnels, reclaim
6. Conveyor, coal transfer
7. Pump, tunnel sump
Description
8.
9.
10.
11.
12.
Tunnel, transfer
Conveyor, coal
transfer
Conveyor, crusher
feed
Sampler, coal
Bin, coal surge
Feeder, weigh belt
1 1,000 tons/hr, 42-in. belt, 500 ft
long, 1.00-hp motor, with 2 fixed
trippers, CS
2 1,000 tons/hr, 42-in. belt, 968 ft
long, 40-hp motor, 1 traveling
tripper, CS
20 13-ft x 13-ft top opening, 3-ft-
deep pyramid, 22-in. x 22-in.
bottom opening, CS
20 120 tons/hr, 24 in. wide, 42-in.-
long pan, with 1-1/2-hp vibrator,
CS
2 7 ft wide, 6 ft deep, 970 ft long,
steel reinforced concrete
2 680 tons/hr, 42-in. belt, 970 ft
long, 25-hp motor, CS
3 60 gpm, 30-ft head, centrifugal,
1-hp motor, CS
1 7 ft wide, 6 ft deep, 320 ft long,
steel reinforced concrete
1 680 tons/hr, 42-in. belt, 320 ft
long, 10-hp motor, CS
1 680 tons/hr, 42-in. belt, 800 ft
long, 200-hp motor, totally enclosed,
1 fixed tripper, CS
1 Automatic coal sampler
1 227,000 ft3, 61 ft wide, 61 ft long,
61 ft high, 31-ft-deep pyramid bottom,
closed top, CS
1 680 tons/hr, 42 in. wide, 10 ft long,
5-hp motor, CS
(continued)
215
-------
TAB1.F A-12 (continued)
14,
Item
Crusher, coal.
15. Bin, coal surge
16. Feeder, weigh belt
17. Ball mill, coal
18. Tank, product surge
19. Agitator, surge tank
20. Pump, cyclone feed
21. Cyclone, oversize
coal
22. Tank, cyclone-
overflow
23. Agitator, overflow
tank
24. Pump, scrubber
feed
25. Pump, binder
unloading
Np_._
2
pescription
340 tons/hr, to crush from 3-in.-
size coal to 3/4-in. size, 200-hp
motor, totally enclosed
110,600 ft3, 48 ft. wide, 48 ft
long., 48 ft. high, 24-ft-deep
pyramid bottom, closed top, CS
340 tons/hr, 30 in. wide, 10 ft
long, 2.5-hp motor, CS
340 tons/hr, 16-ft diameter, 27
ft long, 4,500-hp motor, wet
grind ball mill, to grind coal
from 3/4-in. size to 80% minus
100 mesh, 23% solids slurry
14,000 gal, 13-ft diameter, 14 ft
high, cone bottom, closed top,
neoprene lined, CS
5 hp, neoprene coated, CS
4,644 gpm, 100-ft head, centrifugal,
250-hp motor, neoprene lined, CS
1,161 gpm, 18-in. diameter, heavy
duty cyclone, 15-psig operating
pressure, high density gum rubber-
lined, fiberglass reinforced
polyester
28,900 gal, 17-ft diameter, 17 ft
high, cone bottom, closed top,
neoprene lined, CS
1 10 hp, neoprene coated,
CS
2 10,502 gpm, 50-ft head, centrifugal
300-hp motor, 316L SS '
2 100 gpm, 50-ft head, centrifugal
5-hp motor, CS '
(continued)
21fi
-------
TABLE A-12 (continued)
Item
Tank, binder storage
27. Pump, binder feed
28. Hoist, car shaker
29. Shaker, car
30. Puller, car
Hopper, lime
unloading
No.
Description
32.
33.
3A.
Feeder, lime
vibrating
Conveyor, lime
unloading
Conveyor, lime
unloading
35. Tunnel, conveyor
belt
36. PumP» tunnel sump
37<> Silo, lime storage
Feeder, weigh belt
Conveyor, slaker feed
1 1,880,200 gal, 80-ft diameter, 50
ft high, cone bottom, closed top,
CS
2 43 gpm, 100-ft head, centrifugal,
5-hp motor, CS
1 2,000-lb capacity with 1.5-hp
motor
1 20 hp, railroad, trackside vibrator
1 Railroad car puller with base, wire
rope, 25-hp motor, 5-hp return
motor
1 94 ft3, 8-ft 4-in. x 8-ft 4-in.
top opening, 3-ft-deep pyramid,
with 2-ft 4-in. x 2-ft 4-in.
bottom opening, CS
1 210 tons/hr, 42 in. wide, 5-ft-long
pan, 2.5-hp vibrator, CS
1 210 tons/hr, 24-in. belt, 10 ft
long, 2.5-hp motor, CS
1 210 tons/hr, 24-in. belt, 436 ft
long, 30-hp motor, totally enclosed,
CS
1 7 ft wide, 6 ft high, 70 ft long,
steel reinforced concrete
1 20 gpm, 20-ft head, centrifugal
sump type, 1/2-hp motor, CS
2 477,800 ft3, 78-ft diameter, 100
ft high, cone bottom, closed top, CS
2 37 tons/hr, 18-in. belt, 10 ft long,
1/2-hp motor, CS
1 37 tons/hr, 18-in. belt, 40 ft long,
1/2-hp motor, CS
(continued)
217
-------
TABLE A-12 (continued)
Item
No.
£0. Slaker, lime
41. Pump, slaker
product
42. Tank, 20% lime
feed
43. Agitator, 20% lime
feed tank
44. Pump, 20% lime feed
Description
239.8 tons/hr of 20% slaked" slurry""
product, 20 ft x 43 ft x 9.5 ft
high, 2-hp rake drive motor, 30-hp
mixer
2 768 gpm, 100-ft head, centrifugal,
40-hp motor, neoprene lined, CS
1 370,900 gal, 39-ft diameter, 41.5 ft
high, flat bottom, closed top,
neoprene lined, CS
1 75 hp, neoprene coated, CS
768 gpm, 100-ft head, centrifugal,
40-hp motor, neoprene lined, CS
Area 2—Reactor Area
Item
1. Exchanger, feed/
effluent heat
2. Scrubber, flash
gas
3. Agitator, scrubber
4. Pump, reactor feed
5. Preheater, reactor
6. Reactor, leach
7. Agitators, reactor
No.
Description
6 5,000 ft2 area, Carpenter 20 Cb
3 15-ft diameter, 60 ft high, spray
tower with 11,000 gal, 15-ft diameter
8 ft high, cone bottom, surge tank *
15-psig operating pressure, 316L SS
3 3.5 hp, 316L SS
5 3,500 gpm, 730-ft head, centrifugal
1,500-hp motor, 316L SS *
5 4,200 ft2 area, Hastelloy C
30 28,500 gal, 9-ft diameter, 84 ft
horizontal, 330-psia operating
5 Hastelloy C dividers, 85 mill'
propylene liner, 8-in. acid brick"]T~
6 agitator openings, shell is CS Ck r>
trains of 10 each) '" V
180 75 hp, Hastelloy C
(continued)
218
-------
TABLE A-12 (continued)
Item
8. Tank, flash
9. Pump, thickener feed
rescription
11,000 gaf, 12-ft diameter, 13 ft
high, cone bottom, closed top, 15-
psig operating pressure, 250°F,
Haste]loy C
3,110 gpm, 100-ft head, centrifugal,
200-hp motor, 316T, SS
Area 3 — Coal Filtration Area
Item
_ _
^ Thickener , coal
4.
5.
6.
Pump, thickener
underflow
Tank, thickener
overflow
Pump, neutralizer
feed
Heater, wash water
Filter, coal
7. Pump, vacuum
8. Tank, filtrate
9. Pump, filtrate
0. Heater, wash water
No.
Description
9 13 ft wide, 22 ft long, 21 ft high,
inclined plate gravity settler-
thickener with increased volume
sludge compartment, 1-hp motor,
picket-fence rake
14 540 gpm, 100-ft head, centrifugal,
40-hp motor, neoprene lined, CS
3 4,759 gal, 9-ft diameter, 10 ft
high, flat bottom, neoprene lined,
CS
5 1,491 gpm, 100-ft head, centrifugal,
75-hp motor, neoprene lined, CS
1 985 ft2 area, CS
24 27.75 tons/hr, 12-ft diameter, 24 ft
long, 912 ft2 area, rotary drum type,
5-hp motor drive, 3-hp agitator,
316L SS
24 200-hp system, 316L SS
24 750 gal, 4-ft diameter, 8 ft long,
vacuum receiver, 316L SS
36 400 gpm, 100-ft head, centrifugal,
20-hp motor, neoprene lined, CS
1 1,810 ft2 area, CS
(continued)
219
-------
TABLE A-12 (continued)
Item
11. Tank, coal wash
12. Agitator, coal wash
tank
13. Pump, filter feed
14. Filter, coal
15. Pump, vacuum
16. Tank, filtrate
17. Pump, filtrate
No.
3~
14
24
24
24
36
Description
17,300 gal,"l4.5-ft diameter, 14 ft
high, cone bottom, closed top,
neoprene lined, CS
3 10 hp, neoprene coated, CS
556 gpm, 100-ft head, centrifugal,
35-hp motor, neoprene lined, CS
74 tons/hr, 12-ft diameter, 24 ft
long, 912 ft2 area, rotary drum
type, 5-hp motor drive, 3-hp
agitator, 316L SS
200-hp system, 316L SS
750 gal, 4-ft diameter, 8 ft long
vacuum receiver, 316L SS '
212 gpm, 100-ft head, centrifugal
10-hp motor, neoprene lined, CS
Area 4—product Aggj^me£atj.on_aind_Hand 1 ing
ItemNo-
T.Conveyor, filtered
coal
2. Conveyor, coal storage
feed
3. Conveyor, coal bleed
4. Elevator, coal
5. Conveyor, pelletizlng
feed
Description
1 1,023 tons/hr, 42-in. belt, l6o~ f t~
long, 10-hp motor, CS
1 773 tons/hr, 42-in. belt, 1,500 ft
long, 100-hp motor, 2 fixed
totally enclosed, CS
1 825 tons/hr, 42-in. belt, 100 ft
long, 10-hp motor, totally enclose^
CS a»
5 165 tons/hr, 50 ft high, 24-in. x 3^
in. x 11-3/4-in. continuous bucket ""
belt drive, 15-hp motor, CS *
1 825 tons/hr, 42-in. belt, 510 ft
200-hp motor, 33 fixed trippers
totally enclosed, CS *
(continued)
220
-------
TABU' A-12 (continued)
Item
No.
~6~ Palletizing plants
7. Conveyor, pellet
product
8. Conveyor, pellet
product
9. Conveyor, stocking
10. Kopper, pile reclaim
Feeders, vibrating pan
12. Conveyor, coal
transfer
. Tunnel, conveyor
Tunnel, conveyor
15. Putnp, tunnel sump
__ _________ Description
33 25 ton'/hr pellet izing~plant~,
including 23-ft diameter pan
pelletizer, dryers, and all
support systems
3 575 tons/hr, 36-in. belt, 510 ft
long, 15-bp motor, totally enclosed
CS
1 575 tons/hr, 30-in. belt, 100 ft
long, 5-hp motor, totally enclosed,
CS
2 773 tons/hr, 42-in. belt, 968 ft
long, 40-hp motor, traveling tripper,
CS
20 13-ft x 13-ft top opening, 3-ft-deep
pyramid with 22-in. x 22-in. bottom
opening , CS
20 120 tons/hr, 24 in. wide, 42-in.-long
pan, 1.5-hp vibrator, CS
2 1,000 tons/hr, 42-in. belt, 970 ft
long, 40-hp motor, CS
2 7 ft wide, 6 ft deep, 970 ft long,
steel reinforced concrete
1 7 ft wide, 6 ft deep, 320 ft long,
steel reinforced concrete
3 60 gpm, 30-ft head, centrifugal, 1-
hp motor, CS
Area 5—Neutralization and Water Handling
Jtem
~1~. Tank, neutralizer
No.
Description
1 169,700 gal, 38-ft diameter,~20~fT
high, cone bottom, closed top,
neoprene lined, CS
(continued)
221
-------
TABLE A-12 (continued)
Item
No.
2. Agitator, neutralizer
tank
3. Pump, pond feed
4. Pipeline, pond feed
5. Pump, pond return
6. Pipeline, pond return
7. Tank, recycle water
8. Pump, water feed
9. Pump, water feed
10. Pump, water feed
11. Pump, water feed
12. Pump, water feed
13. Pump, makeup water
Description
1 15 hp, neoprene coated, CS
3 8,169 gpm, 300-ft head, centrifugal,
1,250-hp motor, neoprene lined, CS
2 36-in. diameter, 5,280 ft long, rubber-
lined, CS
3 8,064 gpm, 300-ft head, centrifugal
1,250-hp motor, CS '
1 36-in. diameter, 5,280 ft long, CS
1 8,530,600 gal, 143-ft diameter, 71
ft high, flat bottom, CS
2 9,194 gpm, 100-ft head, centrifugal
400-hp motor, CS *
2 1,432 gpm, 100-ft head, centrifugal
60-hp motor, CS *
2 3,506 gpm, 100-ft head, centrifugal
150-hp motor, CS *
2 2,864 gpm, 100-ft head, centrifugal
125-hp motor, CS *
2 813 gpm, 100-ft head, centrifugal,
40-hp motor, CS
2 1,681 gpm, 100-ft head, centrifugal
75-hp motor, CS '
Area 6—Settling Pond
Item
1. Pond
No.
Description
"l 801 acres, 24.69 ft deep with clay"
lining
222
-------
TABLE A-13. COMBINATION PCC-KVB PROCESS
MATERIAL BALANCE FOR 3.5% S COAL
TABLE A-13 (continued)
>
>
r
\ 1
1
h
r
i
1 1
ia
1 3
i
i
i
i
i
i i
20 \
* ' ]
I 3 I
3 * J
2 <• I
5 |
» I
7 1
• I
* I
1 I
J I
,
rf
rr
T
Stream No.
DescriDtion
Total stream, tons/hr
Stream components, tons/
Coal, bone dry
Pyritic S
Sulfate S
Organic S
Ash
Water
N02
05
S02
FeSOi. in coal
FeSOA. in solution
Fe2(S04)3
Fe(OH)3
Sulfate S, In solution
Na2S03
NaHSO}
NajSOi
Ca(OH)2
CaS03
CaSOi
CaSO^-2H20
NaiFei(S04)2(OH)A
CaO
NaOH
Binder
{Natural nas
preanic sulfate
1
Raw coal feed
to sizine
840.0
680.1
18.3
0.4
10.1
115.1
16.0
2
2 In.x 3/8 in.
coal to
coarse coal
cleaning
310.5
304.6
6.8
0.15
3.7
42.6
5.9
3
Product from
coarse coal
cleaning
276.7
265.3
3.6
0.13
3.3
22.4
11.4
4
Refuse from
coarse coal
cleaning
40.9
39.3
3.2
0.02
0.40
20.2
1.6
5
3/8 in.x 28 raco
to intermediat
coal cleaning
460.4
451.7
10.0
0.23
5.6
63.3
8.7
6
Product from
intermediate
coal cleaning
416.0
386.7
4.8
0.20
4.7
30.2
29.3
7
Refuse from
intermediate
coal cleaning
69.9
65.0
5.2
0.03
0.90
33.1
4.9
(continued)
(continued)
-------
TABLE A-13 (continued)
2
3
2
3
3
3
3
2
2
2
3
3
3
3
3 *
3 a
3«
3 7
?•
30
4 O
6
28 m x 0 coal
to fine
coal c lean infi
» 69.1
a
3
. - 67.7
9 1.4
. 0.04
, 0.84
9.2
1.4
0
I
a
3
*
9
*
7
•
«
0
1
2
5
<.
3
6
7
•
«
9
Product from
fine coal
cleanine
79.4
58.4
0.62
0.03
0.76
4.2
21.0
10
Refuse from
fine coal
cleaninz
12.7
9.3
0.78
0.01
0.08
5.0
3.4
11
Combined
refuse to
di soosal
123.5
113.6
9.3
0.05
1.3
58.3
9.9
NJ
ro
(continued)
TABLE A-13 (continued)
12
Combined
physical product
to chemical
cleaning
i
2
3
t.
3
6
7
a
9
10
1 1
1 2
1 3
K.
1 3
1 6
1 7
i a
1 9
2 0
2 1
2 2
a 3
2 <.
2 3
2 6
2 7
2 a
2 9
30
3 1
3 2
3 3
a j.
3 3
36
3 7
3«
39
4O
772.1
710.4
9.0
0.3
8.7
56.8
61.7
13
Coal to interim
storage
220.6
181.5
2.5
0.10
2.5
16.2
17.6
14A
Direct coal
feed to
chemical
cleaning (5 days
551.5
453.9
6.4
0.25
6.2
40.5
44.0
14B
Feed from
interim
storage to
chemical
cleaning (2 days'
551.5
453.9
6.4
0.25
6.2
40.5
44.0
(continued)
-------
TABLE A-13 (continued)
15
Pulverized coal
to reactor
i
i
i
t
i
i
i
i
i
i
2
2
3
t
a
a
2
a
2 •
9 •
l&
2/
• j
*»
*
i »
»•
1 1
• •
i
i
551.5
453.9
6.4
0.25
6.2
40.5
44.0
16
02 makeup
11.3
11.3
17
N02 makeup
0.119
0.119
18
Coarse coal
(1/4 in.x 28 m)
to coarse coal
leaching
355.9
293.6
0.08
0.16
2.8
21.1
25.9
9.6
2.4
(continued)
TABLE A-13 (continued)
19
Reactor
off -gas and
fine coal to
particulate
scrubber
i
2
3
<•
5
6
7
a
9
1 0
1
1 2
1 3
1 <-
1 5
1 6
1 7
1 •
1 9
2 O
2 1
33
2 3
2 *•
2 3
2 6
2 7
2 •
3 9
30
3 1
* 2
S 9
3-
3 9
3 *
,7
'J •
1 »
<• O
200.5
160.2
0.05
0.09
1.5
11.5
14.1
6.3
5.2
1.3
20
Fine coal
to fine coal
leaching
188.8
160.2
0.05
1.5
11.5
14.1
1.3
21
Scrubber
solution
bleed to
neutralizer
5.7
0.32
5.2
0.09
22
Off-gas to
S02 scrubber
6.0
6.0
(continued)
-------
TABLE A-13 (continued)
TABLE A-13 (continued)
to
N3
23
10X slaked lime
t" eed
i
4.
,
b
7
«
„
,
1
1
!
1
1
,
1
,
I
2 0
2 1
22
a 3
a .,
2 3
2 6
2 7
3. 8
3 9
3 O
3 !
1 2
3 3
3*.
3 -J
3 A
3 7
J«
1 9
40
69.4
- 62.4
6.9
24
20% NaOH
makeup
6.3
5.0
1.2
25
Scrubber
solution
bleed to the
neutralize
37.8
24.5
1.9
11.2
26
50% NaOH
feed to
coarse coal
17.0
8.5
8.5
i
2
1
"•
3
t.
7
8
9
1 O
L 1
12
1 -I
1".
1 ;
1 6
1 7
i a
1»
2 O
2 1
22
a 3
2 fa
2 3
2 «
2 7
2 8
39
30
9 1
1 2
3 3
3fc
3 3
3 6
3 7
It
3 »
<>O
27
Coarse coal
product
343.6
293.6
0.08
0
2.8
21.1
25.9
28
Coarse coal
bleed to
nelletizlnK
51 .5
44.0
0.012
0.4
3.1
3.8
29
Coarse coal
bvpass tc
storage
•>Q2 1
249.6
0.068
2.4
17.9
22.0
30
Coarse coal
leach solution
18.5
3.4
15.1
(continued)
(continued)
-------
TABLE A-13 (continued)
TABLE A-13 (continued)
NJ
NJ
1
2
3
4,
s
*
7
•
*
10
1 1
1 3
I 3
1 *•
1 3
1 »
1 7
1 *
*
•
1
a
»
»•
a s
i •
i
a«
f •
^£
iL
1 X
ti
fc
• i
i*
>T
1*
»*
*.«
31
50% NaOH
feed to fine
coal leaching
3.2
1.6
1.6
32
Fine coal
product
189.1
160.2
0.05
0
1.5
11.5
15.7
33
Fine coal
leach solution
to neutralizer
2.9
2.9
34
Binder
feed to
pelletizing
9.7
4.8
A. 8
35
i
2
3
U
s
6
7
»
*
10
1 1
1 2
1 9
!<•
1*
1 *
1 7
11
1 *
19
2 1
2 2
3 >
>*•
t 9
2 *
2 7
l«
£ 1
1 2
11
Jfc
15
,,
*•
1*
«O
Pelletizing
product
237. A
204.2
0.062
1.9
14.7
11.4
4.8
36
Comb ined
clean coal
product to
storage
529.5
453.9
0.13
4.3
32.6
33.5
4.8
37
20% lime
feed to
neutralizer
49.0
35.2
9.8
38
50% NaOH
feed to
neutral izer
0
0
0
(continued)
(continued)
-------
TABLE A-13 (continued)
TABLE A-13 (continued)
Isi
hO
OO
1
2
3
«•
3
6
7
•
9
1
1
1
1
1
1
L
1
1
1
2
2
a
a
2
2
2
2
2 •
3 *
3 0
3>
3 3
s a
3*i
53
3*
J 7
3f
J*
feO
39
Neutralized
settling pond
_ 111.2
59. S
1.5
3. A
2.6
0.084
38.9
4.7
40
return
37.7
37.7
41
HP steam to
gas preheater
160.9
160.9
42
S t earn to
water heater
81 .3
81.3
(continued)
Steam to
fine coal
water heater
179.4
179.4
02 to
neutralization
1.5
1.5
-------
TABLE A-14. COMBINATION PCC-KVB PROCESS
EQUIPMENT LIST - BASE CASE (5% S COAL)
\—Coal Receiving and Storage
1.
2.
3.
Item
No,
Description
Unloading conveyors for conveying
1,600 tons/hr, 3 in. x 0 raw coal
from unloading station to
stockpiles
Stacking conveyors for distrib-
uting coal along the tops of 2
parallel and adjacent wedge-shaped
open piles, each of 175,000 tons
Hoppers for reclaiming 807 tons/hr 20
of 3 in. x 0 raw coal from
stockpiles
Pan feeders for withdrawing 807
tons/hr of 3 in. x 0 raw coal
from reclaiming hoppers
Collecting conveyors for 807 tons/
hr of 3 in. x 0 raw coal from pan
feeders
Tunnels for collecting conveyors
-, Tunnel sump
/»
pump
Transfer conveyor
Tunnel for transfer conveyor
Tunnel sump pump
20
Inclined conveyor, 500 ft long,
with 1 fixed tripper, 48 in.
wide belt, carbon steel, with
tramp-iron magnet, 125 hp
Elevated horizontal conveyor,
1,000 ft long with 1 traveling
tripper, 48 in. wide belt, tele-
scoping chute, carbon steel,
40 hp
Reclaiming hopper with 14 ft x
14 ft top opening, 3-1/2 ft
deep pyramid, and 24 in. x 24
in. bottom opening, carbon steel
Vibratory pan feeder with 26 in.
wide x 48 in. long pan, carbon
steel, 1.5 hp vibrator
Horizontal conveyor, 1,000 ft
long with 36 in. wide belt,
carbon steel, 35 hp
Steel-reinforced concrete tunnel
8 ft wide x 6 ft deep x 1,000 ft
long
Centrifugal pump, 60 gpm, 30 ft
head, carbon steel, 1 hp
Horizontal conveyor, 320 ft long
with 36 in. wide belt, carbon
steel, 10 hp
Steel-reinforced concrete tunnel,
7 ft wide x 6 ft deep x 320 ft
long
Centrifugal pump, 60 gpm, 30 ft
head, carbon steel, 1 hp
(continued)
229
-------
TABLE A-14 (continued)
Item
No.
Description
11.
12.
13.
Delivery conveyor for 807 tons/hr
of 3 in. x 0 raw coal to raw coal
sizing area
Automatic sampling of coal from
stockpile to raw coal sizing
area
Bulldozer for servicing raw coal
storage piles
Inclined conveyor, enclosed
600 ft long, 36 in. wide belt,
with belt scale, carbon steel'
75 hp
Automatic sampler of plate or
similar type conforming with
ASTM sampling requirements,
primary sampling from 403 tons/
hr of 3 in. x 0 coal from deliverv
conveyors
Diesel bulldozer, 100 hp
Area 2—Raw Coal Sizing
Item
No.
Description
1. Raw coal screens for sizing 807
tons/hr of 3 in. x 0 coal to
95 tons/hr of 3 in. x 1-1/4 in.,
293 tons/hr of 1-1/4 in. x 3/8
in., and 419 tons/hr of 3/8 in.
x 0
2. Crusher for reducing 95 tons/hr
of 3 in. x 1-1/4 in. coal to
2 in. x 0
3. Prewet screen for sizing, 95
tons/hr of crushed coal at
3/8 in.
Double-deck horizontal vibrating
screen, 6 ft wide x 16 ft long,
low-noise suspension, standard
positioning of water sprays for
both decks, stainless steel
flanged plates for screening at
1-1/4 in. and 3/8 in., carbon
steel body, 15 hp
Single roll crusher with 24 in.
x 24 in. roll and stationary
breaker plate, materials of
construction suited to secondarv
crushing of medium-hard bitumino«>
coal, 25 hp
Horizontal vibrating screen 4 ft
wide x 16 ft long, low-noise sus-
pension, standard positioning of
water sprays, stainless steel
plate for screening at 3/8 in.,
carbon steel body, 10 hp
(continued)
230
-------
TABLE A-14 (continued)
Sieve bends for partial dewatering
and screening of 66 tons/hr of 28
mesh x 0 coal from 508 tons/hr of
3/8 in. x 0 coal
Fines screens for finish screening
of 66 tons/hr of 28 mesh x 0 coal
from 508 tons/hr of 3/8 in. x 0
coal
Description
Reversible sieve bend, 7 ft
wide, with deck of 1/8 in.
Bixby-Zimmer Iso-Rod spaced
for 1.2 mm opening, including
feed box distributor, carbon
steel body, 0 hp
Horizontal vibrating screen,
8 ft wide x 16 ft long, deck
of 3/32 in, Bixby-Zimmer, Iso-
Rod spaced for sizing at 28
mesh, low-noise suspension,
standard positioning of water
sprays, carbon steel body,
20 hp
—Coarse Coal Cleaning
1.
Item
No.
Description
Dense medium vessels for processing
298 tons/hr of 2 in. x 3/8 in. coal,
using magnetite medium at nominal
specific gravity of 1.55 for
production of 253 tons/hr of float
2.
Rinse screens for 253 tons/hr of
clean coal (float) at 2 in. x
3/8 in. from dense medium vessel
(continued)
Trough-type vessel, 7 ft wide,
with single chain and flight
conveyor for float and sink
removals at opposite ends of
vessel, float and sink inclines
constructed from steel wedge
wire for drainage of medium
from float and sink products
to bath, controlled level of
bath, controlled distribution
of medium recirculated to bath,
carbon steel frame and tank,
high carbon steel wear bars on
conveyor, 20 hp
Horizontal vibrating screen, 6
ft wide x 16 ft long, low-noise
suspension, standard positioning
of water sprays, carbon steel
frame, deck of 1/8 inch Bixby-
Zimmer Iso-Rod spaced for 1 mm
opening, 15 hp
231
-------
TABLE A-14 (continued)
Item
Rinse screens for 45 tons/hr of
refuse (sink) from dense medium
vessel
No.
1
Centrifuge for dewatering 253
tons/hr of 2 in. x 3/8 in. clean
coal from rinse screens
Description
Horizontal vibrating screen,
4 ft wide x 16 ft long, low-
noise suspension, standard
positioning of water sprays,
carbon steel frame, deck of
1/8 in. Bixby-Zimmer Iso-Rod
spaced for 1 mm opening, 10 hp
Vibrating basket centrifuge,
horizontal or vertical axis'of
basket, cone-shaped basket of
stainless steel screen, indi-
vidual motors and drives for
basket rotation, for vibration
along the axis of the basket,
and if so designed, for oil
pumping, carbon steel body,
60 hp total
Area 4—Intermediate Coal Cleaning
Item
No.
Description
1. Dense medium cyclone feed sump
for makeup of coal slurry con-
prising 442 tons/hr coal at
3/8 in', x 28 mesh and 2,290
tons/hr magnetite medium,
nominal specific gravity of
magnetite medium 1.55
2. Pumps for feeding coal slurry
to dense medium cyclones
3. Dense medium cyclones for
separation of 3/8 in. x 28
mesh coal at specific
gravity 1.55
Cylindrical tank, 14 ft dia x
2 ft high, with 60° cone botto*
and closed top, 7,000 gal,
ground-level installation*
carbon steel *
Centrifugal pump, 3,630 gpm
70 ft total head, 200 hp
Dense medium cyclone, 24 ln
dia with tangential entry of
feed and exit of clean coal
tops, cone angle about 20°
hard nickel or similarly *
abrasion-resistant iron
(continued)
232
-------
TABLE A-14 (continued)
No.
Description
Sieve bends for partial drainage
of medium from 370 tons/hr of clean
coal tops from dense medium cyclones
Drain and rinse screens for 370
tons/hr clean coal tops at 3/8
in. x 28 mesh
Centrifuges for dewatering 370
tons/hr of 3/8 in. x 28 mesh
clean coal from drain and
rinse screens
8.
Sieve bends for partial drainage
of medium from 72 tons/hr of
3/8 in- x 28 mesh refuse from
dense medium cyclones
Drain and rinse screens for 72
tons/hr of 3/8 in. x 28 mesh
refuse
Reversible sieve bend, 7 ft
wide, with deck of 3/32 in.
Bixby-Zimttver Iso-Rod spaced
for 3/4 mm opening, including
feed box distributor, 0 hp
Horizontal vibrating screen,
8 ft wide x 16 ft long, standard
positioning of water sprays in
rinse section, 2-compartment
pan for separate collections
of medium and rinse water, low-
noise suspension, deck of 3/32
in. Bixby-Zimmer Iso-Rod spaced
for 1/2 mm opening, carbon steel
frame, 20 hp
Vibrating basket centrifuge,
horizontal or vertical axis of
basket, cone shaped basket of
stainless steel screen, individual
motors and drives for basket
rotation, for vibration along the
axis of the basket, and if so
designed, for oil pumping, carbon
steel body, 85 hp total
Reversible sieve bend, 4 ft wide,
with deck of 3/32 in. Bixby-
Zimmer Iso-Rod spaced for 3/4
mm opening, including feed box
distributor, 0 hp
Horizontal vibrating screen, 5 ft
wide x 16 ft long, standard posi-
tioning of water sprays in rinse
section, 2-compartment pan for
separate collections of medium
and rinse water, low-noise sus-
pension, deck of 3/32 in. Bixby-
Zimmer Iso-Rod spaced for 1/2
mm opening, carbon steel frame,
12 hp
(continued)
233
-------
TABLE A-14 (continued)
Item
9.
Centrifuge for dewatering 72
tons/hr of 3/8 in. x 28 mesh
refuse from drain and rinse
screens
_Np_.
1
10.
Dense medium recovery system for
dilute medium from rinse screens
in coarse and intermediate
cleaning areas
Description
Vibrating basket centrifuge,
horizontal or vertical axis'
of basket, cone shaped basket
of stainless steel screen,
individual motors and drives
for basket rotation, for vibra-
tion along the axis of the basket,
and if so designed, for oil pump-
ing, carbon steel body, 60 hp
total
Double-drum magnetite recovery
unit with permanent magnets in
drums, 30 in. dia x 10 ft long
drum, 2 drums in series/unit,
complete with dilute medium
sump, magnetite scraper, etc.,
installed at elevation above
dense medium separators, carbon
steel, 10 hp/unit
Area 5--Fine Coal Cleaning
Item
No.
1.
2.
3.
Froth flotation feed sump for
makeup of coal slurry at 10%
solids using 66 tons/hr of
28 mesh x 0 coal
Pump for feeding coal slurry to
froth flotation cells
Froth flotation cells for
treatment of 66 tons/hr of
28 mesh x 0 coal
Des c r ip tjlon
Cylindrical tank, 12-1/2 ft
dia x 2 ft high with 60° cone
bottom and closed top, 5,500
gal, ground-level installation,
carbon steel
Centrifugal pump, 2,700 gpm,
60 ft total head, 75 hp
Bank of 4 froth flotation cells
with 300 ft3/cell, provisions
for agitation, aeration, and
skimming of froth from cell
each bank arranged with 1 feed
box and 1 tailings box, provisions
for reagent storage and reagent
feeding, carbon steel, 130 hp/bar.k
(continued)
234
-------
TABLE A-14 (continued)
4.
Disk filter for filtration of
56 tons/hr clean coal from
froth flotation
6.
Thickener receiving 2,360 gpm of
refuse slurry (tailings) from
froth flotation and filtrate from
refuse filter
Disk filter for filtration of
11 tons/hr refuse (underflow)
from thickener
Pump for returning 2,280 gpm of
clarified water
Description
Continuous rotary vacuum disk
filter, 12 ft, 6 in. dia x 11
disk, 55 stainless steel wire
cloth, complete with vacuum
pumps and receiver, moisture
trap, filtrate pump, and blower,
580 hp
Single compartment bridge-
supported thickener with 80 ft
dia reinforced concrete tank,
system includes drive unit and
lifting device, rake mechanism,
feed well, overflow arrangement
underflow arrangement, and
instrumentation, rotation drive
5 hp, lifting drive, 1 hp
Continuous rotary vacuum disk
filter, 12 ft, 6 in. dia x 6
disk, stainless steel wire
cloth, complete with vacuum
pump and receiver, moisture
trap, filtrate pump, and blower,
200 hp
Centrifugal pump, 1,140 gpm,
150 ft total head, 75 hp
I.tem_ .
i Collecting conveyor for 128
tons/hr of 2 in. x 0 refuse
2 Refuse bin for truck loading
_No.
1
(continued)
235
Horizontal and inclined belt
conveyor, 400 ft long with
24 in. wide belt, carbon steel,
15 hp
Storage bin, 16 ft wide x 26
ft long x 18 ft high on vertical
sides, 13 ft deep pyramidal bottom
with fast opening slides for truck
loading, 3.5 hp
-------
TABLE A-14 (continued)
Item
No.
Description
3. Trucks for transporting 128
tons/hr of 2 in. x 0 refuse
1 mile from coal cleaning
plant to refuse disposal
site
4. Refuse disposal site for 30-yr
operation
5. Bulldozer for spreading refuse
and earth in layers at disposal
site
Off-highway diesel-electric
dump truck, 100 ton payload,
100 yd3 capacity, dump body
for 2 in. x 0 moist, sluggish,
abrasive refuse
"Dry" storage site with 26,000
acre-ft capacity for layered
refuse and earth
Diesel bulldozer, 100 hp
Area 7—Interim Coal Storage
Item
1. Collecting conveyor for 679
tons/hr of 2 in. x 0 cleaned
coal
2. Conveyor, storage bypass
3. Conveyor, coal silo feed
4. Silo, coal storage
5. Feeder, coal
6. Conveyor, coal transfer
No.
Horizontal conveyor, 300 ft
long with 36 in. wide belt,
carbon steel, 20 hp
552 tons/hr, 42 in. belt, 650
ft long, 20 hp motor, carbon
steel
221 tons/hr, 24 in. belt, 880
ft long, 30 hp motor, 4 fixed
trippers, carbon steel
264,720 ft3, 70 ft dia, 70 ft
high, cone bottom, closed top
carbon steel
552 tons/hr rotary gate feeder,
2 hp motor, carbon steel
552 tons/hr, 42 in. belt, 88O ft
long, 75 hp motor, carbon ste«l
(continued)
236
-------
TABLE A-14 (continued)
g __ Raw Material Handling and Preparation^
No.
Description
Feeder, weigh belt
Crusher, coal
Screen, coal
Crusher, coal
Conveyor, reactor area feed
Pump, N02 unloading
Tank, N02 storage
Pump, binder unloading
Automatic coal sampler
3,600 ft3, 15 ft wide, 15 ft
long, 16 ft high, 13 ft deep
pyramid bottom, closed top,
carbon steel
297 tons/hr, 42 in. belt, 10
ft long, 2 hp motor, carbon
steel
297 tons/hr, double roll type,
36 in. dia rolls, 2 each, 25
hp motors, totally enclosed,
carbon steel
297 tons/hr, 119 ft2 area, 7
ft x 17 ft, flip flow vibrating
screen deck, 40 hp motor, carbon
steel
173 tons/hr, double roll type,
30 in. dia rolls, 2 each, 20 hp
motors, totally enclosed, carbon
steel
593 tons/hr, 42 in. belt, 560 ft
long, 100 hp motor, with 4 fixed
trippers, totally enclosed,
carbon steel
70 gpm, 415 ft head, positive
displacement, 15 hp motor, 316
stainless steel
17,600 gal, 10 ft dia, 30 ft
long, horizontal type, 150 psig
operating pressure, 316 stain-
less steel
40 gpm, 50 ft head, centrifugal,
2 hp motor, carbon steel
(continued)
237
-------
TABLE A-14 (continued)
Item
11. Pump, binder storage
12. Pump, binder feed
13. Pump, NaOH unloading
14. Tank, NaOH storage
15. Pump, NaOH feed
16. Pump, NaOH feed
17. Pump, NaOH feed
18. Pump, NaOH transfer
19, Tank, 20% NaOH mix
20. Agitator, NaOH mix tank
21. Pump, 20% NaOH feed
22. Hoist, car shaker
23. Shaker, car
No.
1
1
Description
887,000 gal, 55 ft dia, 50 ft
high, flat bottom, closed top,
carbon steel
20 gpm, 200 ft head, centrifugal,
5 hp motor, carbon steel
55 gpm, 40 ft head, centrifugal,
1.5 hp motor, neoprene lined,
carbon steel
994,000 gal, 59 ft dia, 50 ft
high, flat bottom, closed top,
neoprene lined, carbon steel
13 gpm, 100 ft head, centrifugal,
1 hp motor, neoprene lined,
carbon steel
38 gpm, 100 ft head, centrifugal,
3 hp motor, neoprene lined,
carbon steel
28 gpm, 100 ft head, centrifugal,
3 hp motor, neoprene lined,
carbon steel
13 gpm, 100 ft head, centrifugal.
1 hp motor, neoprene lined,
carbon steel
25,470 gal, 17 ft dia, 15 ft
high, flat bottom, closed top,
neoprene lined, carbon steel
15 hp, neoprene coated, carbon
steel
52 gpm, 100 ft head, centrifugal,
3 hp motor, neoprene lined,
carbon steel
2,000 Ib capacity, 15 hp motor
Railroad, trackside vibrator
20 hp *
(continued)
238
-------
TABLE A-14 (continued)
24. Puller, car
25. Hopper, lime unloading
26. Feeder, lime vibrating
27. Conveyor, lime unloading
28 Conveyor, lime unloading
29. Tunnel, conveyor
30
Pump, tunnel sump
31. Silo, lime storage
32. Feeder, weigh belt
33. Conveyor, slaker feed
34. Slaker, lime
35. Pump, lime slaker product
_Np_.
1
Description
Railroad car puller with base,
wire rope, 25 hp motor, 5 hp
return motor
94 ft3, 8 ft 4 in. x 8 ft 4 in.
top opening, 3 ft deep pyramid,
with 2 ft 4 in. x 2 ft 4 in.
bottom opening
210 tons/hr, 42 in. wide, 5 ft
long pan, 2.5 hp vibrator,
carbon steel
210 tons/hr, 24 in. belt, 10
ft long, 2.5 hp motor, carbon
steel
210 tons/hr, 24 in. belt, 381
ft long, 25 hp motor, totally
enclosed, carbon steel
6 ft wide, 6 ft high, 70 ft
long, steel reinforced concrete
20 gpm, 20 ft head, centrifugal,
0.5 hp motor, carbon steel
430,000 ft3, 74 ft dia, 100 ft
high, cone bottom, closed top,
carbon steel
22 tons/hr, 12 in. belt, 10 ft
long, 0.5 hp motor, carbon steel
22 tons/hr, 12 in. belt, 40 ft
long, 0.75 hp motor, carbon
steel
105.5 tons/hr of 20% slaked
slurry product, 20 ft x 43 ft
x 9.5 ft high, 2 hp motor on
rake drive, 30 hp mixer
338 gpm, 100 ft head, centrifugal,
20 hp motor, neoprene lined,
carbon steel
(continued)
239
-------
TABLE A-1A (continued)
Item
No.
Description
36. Tank, 20% lime feed
37. Agitator, 20% lime feed tank
38. Pump, 20% lime feed
39. Tank, 10% lime feed
40. Agitator, 10% lime feed tank
41. Pump, 10% lime feed
25,470 gal, 17 ft dia, 15 ft
high, flat bottom, closed top,
neoprene lined, carbon steel
10 hp, neoprene coated, carbon
steel
50 gpm, 100 ft head, centrifugal,
3 hp motor, neoprene lined,
carbon steel
322,400 gal, 38 ft dia, 38 ft
high, flat bottom, closed top,
neoprene lined, carbon steel
20 hp, neoprene coated, carbon
steel
647 gpm, 100 ft head, centrifugal,
30 hp motor, neoprene lined
carbon steel
Area 9—Sulfur Oxidation
Item
No.
Description
1. Bin, reactor feed
2. Feeder, weigh belt
3. Reactor, fluidized bed
Fan, scrubber forced draft
5,670 ft3, 19 ft dia, 20 ft
high, cone bottom, closed top,
carbon steel
149 tons/hr, 24 in. belt, 15 ft
long, 1 hp motor, carbon steel
22.3 ft dia, 51 ft high side
cone bottom, cone top, 3. atnios.
phere operating pressure, 315
stainless steel
140,740 aft3/min at 200°F Ap
15 in. H20, 450 hp motor, *316
stainless steel
(continued)
240
-------
TABLE A-14 (continued)
5.
6.
7.
Item
i - -
Fan, recirculating
Heater, oxidizing gas
"Scrubber," vent gas combustion
No.
Description
140,740 aftS/min at 200°F, AP
15 in. H20, 450 hp motor, 316
stainless steel
8,080 ft2 area, 316 stainless
steel
10 ft x 10 ft natural gas fired
N02IDIZER, 10 hp blower, 35 ft
of stack, carbon steel
?n--Reactor Off-Gas Cleaning
, Scrubber, particulate
j. •
2.
3.
Thickener, fine coal
pump, thickener underflow
Tank, thickener overflow
Pump, venturi feed
Absorber, S02
No.
Description
Venturi, 14.8 ft dia, 52 ft
high, with mist eliminator,
316 stainless steel
13 ft wide, 22 ft long, 21 ft
high, inclined plate gravity
settler-thickener with increased
volume sludge compartment, 1 hp
picket-fence rake
354 gpm, 160 ft head, centrifugal,
40 hp motor, neoprene lined,
carbon steel
6,600 gal, 7.5 ft dia, 20 ft
high, flat bottom, neoprene
lined, carbon steel
2,100 gpm, 100 ft head, centrifugal,
100 hp motor, neoprene lined,
carbon steel
Venturi, 14.8 ft dia, 52 ft high,
with mist eliminator, 316 stain-
less steel
(continued)
241
-------
TABLE A-14 (continued)
Item
No.
7. Tank, effluent surge
8. Agitator, effluent surge tank
Description
16,100 gal, 14 ft dia, 14 ft
high, cone bottom, neoprene
lined, carbon steel
10 hp, neoprene coated,
carbon steel
9. Pump, effluent
10. Thickener, absorber
11. Pump, thickener underflow
1,570 gpm, 100 ft head, centrifu-
gal, 75 hp motor, neoprene lined,
carbon steel
13 ft wide, 22 ft long, 21 ft
high, inclined plate gravity
settler-thickener with increased
volume sludge compartment, 1 hp
picket-fence rake
176 gpm, 100 ft head, centrifugal,
10 hp motor, neoprene lined,
carbon steel
12. Tank, thickener overflow
neutralizer
4,280 gal, 9 ft dia, 9 ft high,
cone bottom, neoprene lined,
carbon steel
13. Agitator, thickener
14. Pump, thickener underflow
5 hp, neoprene coated, carbon
steel
1,408 gpm, 100 ft head, centrifugal,
75 hp motor, neoprene lined,
carbon steel
15. Fan, absorber, forced draft
140,740 aftj/min at 200°F, AP
15 in. H20, 450 hp motor, 316
stainless steel
Area 11-Fine Coal Leaching^
Item
1. Tank, water leach
2. Agitator, water leach tank
No.
Description
3,600 gal, 8.5 ft dia, 8.5 ft
high, cone bottom, closed top,
neoprene lined, carbon steel
10 hp, neoprene coated, carbon
steel
(continued)
242
-------
TABLE A-14 (continued)
Item
No.
Description
3. Pump, cyclone feed
, Cyclone, water leach
7t Heater, process water
g. Pump, cyclone feed
o,. Cyclone, water leach
Cyclone, caustic leach
Tank, cyclone underflow
36
5. Tank, cyclone underflow
Agitator, cyclone underflow tank 4
4
6
24
10. Tank' cyclone underflow
Agitator' cyclone underflow tank 4
12. Pump, cyclone feed 6
36
722 gpm, 260 ft head, centrifu-
gal, 125 hp motor, carbon steel
90 gpm, 6 in. dia, heavy duty
cyclone, 100 psig operating
pressure, high density gum
rubber-lined cast iron and
steel
1,614 gal, 6.5 ft dia, 6.5 ft
high, cone bottom, closed top,
neoprene lined, carbon steel
5 hp, neoprene coated, carbon
steel
178 ft^ area, carbon steel
523 gpm, 260 ft head, centrifugal,
100 hp motor, carbon steel
90 gpm, 6 in. dia, heavy duty
cyclone, 100 psig operating
pressure, high density gum
rubber-lined cast iron and
steel
3,600 gal, 8.5 ft dia, 8.5 ft
high, flat bottom, closed top,
neoprene lined, carbon steel
10 hp, neoprene coated, carbon
steel
752 gpm, 260 ft head, centrifugal,
125 hp motor, carbon steel
90 gpm, 6 in. dia, heavy duty
cyclone, 100 psig operating
pressure, high density gum
rubber-lined cast iron and
steel
850 gal, 5.25 ft dia, 5.25 ft
high, flat bottom, closed top,
neoprene lined, carbon steel
(continued)
243
-------
TABLE A-14 (continued)
Item
No.
15. Agitator, cyclone underflow tank 4
Description
10 hp, neoprene coated, carbon
steel
16. Pump, slurry transfer
17. Thickener, fine coal
18. Pump, thickener underflow
85 gpm, 100 ft head, centrifugal,
15 hp motor, neoprene lined,
carbon steel
10 ft wide, 19 ft long, 21 ft
high, inclined plate gravity
settler-thickener with increased
volume sludge compartment, 1 hp
picket-fence rake
3.5 gpm, 100 ft head, centrifugal,
0.25 hp motor, neoprene lined,
carbon steel
19. Tank, thickener overflow
2,000 gal, 7 ft dia, 7 ft high,
flat bottom, neoprene lined,
carbon steel
20. Pump, thickener overflow
21. Tank, leach mix
22. Agitator, leach mix tank
23. Pump, cyclone feed
24. Cyclone, water wash
36
25. Tank, cyclone underflow
26. Agitator, cyclone underflow tank 4
(continued)
667 gpm, 100 ft head, centrifugal,
30 hp motor, neoprene lined,
carbon steel
7,800 gal, 11 ft dia, 11 ft high,
cone bottom, closed top, neoprene
lined, carbon steel
5 hp, neoprene coated, carbon
steel
758 gpm, 260 ft head, centrifugal*
125 hp motor, carbon steel
90 gpm, 6 in. dia, heavy duty
cyclone, 100 psig operating
pressure, high density gum
rubber-lined cast iron and
steel
3,800 gal, 8.5 ft dia, 9 ft high,
cone bottom, closed top, neoprene
lined, carbon steel
10 hp, neoprene coated, carbon
steel
244
-------
TABLE A-14 (continued)
27. Pump, cyclone feed
28. Cyclone, water wash
29. Tank, cyclone underflow
30
31 Pump, cyclone feed
32. Cyclone, wash water
33 Tank, cyclone underflow
3A
35f Pump, centrifugal feed
36< Heater, process water
37. Heater, process water
Centrifuge, fine coal
Description
36
Agitator, cyclone underflow tank 4
36
Agitator, cyclone underflow tank 4
4
4
4
758 gpm, 260 ft head, centrifu-
gal, 125 hp motor, carbon steel
90 gpm, 6 in. dia, heavy duty
cyclone, 100 psig operating
pressure, high density gum
rubber-lined cast iron and
steel
3,800 gal, 8.5 ft dia, 9 ft high,
cone bottom, closed top, neoprene
lined, carbon steel
10 hp, neoprene coated, carbon
steel
758 gpm, 260 ft head, centrifu-
gal, 125 hp motor, carbon steel
90 gpm, 6 in. dia, heavy duty
cyclone, 100 psig operating
pressure, high density gum
rubber-lined cast iron and
steel
1,270 gal, 6 ft dia, 6 ft high,
cone bottom, closed top, neoprene
lined, carbon steel
10 hp, neoprene coated, carbon
steel
437 gpm, 100 ft head, centrifugal,
30 hp motor, neoprene lined,
carbon steel
144 ft2 area, carbon steel
2
102 ft area, carbon steel
44 in. dia, 132 in. long,
continuous screen bowl type,
200 hp motor
(continued)
245
-------
TABLE A-14 (continued)
Item
39. Tank, centrate
40. Pump, centrate return
41. Conveyor, centrifuge product
42. Conveyor, centrifuge product
43. Sampler, coal
44. Elevator, bucket
No.
Description
4 2,000 gal, 7 ft dia, 7 ft high,
cone bottom, closed top, carbon
steel
6 670 gpm, 100 ft head, centrifu-
gal, 30 hp motor, carbon steel
1 209 tons/hr, 30 in. belt, 160
ft long, 5 hp motor, carbon
steel
1 209 tons/hr, 30 in. belt, 180 ft
long, 5 hp motor, carbon steel
1 Automatic coal sampler
2 105 tons/hr, 40 ft high, 16 in.
x 8 in. x 11-3/4 in. continuous
buckets, belt drive, 7.5 hp
motor, carbon steel
Area 12—Coarse Coal Leaching
Item
1. Dewaterer, water leach
2. Pump, overflow
3. Dewaterer, water leach
4. Pump, dewaterer overflow
No.
Description
100 tons/hr, single screw,
spiral dewaterer, 54 in. dia
flights, 34 ft tube length,
40 hp motor, closed top,
carbon steel
347 gpm, 100 ft head, centrifu-
gal, 20 hp motor, neoprene
lined, carbon steel
100 tons/hr, single screw spiral
dewaterer, 54 in. dia flights
34 ft tube length, 40 hp motor,
carbon steel
406 gpm, 100 ft head, centrifu-
gal, 20 hp motor, neoprene
lined, carbon steel
(continued)
246
-------
TABLE A-1A (continued)
5. Heater, process water
6. Tank, caustic leach
7, Agitator, caustic leach tank
8. Pump, thickener feed
9. Thickener, coarse coal
10.
11.
12.
13.
15.
16-
pump, thickener underflow
Tank, thickener overflow
Pump, thickener overflow
Tank, caustic leach
Agitator, caustic leach tank
Dewaterer,
water wash
pump, dewaterer overflow
A
4
163 ft2 area, carbon steel
10,000 gal, 12 ft dia, 12 ft
high, cone bottom, closed top,
neoprene lined, carbon steel
10 hp, neoprene coated, carbon
steel
980 gpm, 100 ft head, centrifu-
gal, 60 hp motor, neoprene
lined, carbon steel
10 ft wide, 19 ft long, 21 ft
high, inclined plate gravity
settler-thickener with increased
volume sludge compartment, 1 hp
picket-fence rake
641 gpm, 100 ft head, centrifugal,
50 hp motor, neoprene lined,
carbon steel
975 gal, 5.5 ft dia, 5.5 ft high,
flat bottom, closed top, neoprene
lined, carbon steel
339 gpm, 100 ft head, centrifugal,
20 hp motor, neoprene lined,
carbon steel
6,460 gal, 10 ft dia, 11 ft high,
flat bottom, closed top, neoprene
lined, carbon steel
5 hp, neoprene coated, carbon
steel
100 tons/hr, single screw spiral
dewaterer, 54 in. dia flights,
34 ft tube length, 40 hp motor,
closed top, carbon steel
900 gpm, 100 ft head, centrifugal,
40 hp motor, neoprene lined,
carbon steel
(continued)
247
-------
TABLE A-14 (continued)
Item
18. Pump, dewaterer overflow
19. Dewaterer, water wash
20. Pump, dewaterer overflow
21. Tank, water wash
22. Agitator, water wash tank
23. Heater, process water
24. Pump, centrifuge feed
25. Heater, process water
26. Centrifuge, coarse coal
27. Tank, centrate
28. Pump, centrate return
29. Conveyor, centrifuge product
No.
17. Dewaterer, water wash
4
6
4
4
Description
100 tons/hr, single screw spiral
dewaterer, 54 in. dia flights,
34 ft tube length, 40 hp motor,
closed top, carbon steel
336 gpm, 100 ft head, centrifugal,
15 hp motor, neoprene lined,
carbon steel
100 tons/hr, single screw spiral
dewaterer, 54 in. dia flights
34 ft tube length, 40 hp motor,
closed top, carbon steel
336 gpm, 100 ft head, centrifugal,
15 hp motor, neoprene lined,
carbon steel
1,070 gal, 5.5 ft dia, 6 ft high,
cone bottom, closed top, neoprene
lined, carbon steel
10 hp, neoprene coated, carbon
steel
58 ft2 area, carbon steel
230 gpm, 100 ft head, centrifugal.
25 hp motor, neoprene lined
carbon steel *
58 ft2 area, carbon steel
230 gpm, continuous oscillating
bowl, 25 hp motor and 5 hp motor
1,070 gal, 5.5 ft dia, 6 ft
336 gpm, 100 ft head, centrifugal.
15 hp motor, carbon steel
384 tons/hr, 30 in. belt, U0 ft
long, 5 hp motor, carbon steel
(continued)
248
-------
TABLE A-14 (continued)
Item
30. Sampler, coal
31. Conveyor, coarse coal bleed
32. Conveyor, stacker feed
33. Elevator, coal dryer feed
34 Elevator, coal mix bin feed
Description
1 Automatic coal sampler
1 56 tons/hr, 18 in. belt, 50
ft long, 5 hp motor, carbon
steel
1 596 tons/hr, 42 in. belt, 715
ft long, 50 hp motor, carbon
steel
8 100 tons/hr, 96 ft high, 24 in.
x 8 in. x 11-3/4 in. continuous
buckets, double chain drive, 20
hp motor, carbon steel
2 134 tons/hr, 40 ft high, 20 in.
x 8 in. x 11-3/4 in. continuous
buckets, belt drive, 7.5 hp
motor, carbon steel
13—Product Agglomeration and Handling
•—~~ ^~
Item
Bin, coal mix
Feeder, coal
3. Conveyor, coal transfer
4. Palletizing plants
No.
11
(continued)
Description
1,725 ftj, 13 ft dia, 13 ft
high, cone bottom, carbon
steel
266 tons/hr, 30 in. belt, 5 ft
long, 1.5 hp motor, carbon
steel
266 tons/hr, 30 in. belt, 200
ft long, 40 hp motor, 11 fixed
trippers, carbon steel
25 tons/hr package pelletizing
plants including 23 ft dia pan
pelletizer, dryers and all
support systems
249
-------
TABLE A-14 (continued)
Item
5. Conveyor, pelletizer product
6. Conveyor, pelletizer product
7. Conveyor, stacker
8. Hopper, pile reclaim
9. Feeders, vibrating pan
10. Conveyor, coal transfer
11. Tunnel, conveyor
12. Tunnel, conveyor
13. Pump, tunnel sump
No.
1
20
20
125 tons/hr, 24 in. belt,
185 ft long, 2 hp motor/
carbon steel
125 tons/hr, 24 in. belt,
130 ft long, 2 hp motor/
carbon steel
596 tons/hr, 42 in. belt
968 ft long, 25 hp motor*
traveling tripper, carbon
steel
13 ft x 13 ft top opening,
3 ft deep pyramid, with 22
in. x 22 in. bottom opening
carbon steel
120 tons/hr, 24 in. wide 42
in. long pan, 1.5 hp vibrator
carbon steel
1,000 tons/hr, 42 in. belt 970
ft long, 40 hp motor, carbon
steel
7 ft wide, 6 ft deep, 970 ft
long, steel-reinforced concrete
7 ft wide, 6 ft deep, 320 ft
long, steel-reinforced concrete
60 gpm, 30 ft head, centrifugal
1 hp motor, carbon steel
Area 14—Leach Solution Neutralization and Water Handling
Item No. D
1. Tank, neutralizer stage 1 4
2. Agitator, neutralizer stage 1 tank 4
25,600 gal, 16 ft dia, 17 f,
high, flat bottom, closed ton
neoprene lined, carbon steei '
10 hp, neoprene coated C~K
steel ' carbon
(continued)
250
-------
TABLE A-14 (continued)
3.
Item
Tank, neutralizer stage 2
No.
Agitator, neutralizer stage 2 tank 4
5.
6.
Tank, neutralizer stage 3
Agitator, neutralizer stage 3 tank 4
Tank, neutralizer stage 4
/ «
Agitator,
neutralizer stage 4 tank 4
9.
10.
11-
12-
13-
15-
16.
pump, P°nd feed
pipeline, pond feed
pump, pond return
pipeline, pond return
Tank, recycle water
pump, water feed
Pump, water feed
Pump)
water feed
Description
8,500 gal, 11 ft dia, 12 ft
high, flat bottom, closed top,
neoprene lined, carbon steel
10 hp, neoprene coated, carbon
steel
8,500 gal, 11 ft dia, 12 ft
high, flat bottom, closed top,
neoprene lined, carbon steel
10 hp, neoprene coated, carbon
steel
8,500 gal, 11 ft dia, 12 ft
high, flat bottom, closed top,
neoprene lined, carbon steel
10 hp, neoprene coated, carbon
steel
11,480 gpra, 300 ft head, centrifu-
gal, 1,750 hp motor, neoprene
lined, carbon steel
30 in. dia, 5,280 ft long, rubber
lined, carbon steel
11,156 gpm, 300 ft head, centrifu-
gal, 1,500 hp motor, carbon steel
30 in. dia, 5,280 ft long, carbon
steel
5,400,000 gal, 150 ft dia, 41 ft
high, flat bottom, carbon steel
4,184 gpm, 100 ft head, centrifugal,
200 hp motor, carbon steel
697 gpm, 100 ft head, centrifugal,
30 hp motor, carbon steel
39 gpm, 100 ft head, centrifugal,
2 hp motor, carbon steel
(continued)
251
-------
TABLE A-14 (continued)
Item
17. Pump, water feed
18. Pump, water feed
19. Pump, water feed
20. Pump, water feed
21. Pump, makeup water
No.
Description^
1,152 gpm, 100 ft head, centrifu-
gal, 50 hp motor, carbon steel
2,441 gpm, 100 ft head, centrifu-
gal, 125 hp motor, carbon steel
1,624 gpm, 100 ft head, centrifu-
gal, 75 hp motor, carbon steel
1,771 gpm, 100 ft head, centrifu-
gal, 75 hp motor, carbon steel
752 gpm, 100 ft head, centrifu-
gal, 40 hp motor, carbon steel
Area 15--Settling Pond
Item
No.
Descripjtion
1. Pond
932 acres, 25.58 ft deep,
with clay lining
252
-------
APPENDIX B
ECONOMIC DATA
253
-------
TABLE B-l. FCC 1 PROCESS
TOTAL CAPITAL INVESTMENT
(Dense-medium vessel, dense-
medium cyclone, froth flotation)
Uirrct_ Investment
Case variation - 0.7% S coal
Investment, $
Coal receiving and storage g ^g QQQ
Raw coal sizing l,'616,'oOO
Coarse coal cleaning 1,575,000
Intermediate coal cleaning 2 234 000
Fine coal cleaning 2,696*000
Refuse disposal as landfill 1,904 000
Clean coal storage 8,459?QQQ
Total areas 27,283,000
Services, utilities, and miscellaneous 1,637 000
Total direct investment 28,920,000
Indirect Investment
Engineering design and supervision 2,429,000
Architect and engineering contractor 578,000
Construction expense 3,441 000
Contractor fees 972 QOO
Total indirect investment
Cont ingency
Total f;>.<'c invest •;»•.!
Other Capital Charges
Allowance for startup and modifications 4,179 000
Interest during construction 5,851,QQQ
Total depreciable investment 51,821,000
Land 2,174,000
Working capital 10.696^000
Total capital investment 64,691,000
Dollars of total capital per kU of generating
capacity 32.35
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
254
-------
TABLE B-2. PCC I PROCESS
ANNUAL REVENUE REQUIREMENTS
(Dense-medium vessel, dense-
mediun cyclone, froth flotation)
- — ~— — — — • — • ' •
Case variation - Q.7X S coal
Annual
quantity
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
process material: magnetite, Grade E
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
283,400 tons
144,000 man-hr
47,600 legal
14,900,000 kWh
97,000 gal
2,720 tons
4,000 man-hr
Unit
cost. $
31.58/ton
13.80/man-hr
0.13/kgal
0.039/kUh
0.70/aal
93.31/ton
18.70/man-hr
Total annual
cost, $
8,949,000
8,949,000
1,987,000
6,000
581,000
68,000
254,000
1,735,000
75,000
4,706,000
13,655,000
Jndirect Costs
Capital charges
Depreciation, Interim replacements,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6X of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 103! of sales revenue
Total Indirect costs
Cross annual revenue requirements
3,109,000
5,563,000
993,000
199,000
9,864,000
23,519,000
None
Total annual revenue requirements
23,519,000
C/lb
MA.U_s/kWh jailtur. raBftV-ttd
Equivalent unit revenue requirements 2.14 188
Basis
Clean coal production capacity for 2,000 MW-c«»l-r i rod i>ow,.r ,,i.,nt ,.„ ,. , ,
9.500 Btu/kWh and 5.500 hr/yr. ' 'M'.>.itinB .it
Total direct investment, $28,920,000; total depreciable Investment SSI »}1 OOft- i
total capital investment, $64,691,000. ' *51 >82V •000; -lnd
^r ,„,, , •, mil
.....
Clean coal (moisture-free): 4,354,000 tons/yr, 0.62X si.lfvir 7
Btu/U>, imd 0.51 Ib S/MBtu. '
255
-------
TABLE B-3. PCC 1 PROCESS
TOTAL CAPITAL INVESTMENT
(Dense-medium vessel, dense-
medium cyclone, froth flotation)
Case variation - 2% S coal
Investment, $
Direct Invi-stni.¥nt
Coal receiving and storage
Raw coal sizing
Coarse coal cleaning
Intermediate coal cleaning
Fine coal cleaning
Refuse disposal as landfill
Clean coal storage
Total areas
Services, utilities, and miscellaneous
Total direct investment
Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total indirect investment
Contingency
Total fixed investment
Cither Capital Charges
Allowance for startup and modifications
Interest during construction
Total depreciable investment
Land
Working capital
Total capital investment
Dollars of total capital per kW of generating
capacity
8,529,000
1,543,000
1,512,000
2,132,000
2,573,000
2,558,000
8,028,000
26,875,000
1,613,000
28,488,000
2,393,000
570,000
3,390,000
957,000
7,310,000
5,370,000
41,168,000
4,117,000
5,764,000
51,049,000
3,008,000
8,829,000
62,886,000
31.44
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
256
-------
TABLE B-4. PCC I PROCESS
ANNUAL REVENUE REQUIREMENTS
(Dense-medium vessel, dense-
medium cyclone, froth flotation)
Cas<
> variation - 2% S coal
Annual
quantity
Unit
cost. S
Total annual
cost, $
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Converstion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Process material: magnetite, Grade E
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
315,600 tons
31.58/ton
144,000 man-hr 13.80/man-hr
9.966.000
9,966,000
1,987,000
39,600 kgal
14,108,000 kWh
119,000 gal
2,490 tons
4,000 man-hr
0.13/kgal
0.039/kWh
0.70/gal
93.31/ton
18.70/man-hr
5,000
550,000
83,000
232,000
1,709,000
75,000
4,641,000
14,607,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Cross annual revenue requirements
3,063,000
5,408,000
993,000
199.0OO
9,663,000
24.270,000
Byproduct Sales Revenue
None
Total annual revenue requirements
C/lb
Mills/kWh sultur removed
Equivalent unit revenue requirements 2.21
33.5
24,270,000
Basis
Midwest coal-cleaning plant location; time basis for sea Una mid-1982- nl
30years; operatins time, 6,000 hr/yr. ' ' '
Cd1r 2
' «1.0«.000; and
.
Clean coal (moisture-free): 3,749,000 tons/yr. 1.36Z sulfur, , *„ .
Btu/lb, and 0.97 Ib S/MBtu. *' "• >*.000
257
-------
TABLE B-5. PCC I PROCESS
TOTAL CAPITAL INVESTMENT
(Dense-medium vessel, dense-
medium cyclone, froth flotation)
Case variation - 3.5% S coal
Investment, $
Direct Investment
Coal receiving and storage 8,608,000
Raw coal sizing 1,564,000
Coarse coal cleaning 1,547,000
Intermediate coal cleaning 2,162,000
Fine coal cleaning 2,594,000
Refuse disposal as landfill 2,581 000
Clean coal storage 8,'048.'000
Total areas 27,104,000
Services, utilities, and miscellaneous 1,626 000
Total direct investment 28,730,000
Indirect Investment
Engineering design and supervision 2,413,000
Architect and engineering contractor 575,000
Construction expense 3,419,000
Contractor fees 965,000
Total indirect Investment 7,372,000
Contingency 5,415,000
Total fixed investment 41,517,000
Other Capital Charges
Allowance for startup and modifications 4,152,000
Interest during construction 5,812,000
Total depreciable investment 51,481,000
Land 3,034,000
Working capital 9,110.000
Total capital Investment 63,625,000
Dollars of total capital per kW of generating
capacity 31.81
Basis
Midwest location of coal-cleaning plant with project begin-
ningmid-1979, ending mid-1982^ average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean-coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption
7 weeks direct revenue costs (excluding Btu loss), and 7
weeka operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
258
-------
TABLE B-6. PCC I PROCESS
ANNUAL REVENUE REQUIREMENTS
(Dense-medium vessel, dense-
tnediun cyclone, froth flotation)
Case variation - 3.5Z S coal
Annual Unit
Quantity co.t, f
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Process material: magnetite, Grade E
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
368,650 tons
144,000 man-hr
39,600 kgal
14,337,000 kWh
121,000 gal
2,550 tons
4,000 man-hr
31.58/ton
13.80/wan-hr
0.13/kgal
0. 039/kWh
0.70/gal
93.31/ton
18.70/Mn-hr
Total annual
cost. $
H.642. 000
11,642,000
1,987,000
5,000
559,000
85,000
238,000
1,723.000
____751000
4,672,000
16,314,000
InJireet Costs
Capital charges
Depreciation, interim replacements,
and Insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total Indirect costs
Cross annual revenue requirements
Byproduct Sales Revenue
None
Total annual revenue requirements
Equivalent unit revenue requirements
2.37
22.3
Basis
3,089,000
5.472.000
993,000
199,TOO
9,753,000
26,067,000
26,067,000
Midwest coal-cleaning plant location; time basis for scaline -JH ,o«, ,
30 years; operating tlmo, 6,000 hr/yr. scaling. Kld-1982; plant life,
Clean-coal production capacity for 2,000-MW coal-flr»^
9,500 Btu/V.Wh and 5,500 hr/yr. P0"" Pla"t "peratinR at
Total direct investment, $28,730,000; total deem-1am,, <
total capital Investment, $63.625,000. dePreclat>^ investment, $51.481.000; and
Rsw coal (moisture-free): 4,480,000 tons/yr 3 51 snlf,,- it «.
and2.79 Ib S/MBtu. '* ' '^ sn"»r. 14.0% ash, 12,500 Btu/lh.
Clean coal (moisture-free): 3,862,000 tons/yr, 2.55X siilf
Btu/lb, and 1.91 Ib S/MBtu. >>r* 7'997 ash. 13.400
259
-------
TABLE B-7. PCC I PROCESS
TOTAL CAPITAL INVESTMENT
(Dense-medium vessel, dense-
medium cyclone, froth flotation)
Base case - 5% S coal
Investmentt $
Direct Investment
Coal receiving and storage 8,841,000
Raw coal sizing 1,627,000
Coarse coal cleaning 1,585,000
Intermediate coal cleaning 2,249,000
Fine coal cleaning 2,696,000
Refuse disposal as landfill 3,058,000
Clean coal storage 8,261.000
Total areas 28,317,000
Services, utilities, and miscellaneous 1,699,000
Total direct investment 30,016,000
Indirect Investment
Engineering design and supervision 2,521,000
Architect and engineering contractor 600,000
Construction expense 3,572,000
Contractor fees 1,009.000
Total indirect investment 7,702,000
Contingency 5,658.000
Total fixed investment 43,376,000
Other Capital Charges
Allowance for startup and modifications 4,337,000
Interest during construction 6,073,000
Total depreciable investment 53,786,000
Land 3,686,000
Working capital 9,946.000
Total capital investment 67,418,000
Dollars of total capital per kW of generating
capacity 33.71
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs (excluding Btu loss), and 7
weeks operating,overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
260
-------
TABLE B-8. PCC I PROCESS
ANNUAL REVENUE REQUIREMENTS
(Dense-medium vessel, detise-
medlum cyclone, froth flotation)
Base case - 5/8 S coal
Annual
quantity
Unit
cost, $
Total annual
cost, $
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Process material: magnetite, Grade E
Maintenance, 6% of direct Investment
Analyses
Total conversion costs
Total direct costs
478,100 tons
31.58/ton
15,098.000
15,098,000
144,000 man-hr 13.80/man-hr 1,987,000
45,300 kgal
15,110,00(1 kWh
145,000 gal
2,760 tons
4,000 man-hr
0.13/kgal
0.039/kWh
0.70/gal
93,31/ton
18.70/man-hr
6,000
589,000
102,000
257,000
1,801,000
75.000
4,817,000
19,915,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 102 of sales revenue
Total indirect costs
fiross annual revenue requirements
Byproduct Sales Revenue
None
Total annual revenue requirements
3,227,000
5,798,000
993,000
199,000
10,217,000
30,132,000
30,132,000
Mills/kWh
Equivalent unit revenue requirements
2.74
C/lb
Fur r.
16.3
Basis
; plant life.
Midwest coal-cleaning plant location; time basis for scalii»
30 years; operating time, 6,000 br/yr.
Clean coal production capacity for 2,000-MW coal-flrwl ,»~.
9,500 Btu/kWh and 5,500 hr/yr. power plant operating at
Total direct investment, $30,016,000; total deoreciahio *
total capital investment, $67,418.000. aepr«cl««>l« investment, $53,786,000; „
Raw coal (moisture-free ): 4,840,000 tons/yr, 51 sulfur i* 7,
and 4.17 Ib S/MBtu. sulfur, 16. 7* ash, 12,000 Btu/U,
Clean coal (moisture-free): 4,073,000 tons/vr 3 67*
and 2.84 Ib S/MBtu. tonS,yt, 3.671 sulfurj
261
-------
TABLE B-9. PCC II PROCESS
TOTAL CAPITAL INVESTMENT
(Low-gravity D.M. cyclone, high-gravity
D.M. cyclone, froth flotation)
Case variation - 0.7% S coal
Investment, $
Direct Investment
Coal receiving and storage 8,821,000
Raw coal sizing 1,839,000
Low-gravity cleaning 3,553,000
High-gravity cleaning 1,631,000
Fine coal cleaning 4,691,000
Refuse disposal as landfill 1,956,000
Clean coal storage 6,758,000
Middling coal storage 4,623.000
Total areas 33,872,000
Services, utilities, and miscellaneous 2,032,000
Total direct investment 35,904,000
todirect Investment
Engineering design and supervision 3,016,000
Architect and engineering contractor 718,000
Construction expense 4,273,000
Contractor fees 1,206,000
Total indirect investment 9,213,000
Contingency 6,768,000
Total fixed investment 51,885,000
Other Capital Charges
Allowance for startup and modifications 5,119 000
Interest during construction 7,264.OOP
Total depreciable investment 64,268,000
Land 2,251,000
Working capital 10,843.000
Total capital investment 77,362,000
Dollars of total capital per kW of generating
capacity 38.68
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean-coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
262
-------
TABLE B-10. PCC II PROCESS
ANNUAL REVENUE REQUIREMENTS
(Low-gravity D.M, cyclone, high-gravity
D.M. cyclone, froth flotation)
Case variation - 0.7% S coal
Annual Unit
quantity cost. $
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Process material: miiRtu'tlto, c.radi- E
Maintenance, bit of direct Investment
Analyses
Total conversion costs
Total direct costs
295,200 tons 31.58/ton
144,000 man-hr 13.80/raan-hr
93,600 legal 0.13/kRal
27,269,000 kWh O.im/kWh
116,000 gal 0.70/gal
2,900 tons 93.31/ton
4,000 man-hr 18. 70/man-hr
Total annual
cost, S
9,322,000
9,322,000
1,987,000
12,000
1,064,000
81,000
271,000
2,154,000
75,000
5,644,000
14,966,000
Indirect Costs
Capital charges
Depreciation, Interim replacements,
and insurance at 62 of total
depreciable Investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50X of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10X of sales revenue
Total indirect costs
Oross annual revenue requirements
Byproduct Sales Revenue
None
Total annual revenue requirements
Equivalent unit revenue requirements
1.856.000
6,653,000
995,000
199,000
11,701,000
26,667,000
26,667,000
MiUsTkWh
2.42
0/lb
sulfur removed
197.6
Basis
Midwest location of coal-cleaning plant; time basis for scaltne miri ioa->
30 years; operating time, 6,000 hr/yr. 8> """-I"?; plant life,
'SS/^inStroO^/^r11* f°r 2l00°"MW C°al-£Ired POWer »la"< °*««1"« „ ,tsoo
Total direct investment, $35,904,000; total depreciable invest«nt S64 ?w» nnn
capital investment, $77,362,000. »t»i«e, 564,268.000; total
Raw coal (moisture-free): 4,787,000 ton/yr, 0.7% sulfur 11 « ,„>. ,, ,„
and 0.60 Ih S/MBtu. ' * "Sh' U'700 "u/lb.
Clean coal (moisture-free): 4,350,000 ton/yr, 0.621 sulfur, 7.441 ash u ,nn . ,,
and 0.51 lb S/MBtu. "Sh> l2'100 •*«/»«».
263
-------
TABLE B-ll. PCC II PROCESS
TOTAL CAPITAL INVESTMENT
(Low-gravity D.M. cyclone, high-gravity
D.M. cyclone, froth flotation)
Case variation - 2% S coal
Investment, S
Direct Investment
Coal receiving and storage 8,560,000
Raw coal sizing 1,751,000
Low-gravity cleaning 3,404,000
High-gravity cleaning 1,588,000
Fine coal cleaning 4,504,000
Refuse disposal as landfill 2,621,000
Clean coal storage 6,482,000
Middling coal storage 4,345,000
Total areas 33,255,000
Services, utilities, and miscellaneous 1,995,000
Total direct investment 35,250,000
Indirect Investment
Engineering design and supervision 2,961,000
Architect and engineering contractor 705,000
Construction expense 4,195,000
Contractor fees 1,184.000
Total indirect investment 9,045,000
Contingency 6,644.000
Total fixed investment 50,939,000
Other Capital Charges
Allowance for startup and modifications 5,094,000
Interest during construction 7,131,000
Total depreciable investment 63,164,000
Land 3,117,000
Working capital 8.989.000
Total capital investment 75,270,000
Dollars of total capital per kW of generating
capacity 37.64
Basis
Midwest location of coal—cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean-coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
264
-------
TABLE B-12. PCC II PROCESS
ANNUAL REVENUE REQUIREMENTS
(Low-gravity D.M. cyclone, high-gravity
D.M. cyclone, froth flotation)
Case variation - 2% S coal
Annual Unit Total annual
quantity cost, $ cost, S
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Process material: magnetite, Grade E
Maintenance, f>% of direct investment
Analyses
Total conversion costs
Total direct costs
339,100 tons 31.58/ton
144,000 man-hr 13.80/man-hr
76,200 kgal 0.13/kRal
25,869,000 kWh 0.039/MJh
123,000 gal 0.70/gal
2,650 tons 93.31/ton
A, 000 man-hr 18.70/man-hr
10^709,000
10,709,000
1,987,000
10,000
1.009,000
86,000
247,000
2,115,000
75.000
S, 529. 000
16,Z38,000
Indirect_Costs
Capital charges
Depreciation, interim replacements,
and insurance at 67. of total
depreciable Investment
Average cost of capital and taxes
at 8.6Z of total capital investment
Overheads
Plant, 502 of operating labor and
supervision
fufainiatrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
3,790,000
6,473.000
993,000
199,OOO
11,455,000
27,693,000
Sales Revenue
Bone
Total annual revenue requirements
Equivalent unit revenue requirements
C/lb
Mills/kVlh sulfur renovcd
2-52 36.5
27.693,000
Basis
Midwest location of coal-cleaning plant; time basis for scaling, mid-1982; plant life
30 years; operating time, 6,000 hr/yr. •
Clean-coal production capacity for 2,000-MW coal-fired power plant oper«tlnR «t 9 500
Btu/kWh and 5,500 hr/yr.
Total direct investment, $35,250,000; total depreciable investment, $63,164 000- total
capital investment, $75,270,000. '
Raw coal (moisture-free): 4,384,000 ton/yr, 2X sulfur, 14.5J ash, 12.800 Btu/lb
1.56 Ib S/MBtu.
Clean coal (moisture-free): 3,747,000 ton/yr, 1.33X sulfur,7.121 ash, 13,900 Btu/lb
and 0.96 Ib S/MBtu. • •
265
-------
TABLE B-L3. PCC II PROCESS
TOTAL CAPITAL INVESTMENT
(Low-gravity D.M. cyclone, high-gravity
D.M. cyclone, froth flotation)
Case variation - 3.5% S coal
Investment, $
Direct Investment
Coal receiving and storage 8,635,000
Raw coal sizing 1,776,000
Low-gravity cleaning 3,448,000
High-gravity cleaning 1,654,000
Fine coal cleaning 4,552,000
Refuse disposal as landfill 2,513,000
Clean coal storage 6,432,000
Middling coal storage 4,463.000
Total areas 33,473,000
Services, utilities, and miscellaneous 2,008.000
Total direct investment 35,481,000
Indirect Investment
Engineering design and supervision 2,980,000
Architect and engineering contractor 710,000
Construction expense 4,222,000
Contractor fees 1,192.000
Total indirect investment 9,104,000
Contingency 6,688.000
Total fixed investment 51,273,000
Other Capital Charges
Allowance for startup and modifications 5,127,000
Interest during construction 7,178.000
Total depreciable investment 63,578,000
Land 3,124,000
Working capital 9,265.000
Total capital investment 75,967,000
Dollar* of total capital per kU of generating
capacity 37.98
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean-coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basts).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
266
-------
TABLE B-14. PCC II PROCESS
ANNUAL REVENUE REQUIREMENTS
(Low-gravity D.M. cyclone, high-gravity
D.M. cyclone, froth flotation)
Case variation - 3.52 S coal
Annual Unit
quantity cost, S
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
process material; magnetite Grade E
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
388,600 tons 31.58/ton
144,000 man-hr 13.80/man-hr
71,000 kgal 0.13/kgal
26,273,000 kWh 0.039/kWh
124,000 gal 0.70/gal
2,720 tons 93.31/ton
4,000 man-hr 18.70/man-hr
Total annual
cost, ?
12, 272, 000
12,272,000
1,987,000
9,000
1,025,000
87,000
254,000
2,129,000
75,000
5,566,000
17,838,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6X of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
plant, 50X of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Cross annual revenue requirements
3,815,000
6,542,000
993,000
199,000
11,549,000
29,387,000
Sa .ies Revenue
None
Total annual revenue requirements
Equivalent unit revenue requirements
Basis
Mills/kWh
2.67
C/lb
sulfur removed
24.1
29,387,000
L» »•=»
Midwest location of coal-cleaning plant; time basis for scalina mtd-iqio. ~i » ,, ,
30 years, operating time, 6,000 hr/yr. ' plant llfe-
operating at 9,500
Total direct investment, $35,481,000; total depreciable investment $63 578 nnn r
apital investment, $75,967,000. ' »OJ«:>/O«OOO, total
" r' 3'5Z sulfur> "•<>* ash, 12,500 Btu/lb,
Clean coal (moisture-free): 3,860,000 ton/yr, 2.50Z sulfur 7 681 ash i,
Btu/lb, and 1.86 Ib S/MBtu. ' ' ' ".400
267
-------
TABLE B-15. PCC II PROCESS
TOTAL CAPITAL INVESTMENT
(Low-gravity D.M. cyclone, high-gravity
D.M. cyclone, froth flotation)
Base case - 5% S coal
Investment, S
Direct Investment
Coal receiving and storage 8,841,000
Raw coal sizing 1,845,000
Low-gravity cleaning 3,564,000
High-gravity cleaning 1,782,000
Fine coal cleaning 4,706,000
Refuse disposal as landfill 3,058,000
Clean coal storage 6,397,000
Middling coal storage 4.632.000
Total areas 34,825,000
Services, utilities, and miscellaneous 2,090rOQO
Total direct investment 36,915,000
Indirect Investment
Engineering design and supervision 3,101,000
Architect and engineering contractor 738,000
Construction expense 4,393,000
Contractor fees _L>_240,000
Total indirect investment 9,472,000
Contingency 6.958,000
Total fixed investment 53,345,000
Other Capital Charges
Allowance for startup and nodifications 5,335,000
Interest during construction 7,468.000
Total depreciable investment 66,148,000
Land 3,703,000
Working capital 10.033.000
Total capital investment 79,884,000
Dollars of total capital per kW of generating
capacity 39i94
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption 7
weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
268
-------
TABLE B-16. PCC II PROCESS
ANNUAL REVENUE REQUIREMENTS
(Low-gravity D.M. cyclone, high-gravity
D.M. cyclone, froth flotation)
Base
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Process material, magnetite, Grade E
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
case - 5Z S coal
Annual
quantity
458,650 tons
144,000 man-hr
85,800 kgal
27,384,000 kWh
148,000 gal
2,920 tons
4,000 man-hr
Unit
cost, S
31.58/ton
13.80/man-hr
0. 13/kgal
0.039/kWh
0.70/gal
93.31/ton
18.70/man-hr
Total annual
cost, $
14 J484, 000
14,484,000
1,987,000
11,000
1,068,000
104,000
272,000
2,215,000
75,000
5,732,000
20,216,000
jndirect Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor.
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
3,969,000
6,870,000
993,000
199,000
12,031,000
32,247,000
Byproduct Sales Revenue
None
Total annual revenue requirements
Equivalent unit revenue requirements
Mills/kWh
C/lb
sulfur removed
2.93
16.3
32,247,000
Basis
Midwest location of coal-cleaning plant; time basis for scaling, mid-1982; plant life
30 years; operating time, 6,000 hr/yr. '
Clean coal production capacity for 2,000-MW coal-fired power plant operating at 9 500
Btu/kWh and 5,500 hr/yr. '
Total direct investment, $36,915,000; total depreciable investment, $66,148,000; total
capital investment, $79,384,000.
Raw coal (moisture-free): 4,820,000 ton/yr, 52 sulfur, 16.7Z ash, 12,000 Btu/lb,
and 4.17 Ib S/MBtu.
Clean coal (moisture-free): 4,049,000 ton/yr, 3.51% sulfur, 9.25Z ash, 13,100 Btu/lh
and 2.68 Ib S/MBtu.
269
-------
TABLE B-17. PCC III PROCESS
TOTAL CAPITAL INVESTMENT
(Dense-medium cyclone, concentrating table)
Case variation - 0.7% S coal
Investment, g
Direct Investment
Coal receiving and storage 8,822,000
Raw coal sizing 2,430,000
Coarse coal cleaning 3,898,000
Fine coal cleaning 7,828,000
Refuse disposal as landfill 1,966,000
Clean coal storage 8.453.OOP
Total areas 33,397,000
Services, utilities, and miscellaneous 2,004,000
Total direct investment 35,401,000
Indirect Investment
Engineering design and supervision 2,974,000
Architect and engineering contractor 708,000
Construction expense 4,213,000
Contractor fees 1,189.000
Total indirect investment 9,084,000
Contingency 6,673.000
Total fixed investment 51,158,000
Other Capital Charges
Allowance for startup and modifications 5,116,000
Interest during construction 7,162,000
Total depreciable investment 63,436,000
Land 2,264,000
Working capital 10,829.000
Total capital investment 76,529,000
Dollars of total capital per kW of generating
capacity 38.26
Basis
Midwest location of coal-cleaning plant with prelect begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean-coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
270
-------
TABLE B-18. PCC 111 PROCESS
ANNUAL REVENUE REQUIREMENTS
(Dense-medium cyclone, concentrating table)
Case variation - 0.7% S coal
, Annual Unit Total annual
quantity cost, $ cost, $
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Process material; magnetite, (Jrade E
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
307,500 tons 31.58/ton
144,000 man-hr 13.80/man-hr
27,900 kgal 0.13/kgal
13,408,000 kWh 0.039/kWh
97,000 gal 0.70/gal
1,950 tons 93.31/ton
4,000 man-hr 18. 70/raan-hr
9,711,000
9,711,000
1,987,000
4,000
523,000
68,000
182,000
2,124,000
75,000
4,963,000
14,674,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 502 of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Cross annual revenue requirements
3,806,000
6,581,000
993,000
199,000
11,579,000
26,253,000
jyproduct Salcs_Rjeyenuc
None
Total annual revenue requirements
Equivalent unit revenue- rc-quiremont s
Mllls/kWh
c/lh
sulfur removed
2.39
212.0
26,253,000
Basis
Midwest location of cosl-cleaning plant; time basis for scaling, mid-1982; plant life,
30 years; operating time, 6,000 hr/yr.
Clean-coal production capacity for 2,000-MW coal-fired power plant operating at 9,500
Btu/kWh and 5,500 hr/yr.
Total direct investment, $35,401,000; total depreciable investment, $63,436,000; total
caoital investment, $76,529,000.
Raw coal (moisture-free): 4,825,000 ton/yr, 0.7% sulfur, 11.5% ash, 11,700 Btu/lb,
and 0.60 lb S/MBtu.
Clean coal (molsMire-free): 4,384,000 ton/yr, 0.63% sulfur, 8.10% ash, 12,100 Btu/lb,
and 0.52 Ih S/MBtu.
271
-------
TABLE B-19. PCC III PROCESS
TOTAL CAPITAL INVESTMENT
(Dense-medium cyclone, concentrating table)
Case variation - 2% S coal
Investment, $
Direct Investment
Coal receiving and storage 8,538,000
Raw coal sizing 2,317,000
Coarse coal cleaning 3,724,000
Fine coal cleaning 7,315,000
Refuse disposal as landfill 2,497,000
Clean coal storage 8,030.000
Total areas 32,421,000
Services, utilities, and miscellaneous 1,945.000
Total direct investment 34,366,000
Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total indirect investment
Contingency
Total fixed investment
2,887,000
687,000
4,090,000
1,155.000
8,819,000
6,478.000
49,663,000
Other Capital Charges
Allowance for startup and modifications 4,966,000
Interest during construction 6.953,000
Total depreciable investment 61,582,000
Land 2,944,000
Working capital 8,899.000
Total capital investment 73,425,000
Dollars 6f total capital per kW of generating
capacity 36.71
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean-coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
272
-------
TABLE B-20. PCC HI PROCESS
ANNUAL REVENUE REQUIREMENTS
(Dense-medium cyclone, concentrating table)
Case variation -
Direct Costs
Raw materials
Coal loss (Btu basis)
Total rav materials cost
Conversion coats
Operating labor and supervision
Utilities
Process water
Electricity 12,
Diesel fuel
Process material: magnetite, Grade E
Maintenance, 62 of direct investment
Analyses
Total conversion costs
Total direct costs
2* S coal
Annual
quantity
318,900 tons
144,000 oan-hr
22,600 Xgal
659,000 kWh
113,000 gal
1,780 tons
4,000 man-hr
Unit
cost, S
31.58/ton
13.80/man-hr
0.13/kgal
0.039/kWh
0. 70/g«l
93.31/ton
18.70/m*n-hr
Total annual
cost, $
10,071,000
10,071,000
1,987,000
3,000
494,000
79,000
166,000
2,062,000
75,000
4.866.000
14,937,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and Insurance at 67. of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, SOX of operating labor and
supervision
Administrative, 10X of operating labor
Marketing, 10% of sales revenue
Total Indirect costs
Gross annual revenue requirements
Byproduct Sales Revenue
None
Total annual revenue requirements
Equivalent unit revenue requirements
3,695,000
6,315,000
993,000
199,000
11,202,000
26,139,000
26,139,000
Mills/KHh sulfur removed
2.38 38.3
Basis
Midwest location of coal-cleaning plant; time basis for scaling, aid-1982-
life, 30 years; operating tine, 6,000 hr/yr. *
Clean-coal production capacity for 2,000-MW coal-fired power plant operatina at
9,500 Btu/kWh and 5,500 hr/yr.
Total direct Investment, $34,366,000; total depreciable Investment, $61,582,000-
total capital investment, $73,425,000. *
Raw coal (moisture-free) •. 4,384,000 ton/yr, 2% sulfur, 14.55! ash, 12,800 Btu/lb and
1.56 Ib S/MBtu. '
Clean coal (moisture-free): 3,787,000 ton/yr, 1.42Z sulfur, 8.08X ash, 13,700 Btu/lb
and 1.03 Ib S/MBtu.
273
-------
TABLE B-21. PCC III PROCESS
TOTAL CAPITAL INVESTMENT
(Dense-medium cyclone, concentrating table)
Case variation - 3.5X S coal
Investment, $
Direct Investment
Coal receiving and storage 8,609,000
Raw coal sizing 2,346,000
Coarse coal cleaning 3,768,000
Fine coal cleaning 7,450,000
Refuse disposal as landfill 2,497,000
Clean coal storage 8,112.000
Total areas 32,782,000
Services, utilities, and miscellaneous 1,967.000
Total direct investment 34,749,000
Indirect Investment
Engineering design and supervision 2,919,000
Architect and engineering contractor 695,000
Construction expense 4,135,000
Contractor fees 1,168,000
Total indirect investment 8,917,000
Contingency 6,550?OOP
Total fixed investment 50,216,000
Other Capital Charges
Allowance for startup and modifications 5,022,000
Interest during construction _7,030,OOP
Total depreciable investment 62,268,000
Land 2,944,000
Working capital 9,167.000
Total capital investment 74,379,000
Dollars of total capital per kW of generating
capacity 37.19
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean-coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
274
-------
TABLE B-22. PCC III PROCESS
ANNUAL REVENUE REQUIREMENTS
(Dense-medium cyclone, concentrating table)
Case variation
Direct Cost*
Saw material*
Coal loss (Btu basis)
Total rav naterials cost
Conversion coats
Operating labor and supervision
Utilities
Frocesa water
Electricity
Diesel fuel
Process material: magnetite, Grade E
Maintenance, 6Z of direct investment
Analyses
Total conversion costs
Total direct coats
- 3.51 S coal
Annual
quantity
363,400 tons
144,000 nan-hr
23,300 legal
12,849,000 kWh
114,000 sal
1,820 tons
4,000 man-hr
Unit
cost. $
31.58/ton
13.80/man-hr
0.13/kg«l
0.039/kHh
0.70/g«l
93.31/ton
18.70/asa-hr
Total annual
cost. $
11,476.000
11.476,000
1,987,000
3,000
501,000
80,000
170,000
2,085,000
75.000
4.901,000
16,377,000
Indirect Costs
Capital charges
Depreciation, Interim replacements.
and insurance at 6% of total
depreciable Investment
Average cost of capital and taxes
at 8.62 of total capital investment
Overheads
Plant, 507. of operating labor and
supervision
Administrative, 10* of operating labor
Marketing, 10! of sales revenue
Total Indirect costs
Gross annual revenue requirements
Byproduct Sales Revenue
None
Total annual revenue requirements
3,736,000
6,397.000
991.000
199,000
11,325.000
27,702,000
27,702,000
Equivalent unit revenue requirements
C/lb
Mllle/kWh sulfur removed
2.52
25.3
Baals
Mldweet location of coal-cleaning plant; time basis for scalln*. mid-1982-
life, 30 years; operating time. 6,000 hr/yr. *
Clean-coal production capacity for 2.000-HH coal-fired power plant operatic*
9,500 Btu/kHh and 5,500 hr/yr. ^ "*
Total direct Investment, $34,749,000; tots.! depreciable Investment $62 268 nn
total capital Investment, $74,379.000. * »««..£oo,«
U.50C Btu/lb. „*
275
-------
TABLE B-23. FCC III PROCESS
TOTAL CAPITAL INVESTMENT
(Dense-medium cyclone, concentrating table)
Base case - 5% S coal
Investment, $
Direct Investment
Coal receiving and storage 8,841,000
Raw coal sizing 2,438,000
Coarse coal cleaning 3,912,000
Fine coal cleaning 7,850,000
Refuse disposal as landfill 2,980,000
Clean coal storage 8,261,000
Total areas 34,282,000
Services, utilities, and miscellaneous 2,057,000
Total direct investment 36,339,000
Indirect Investment
Engineering design and supervision 3,052,000
Architect and engineering contractor 727,000
Construction expense 4,324,000
Contractor fees 1,221,000
Total indirect investment 9,324,000
Contingency 6,849.000
Total fixed investment 52,512,000
Other Capital Charges^
Allowance for startup and modifications 5,251,000
Interest during construction 7,352,000
Total depreciable investment 65,115,000
Land 3,583,000
Working capital 10,007,000
Total capital investment 78,705,000
Dollars of total capital per kW of generating
capacity 39.35
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs (excluding Btu loss), and 7
weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
276
-------
TABLE B-24. PCC III PROCESS
ANNUAL REVENUE REQUIREMENTS
(Dense-medium cyclone, concentrating table)
Basp rasp *
Direct Costs
Raw materials
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process vater
Electricity
Diesel fuel
Process material: magnetite, Grade E
Maintenance, 6% of direct investment
Analyses
Total conversion coats
Total direct costs
5% S coal
Annual
quantity
471,800 tons
144,000 man-hr
25,600 kgal
13,459,000 kWh
138,000 gal
1,970 tons
4,000 man-hr
Unit
cost, $
31.58/ton
13 . 80/raan-hr
0.13/kgal
0.039/kWh
0.70/gal
93.31/ton
18.70/man-hr
Total annual
cost, $
14,889,000
14,889,000
1,987,000
3,000
525,000
97 , 000
184,000
2,180,000
75,000
5,051,000
19,940,000
indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6X of total
depreciable investment
Average cost of capital and taxes
at 8.6X of total capital investment
Overheads
Plant, 5015 of operating labor and
supervision
Administrative, 10* of operating labor
Marketing, 102 of sales revenue
Total Indirect costs
Gross annual revenue requirements
3,907,000
6,769.000
993,000
199,000
11.868.000
31,808.000
Byproduct Sales Revenue
None
Total annual revenue requirements
Equivalent unit revenue requirements
31,808.000
e/ib
Milla/kWh sulfur removed
2.89
18.2
Ba«i>
Midwest location of coal-cleaning plant; time basis for scaling, mid-1982; plant
life, 30 years; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power plant operating at
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $9,324,000; total depreciable investment, $65,115,000;
total capital investment, $78,705,000.
Raw coal (moisture-free): 4,855,000 ton/yr, 5X sulfur, 16.7* a»h, 12.000 Btu/lb and
4.17 Ib S/MBtu. '
Clean coal (moisture-free): 4,111,000 ton/yr, 3.78X sulfur, 10,60t aah, 12.800 Btu/lb
and 2.94 Ib S/MBtu.
277
-------
TABLE B-25. KVB PROCESS
TOTAL CAPITAL INVESTMENT
Case variation - 0.7% S
Investment. $
Direct Investment
Raw material handling and preparation 10,721,000
Sulfur oxidation 6,291,900
Reactor off-gas cleaning 11,448^200
Fine coal leaching 7,906,200
Coarse coal leaching 7,141,300
Product agglomeration and handling 12,212,100
Leach solution neutralization and water handling 6,250,300
Settling pond 3,962.500
Subtotal 65,933,500
Services, utilities, and miscellaneous 3,956.000
Total direct investment 69,889,500
Indirect Investment
Engineering design and supervision 6,388,100
Architect and engineering contractor 1,568,300
Construction expense 8,494,200
Contractor fees 2,421.200
Total indirect investment 18,871,800
Contingency 17.752.300
Total fixed investment 106,513,600
Other Capital Charges
Allowance for startup and modifications 10,651,400
Interest during construction 14,911.900
Total depreciable investment 132,076,900
Land 1,122,200
Working capital 15.710.900
Total capital Investment 148,910,000
Dollars of total capital per kW of generating
capacity 74.5
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs, and 7 weeks operating overheads.
Pond site for .sludp.e disposal located 1 mile from coal
preparation plant.
278
-------
TABLE B-26. KVB PROCESS
ANNUAL REVENUE REQUIREMENTS
Case variation - 0.7% S
Annual
quantity
Unit
cost , S
Total annual
cost, S
n-lrect Costs
Raw materials
Lime
Oxygen
N02
NaOH (50%)
Sodium lignin sulfonatc
Natural gas
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
22,200 tons
25,216 tons
952 tons
12,029 tons
81,200 tons
24,000 kft3
43.31/ton
21.13/ton
665.28/ton
99.57/ton
83.17/ton
2.93/kft3
961,500
532,800
633,300
1,197,700
6,753,400
70,300
152,000 man-hr 13.80/man-hr
10,149,000
2,097,600
6,958,287 MBtu
2,898,838 kgal
242,458,453 kWh
24,000 man-hr
2. 54 /MBtu
0.09/kgal
0.039/kWh
18.70/man-hr
17,674,000
260,900
9,455,900
4,193,400
448,800
34,150,600
44,279,600
_Indire£t_Costs
Capital charges
Depreciation, interim replacements, and
insurance at 67. of total depreciable
investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
7,924,600
i:,806,300
1,048,800
209,800
21 .989,500
66,269,100
None
Total annual revenue requirements
66,269,100
E
-------
TABLE B-27. KVB PROCESS
TOTAL CAPITAL INVESTMENT
Case variation - 2.0% S
Investment $
Direct Investment
Raw material handling and preparation 10,197,600
Sulfur oxidation 5,984 700
Reactor off-gas cleaning 10,389,300
Fine coal leaching 7,426,700
Coarse coal leaching 6,624^800
Product agglomeration and handling 11,328 800
Leach solution neutralization and water handling 5,913,200
Settling pond 8,321j400
Subtotal 66,686,500
Services, utilities, and miscellaneous 4,001.200
Total direct investment 70,687,700
Indirect Investment
Engineering design and supervision 6,463 100
Architect and engineering contractor 1,568,600
Construction expense 8,476,900
Contractor fees 2,442flQQ
Total indirect investment 18,950,700
Contingency 17,927.700
Total fixed investment 107,566,100
Other Capital Charges
Allowance for startup and modifications 10,756,600
Interest during construction 15,059.300
Total depreciable investment 133,382,000
Land 1,993,700
Working capital 16,652.400
Total capital investment 152,028,100
Dollars of total capital per kW of generating
capacity 76.0
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating
overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
280
-------
TABLE B-28. KVB PROCESS
ANNUAL REVENUE REQUIREMENTS
Case variation - 2. OX S
Annual
quantity
Unit
cost, S
Total annual
cost, S
Direct Costs
Raw materials
Lime
Oxygen
N02
NaOH (50Z)
Sodium lignin sulfonate
Natural gas
Total raw materials costs
Conversion costs
Operating labor and supervision
utilities
Steam
Process water
Electricity
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
89,416 tons
117,232 tons
952 tons
44,552 tons
75,200 tons
24,000 kft^
43.31/ton
21.13/ton
665.28/ton
99. 57 /ton
83. 17 /ton
2.93/kft3
3,872,600
2,477,100
633,300
4,436,000
6,254,400
70,300
152,000 man-hr
13.80/man-hr
17,743,700
2,097,600
5,352,009 MBtu
2,663,074 kgal
222,739,157 kWh
24,000 man-hr
2. 54 /MBtu
0.09/kgal
0.039/kWh
18. 70 /man-hr
13,594,100
239,700
8,686,800
4,241,300
448,800
29,308,300
47,052,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
8,002,900
13,074,400
1,048.800
209.800
22,335,900
69,387.900
Byproduct Sales Revenue
None
Total annual revenue requirements
C/lb
Mills/kHh sulfur removed
Equivalent unit revenue requirements 6.3
57.9
69,387,900
Basis
Midwest coal-cleaning plant location; time basts for scaling, mid-1982; plant life,
30 years; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power plant operating at
9 500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $70,687,700; total depreciable investment, $133,382,000; and
total capital investment, $152,028,100.
Raw coal (moisture-free): 4,023,998 tons/yr, 2.OX sulfur. 14.5Z ash, 13.0OO Rn.Mh,
and 1.5 Ib S/MBtu.
Clean coal (moisture-free): 3.899,254 tons/yr, 0.53X sulfur, 13.3X ash, 13.400
and 0.40 Ib S/MBtu
281
-------
TABLE B-29. KVB PROCESS
TOTAL CAPITAL INVESTMENT
Case variation - 3.5% S
Investment, $
Direct Investment
Raw material handling and preparation 10,197,600
Sulfur oxidation 5,984,700
Reactor off-gas cleaning 10,889,300
Fine coal leaching 7,426,700
Coarse coal leaching 6,624,800
Product agglomeration and handling 11,328,800
Leach solution neutralization and water handling 5,913,200
Settling pond 12,756.000
Subtotal 71,121,100
Services, utilities, and miscellaneous 4,267.300
Total direct investment 75,388,400
Indirect Investment
Engineering design and supervision 6,567,200
Architect and engineering contractor 1>579,000
Construction expense 8,825,400
Contractor fees 2,564T600
Total indirect investment 19,536,200
Contingency 18,984.900
Total fixed investment 113,909,500
Other Capital Charges
Allowance for startup and modifications 11,391,000
Interest during construction 15.947,300
Total depreciable investment 141,247,800
Land 2,881,200
Working capital 18,552.300
Total capital investment 162,681,300
Dollars of total capital per kW of generating
capacity 81.3
Basis
Midwest location of coal-cleaning plant with project beginn-
ing mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs, and 7 weeks operating overheads.
1'ond sitr for sludge disposal located 1 mile from coal
preparation plant.
282
-------
TABLE B-30. KVB PROCESS
ANNUAL REVENUE REQUIREMENTS
Case variation - 3.5% S
Annual quantity
Unit
cost. $
Total annual
cost, $
materials
time
Oxygen
H02
NeOH (50%)
Sodium llgnin aulfonate
Natural gas
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
process water
Electricity
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
137,952 tons
198, 784 tons
952 tons
81,003 tons
75,200 tons
24,000 kft3
43.31/ton
21.13/ton
665. 261 ton
99. 57 /ton
83.17/ton
2.93/ton
5,974,700
4,200,300
633.300
6,065,500
6,254,400
70,300
152,000 man-hr 13.80/aan-hr
5,350,723 MBtu
2,663,074 kgal
222,739,157 kWh
24,000 man-hr
2.54/MBtu
0.09/kgal
0.039/kWh
18.70/man-hr
25,198,500
2,097,600
13,590,800
239,700
8,686,800
4,523,300
448.800
29,587,000
54,785,500
r.T>ltal charges
Depreciation, interim replacement,
and insurance at 6% of total
depreciable investment
Average coat of capital and taxes
at 8.6X of total capital investment
Overheads
Plant, SOS! of operating labor
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
8,474,900
13,990,600
1.048.800
209,800
23,724,100
78,509,600
pyjroduct Sales Revenue
None
Total annual revenue requirements
Equivalent unit revenue requirements
78,509,600
C/lb
Mills/kWh sulfur removed
7.1
37.0
Baals
'wtdwest coal-cleaning plant location; time basis for scaling, mid-1982; plant life.
\0 years; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000 MW coal-fired power plant operating at 9.500
Rt-u/kWh and 5,500 hr/yr.
T«»al direct investment, $75,388,400; total depreciable investment, $141,247,800; and
total capital investment, $162,681,300.
Raw coal (moisture-free): 4,148,437 ton/yr, 3.52 sulfur, 14.OZ ash, 12,700 Btu/lb, and
2.8 lb S/MBtu. __ ^ 3,928,571 tons/yr, 1.00% sulfur. 11.91 ash, 13,300 Btu/lb,
283
and 0.75 Ib S/MBtu.
-------
TABLE B-31. KVB PROCESS
TOTAL CAPITAL INVESTMENT
Base case -5% S coal
Investment. $
Direct Investment
Raw material handling and preparation 10,197,600
Sulfur oxidation 5,984,700
Reactor off-gas cleaning 10,889,300
Fine coal leaching 7,426,700
Coarse coal leaching 6,624,800
Product agglomeration and handling 11,328,800
Leach solution neutralization and water handling 5,913,200
Settling pond 16.203.000
Subtotal 74,568,100
Services, utilities, and miscellaneous 4.474T100
Total direct investment 79,042,200
Indirect Investment
Engineering design and supervision 6,639,900
Architect and engineering contractor 1,586,300
Construction expense 9,407,800
Contractor fees 2.658.500
Total indirect investment 20,292,500
Contingency 19,866.900
Total fixed investment 119,201,600
Other Capital Charges
Allowance for startup and modifications 11,920,200
Interest during construction 16,688.200
Total depreciable investment 147,810,000
Land 3,611,000
Working capital 19.945.200
Total capital investment 171,366 200
Dollars of total capital per kW of generating
capacity 85.7
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating
overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
284
-------
TABLE B-32. KVB PROCESS
ANNUAL REVENUE REQUIREMENTS
Base case - 5% S coal
Direct Costs
Raw materials
Lime
Oxygen
NO?
NaOH (502)
Sodium lignin sulfonate
Natural gas
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance, 6% of direct investment
Analysis
Total conversion costs
Total direct costs
Annual quantity
Unit cost, $
Total annual
cost, $
197,603 tons
297,600 tons
952 tons
152,880 tons
75,200 tons
24,000 kft3
43.31/ton
21.13/ton
665.28/ton
99.57/ton
83.17/ton
2.93/kft3
8,558,200
6,288,300
633,300
15,222,300
6,254,400
70,300
152,000 man-hr 13.80/man-hr
37,026,800
2,097,600
5,349,838 MBtu
2,663,074 kgal
222,739,157 kWh
24,000 man-hr
2. 54 /MBtu
0.09/kgal
0.039/kWh
18. 70 /man-hr
13,588.600
239,700
8,686,800
4,742,500
448,800
29 , 804 . OOO
66.S30.800
Indirect_Cosjts
Capital charges
Depreciation, interim replacements, and
insurance at 6% of total depreciable
investment
Average cost of capital and taxes at
8.6% of total capital investment
Overheads
Plant, 50% of operating labor and supervision
Administrative, 10% of operating labor and supervision
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
8,868.600
14,737,500
1,048.800
209,800
24.864,700
91,695,500
None
Total annual revenue requirements
C/lb
MiUs/kVih sulfur removed
Equivalent unit revenue requirements 8.3
27.4
91,695,500
Basis
Midwest coal-cleaning plant location; time basis for scaling, mid-1982; plant life,
30 years; operating timp, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power plant operating at
9 500 Btu'Mih and 5,500 hr/yr.
Total direct investment, $79,042,200; total depreciable investment, $147,810,000; and
total capital investment, $171,366,200.
Raw coal (moisture-free): 4,396,860 tons/yr, 5.0% sulfur, 16.7% ash, 12,000 Btu/lb
and A.2 Ib S/MBtu.
Clean coal (moisture-free): 4,050,388 tons/yr, 1.32% sulfur, 13.7Z ash, 12,900 Btu/lb,
and 1.02 Ib S/MBtu.
285
-------
TABLE B-33. TRW GRAVICHEM PROCESS
TOTAL CAPITAL INVESTMENT
Case variation - 0.7% S
Investment, $
Direct Investment
Raw material handling and preparation 7,874,600
Gravichem separation 8,309,600
Float coal washing 7,559,400
Reactor - regenerator 21,561,000
Acetone leaching 13,177,700
Acetone recovery and coal drying 29,606,100
Leach solution concentration 3,258 900
Neutralization and pond water handling 1,881,500
Product agglomeration and handling 13,062,800
Utility water handling 1,118,200
Settling pond 1,202.700
Subtotal 108,612,500
Services, utilities, and miscellaneous 6,516.800
Total direct investment 115,129,300
Indirect Investment
Engineering design and supervision 5,512,800
Architect and engineering contractor 1,365,300
Construction expense 12,733,200
Contractor fees 3,538.100
Total indirect investment 23,149,400
Contingency 27,655.700
Total fixed investment 165,934,400
Other Capital Charges
Allowance for startup and modifications 16,593,400
Interest during construction 23,230,800
Total depreciable investment 205,758,600
Land 587,000
Working capital 15,242,500
Total capital investment 221,059,800
Dollars of total capital per kW of generating
capacity 110.5
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982, average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and "),500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating over-
heads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
286
-------
TABLE B-34. TRW GRAVICHEM PROCESS
ANNUAL REVENUE REQUIREMENTS
Casi
3 variation - 0.7% S
Annual
quantity
Unit
cost, 5
Total annual
cost, $
Pirect Costs
Raw materials
Lime
Oxygen
Acetone
Copperas
Sulfuric acid
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
9,602 tons
4,513 tons
2,872 tons
2,257 tons
6,705 tons
43.3l/ton
21.13/ton
471.24/ton
72.07/ton
45.L8/ton
160,000 man-hr 13.80/man-hr
8,(144, 368 MBtu
15,736,259 kgal
197,377,072 kWh
2. 54 /MBtu
0.07/kgal
0.039/kWh
32,000 man-hr 18.70/man-hr
415,900
95,400
1.353,400
162,700
302.900
2,330,300
2.208,000
-!'>,43'^, 7no
1.101.SOO
7,697,700
6,907,800
598,400
3«,94f>. 101)
41 .^/h.MM)
tnitireet Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.62 of total capital Investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
12,145,500
II.OU.UIO
1,104.000
220,800
9.900
7 », 967, 70(1
Sales Revenue
Sulfur
Total annual revenue requirements
2,865 IOIXR tons 51. OO/ long ton
73,815,900
Equivalent unit revenue requirement
Mtlls/kWh
c/lh
h.7
414.0
Basis
Midwest coal-cleaning plant location; time basis for scaling, «td-l982- nlant H f .
30 years; operating time, 8,000 hr/yr. ' plant Ute>
Clean coal production capacity for 2,000 MW coal-fired power plant
9 500 Btu/kWh and 5,500 hr/yr.
Ra« coal (moisture-free): 4,4»7,802 tons/yr, 0.7>. sulfur, U.SZ.»sh. U.7«ORtu/lh
*ind ()• f> IV* S/MBtu . *
Clean coal (moisture-free)-. 4,465,812 tons/yr, 0.502 sulfur, H.-iz ilsh ,, 7(w „ ., .
iind 0.43 Ib S/Mbtu.
287
-------
TABLE B-35. TRW GRAVICHEM PROCESS
TOTAL CAPITAL INVESTMENT
Case variation - 2.0% S
Investment. $
Direct Investment
Raw material handling and preparation 7,874,600
Gravlchem separation 7,915,700
Float coal washing 7,201,100
Reactor - regenerator 20,539,000
Acetone leaching 12,553,100
Acetone recovery and coal drying 28,202,800
Leach solution concentration 3,104,400
Neutralization and pond water handling 1,792,300
Product agglomeration and handling 12,188,600
Utility water handling 1,065,200
Settling pond 4,149.800
Subtotal 106,586,600
Services, utilities, and miscellaneous 6,395.200
Total direct investment 112,981,800
Indirect Investment
Engineering design and supervision 5,630,000
Architect and engineering contractor 1,376,400
Construction expense 12,682,400
Contractor fees 3,487,800
Total indirect investment 23,176,600
Contingency 27.231.700
Total fixed investment 163,390,100
Other Capital Charges
Allowance for startup and modifications 16,339,000
Interest during construction 22,874.600
Total depreciable Investment 202,603,700
Land 1,167,700
Working capital 14.930.000
Total capital investment 218,701,400
Dollars of total capital per kW of
generating capacity 109.4
Basis
Midwest location of coal-cleaning plant with project
beginning mid-1979, ending mid-1982; average basis
for cost scaling, end-1980; operating time, 8,000
hr/yr.
Clean coal production capacity for 2,000-MW coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis) .
Working capital provides for 3 weeks raw coal consump-
tion, 7 weeks direct revenue costs, and 7 weeks
operating overheads.
Pond site for sludge disposal located 1 mile from
coal preparation plant.
288
-------
TABLE B-36. TRW GRAVICHEM PROCESS
ANNUAL REVENUE REQUIREMENTS
Case variation - 2.0% S
Annual
quantity
Unit
cost, §
Total annual
cost, $
THreet Costs
Raw materials
Lime
Oxygen
Acetone
Copperas
Sulfuric acid
Total raw materials costs
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
48,992 tons
23,016 tons
2,872 tons
11,508 tons
34,195 tons
43.31/ton
21.13/ton
471.24/ton
72.07/ton
45.18/ton
2,121,800
486 , 300
1,353,400
829,400
1,54/1,900
160,000 man-hr 13.80/man-hr
6,335,800
2,208,000
7,313,062 MBtu
14,512,600 kgal
182,028,933 kWh
32,000 man-hr
2.54/MBtu
0.07 /kgal
0.039/kWh
18.70/man-hr
18,575,200
1,015,900
7,099,100
6,778,900
598,400
36,275,500
42,611,300
jndirect Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
12,156,200
18,808,300
1,104,000
220,800
50.800
32,340,100
74,951,400
Byproduct Sales Revenue
Sulfur 16,054 long tons 53.OO/long ton
Total annual revenue requirements
C/lb
Mills/kWh sulfur removed
Equivalent unit revenue requirements 6.7
74.2
(850.900)
74,100,500
lias is
Midwest coal-cleaning plant location; time basis for scaling. Bid-lQft?- ~i._.. nt
30 years; operating time, 8,000 hr/yr. ' Pl*nt ll"'
Clean coal production capacity for 2,000-MW coal-fired power »lant ntu.i-.t-4... .
9,500 Btu/kVlh and 5,500 hr/yr. r * "P6'*""* »*
Total direct investment, $112,981,800; total depreciable Investment S202 Mn ?nn
and total capital investment, $218,701,400. "c> »«»z.603,700,
Raw coal (moisture-free): 4,037,586 tons/yr, 2,OX sulfur. 14 51 aah i-» o/w, . ,,w
and 1.5 Ib S/MBtu. * asn> IJ.WX> »tu/lb.
Clean coal (moisture-free): 3,928,571 tons/yr. 0.78Zsulfur, 13.41 ,»„, 13 IQO BCu/lb
and 0-59 Ib S/MBtu. ' *
289
-------
TABLE B-37. TRW GRAVICHEM PROCESS
TOTAL CAPITAL INVESTMENT
Case variation - 3.5% S
Investment, $
I)irect Investment
Raw material handling and preparation 7,874,600
Cravichem separation 7,915,700
Float coal washing 7,201,100
Reactor - regenerator 20,539,000
Acetone leaching 12,553,100
Acetone recovery and coal drying 28,202,800
Leach solution concentration 3,104,400
Neutralization and pond water handling 1,792,300
Product agglomeration and handling 12,188,600
Utility water handling 1,065,200
Settling pond 6,096,700
Subtotal 108,533,500
Services, utilities, and miscellaneous 6,512,000
Total direct investment . 115,045,500
[nd i rect investment^
Engineering design and supervision 5,682,000
Architect and engineering contractor 1.382,200
Construction expense 12,852,600
Contractor fees -_l«J?_if>j.2.0I!
Total indirect investment 23,453,000
Contingency _J-2*WLJQQ.
Total fixed investment 166,198,200
Othcr_ Cnjii tal Charges
Allowance for startup and modifications 16,619,800
Interest during construction _2ii.2.
-------
TABLE B-38. TRW GRAVICHEM PROCESS
ANNUAL REVENUE REQUIREMENTS
Direct Costs
Raw materials
Lime
Oxygen
Acetone
Copperos
Sulfuric acid
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance, 6% of direct
investment
Analyses
Total conversion costs
Total direct costs
Case variation - 3.5% S
Annual
quantity
80,816 tons
37,968 tons
2,872 tons
18,984 tons
56,A08 tons
160,000 raan-hr
7,047,830 MBtu
14,512,600 kgal
182,028,933 kWh
32,000 man-hr
Unit
cost. $
43.31/ton
21.13/ton
471.24/ton
72.07/ton
45.18/ton
13.80/man-hr
2.54/MBtu
0.07/kgal
0.039/kWh
18.70/man-hr
Total annual
cost, S
3,500,100
802,300
1,353,400
1,368,200
2.548.500
9,572,500
2,208,000
17.901,500
1,015,900
7,099,100
6,902,700
598.400
35,725,600
45,298,100
Indirect Costs
Capital charges
Depreciation, interim replacement,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor
and supervision
Administrative, 10% of operating
labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
Byproduct Sales Revenues.
Sulfur 28,022 long tons 53.0O/lonR ton
Total annual revenue requirements
C/lb
Mills/kWh sulfur renov
12,365,100
19,189,500
1.104.000
220,800
83.600
32,963,000
78,261,100
(1.485.200)
76.775.900
Equivalent unit revenue requirements
7.0
44.0
Basis
"I.. 30
. 5206,085.700; ^
h. 12.700 Btu/lk. and
-sh. !3.300 Btu/lb.
291
-------
TABLE B-39. TRW GRAVICHEM PROCESS
TOTAL CAPITAL INVESTMENT
Base case - 5% S coal
Investment, $
Direct Investment
Raw material handling and preparation 7,874,600
"Gravichem" separation 7,915,700
Float coal washing 7,201,100
Reactor - regenerator 20,539,000
Acetone leaching 12,553,100
Acetone recovery and coal drying 28,202,800
Leach solution concentration 3,104,400
Neutralization and pond water handling 1,792,300
Product agglomeration and handling 12,188,600
Utility water handling 1,065,200
Settling pond 8,219,500
Subtotal 110,656,300
Services, utilities, and miscellaneous 6,639.400
Total direct investment 117,295,700
Indirect Investment
Engineering design and supervision 5, 738 ,"500
Architect and engineering contractor 1,387,900
Construction expense 13,028,600
Contractor fees 3,588,600
Total indirect investment 23,743,600
Contingency 28,207.900
Total fixed investment 169,247,200
Other Capital Charges
Allowance for startup and modifications 16,924,700
Interest during construction 23,694,600
Total depreciable investment 209,866,500
Land 1,988,200
Working capital 16,194.400
Total capital investment 228,049,100
Dollars of total capital per kW of generating
capacity 114.0
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating
overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
292
-------
TABLE B-40. TRW GRAV1CHEM PROCESS
ANNUAL REVENUE REQUIREMENTS
Base case - 5% S coal
Direct Costs
Raw materials
Lime
Oxygen
Acetone
Copperas
Sulfuric acid
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance, 6% of direct investment
Analysis
• Total conversion costs
Total direct costs
Annual quantity
Unit cost, $
Total annual
cost, $
119,200 tons
56,000 tons
2,872 tons
28,000 tons
83,200 tons
43.31/ton
21.13/ton
471.24/ton
72.07/ton
45.18/ton
160,000 man-hr 13.80/man-hr
5,162,600
1,183,500
1,353,400
2,018,000
3,759,000
13,476,500
2,208,000
6,728,550 MBtu
14,512,600 kgal
182,028,933 kWh
32,000 man-hr
2. 54 /MBtu
0.07/kgal
0.039/kWh
18. 70 /man-hr
17,090,500
1,015,900
7,099,100
7,037,700
598_,400
35,049,600
48,526,100
Capital charges
Depreciation, interim replacement, and
insurance at 6% of total depreciable
investment
Average cost of capital and taxes at
8.6% of total capital investment
Overheads
Plane, 50% of operating labor and supervision
Administrative, 10% of operating labor and supervision
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
12,592,000
19,612,200
),104,000
220,800
123.500
33,652,500
82,178,600
Byproduct Sales Revenue
Sulfur 45,4U long tons 53.00/long ton
Total annual revenue requirements
urns/mil suny ream.,..!
Equivalent unit revenue requirements 7.3
27.4
(2.406.800J
79.771.fiOO
Basis
ISIS
Midwest coal-cleaning olant location; time basis for scaling, mid-1982- olant Hf» 1O
years; operating time, 8,000 hr/yr. *
Clean coal production capacity for 2,000-MW, coal-fifed power plant operating at 9 550
Btu/kWh and 5,500 hr/yr.
Total direct investment, $117,295,700; total depreciable investment, $209,866 500- and
total capital investment, $228,049,100. * *
Raw coal (moisture-free): 4,364,642 tons/yr, 5.02 sulfur, 16.73; asll 12 OO(, „,,,,.
and 4.2 Ib S/MBtn. ' Br"'lh,
Clean coal (molKttire-free) : 4,050,389 tons/yr, 1.95% sulfur, 13,Mash 12 900 i»-../it.
and 1.51 Ib S/MBtu. ' «'"">
293
-------
TABLE B-41. KENNECOTT PROCESS
TOTAL CAPITAL INVESTMENT
Case variation - 0.7% S
Investment, $
Direct Investment
Raw materials handling and preparation 14,549,700
Reactor area 52,321,600
Coal filtration area 25,713,500
Product agglomeration and handling 30,376,700
Neutralization and water handling 6,459.400
Settling pond 2,186.400
Subtotal 131,609,300
Services, utilities, and miscellaneous 7,896.400
Total direct investment 139,503,700
Indirect Investment
Engineering design and supervision 3,461,400
Architect and engineering contractor 846,100
Construction expense 15,116,800
Contractor fees 4,094.100
Total indirect investment 23,518,400
Contingency 32,604.400
Total fixed investment 195,626,500
Other Capital Charges
Allowance for startup and modifications 19,562,700
Interest during construction 27,387,700
Total depreciable investment 242,576,900
Land 611,600
Working capital 26,035,800
Total capital investment 269,224,300
Dollars total capital per kW of
generating capacity 134.6
Basis
Midwest location of coal-cleaning plant with project
beginning mid-1979, ending mid-1982; average basis for
cost scaling, end-1980; operating time 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power lant basis).
Working capital provides for 3 weeks raw coal consump-
tion, 7 weeks direct revenue costs and 7 weeks
operating overheads.
Fond site for sludge disposal located 1 mile from
coal preparation plant.
294
-------
TABLE R-42. KENNECOTT PROCESS
ANNUAL REVENUE REQUIREMENTS
Case variation - 0. 7% S
Annual
quantity
Direct Costs
Raw materials
Line
Oxygen
Sodium lignin sulfonate
Total raw materials costs
Conversion costs
Operating labor and supervision
Utilities
Process Btu loss
Steam
Process water
Electricity
Maintenance, 6X of direct investment
Analyses
22,899 tons
556,658 tons
174,421 tons
168,000 man-hr
1,666,029 MBtu
13,704,284 tons
9,440,960 kgal
713,048,746 kV)h
32,000 wan-hr
Unit Total annual
cost, $ cost. S
43.31/ton
21.13/ton
83.17/ton
13. 80 /man-hr
1 . 36/MBtu
2.54/HBtu
0.07 /kgal
0.039/kWh
18.70/wan-hr
991,800
11,762,200
14,506,600
27,260,600
2,318,400
2,265,800
34,808,900
660,900
27,808,900
8,370,200
598,400
Total conversion costs
Total direct costs
Tndirect Costs,
Capital charges
Depreciation, interim replacement,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10T of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
Byproduct Sales Revenue
Hone
Total annual revenue requirements
Equivalent unit revenue requirements
104,09^,100
14,554,600
2»,1^3, JOO
1,159,200
231,800
19.098,900
14J.191,000
141,191,000
C/lh
Hills/kWh sulfur removed
11.0 610.fi
Basis
1BJ.B
Midwest coal-cleaning plant location; time basis for scaling mid-left?. «t
30 years; opt-nil ln« tUu, 8,000 hr/yr. *' """• pUnt life.
Clean coal production capacity for 2,000 MW coal-fired power plant ot.., n
9,500 Btu/kWh and 5,500 hr/yr. P nt °P«ating at
Total direct investment, $139,503,700; total depreciable investment «ii e-,* ^
total capital investment, $269,224,300. ' ^^Z'S'S.WO; «nd
Clean coal (moisture-free): 4,837,963 tons/yr, 0.45Z sulfur 11 i* w ,„ „
and 0.42 Ib S/MBtu. ' vl* ash- 10.800 Btu/lb,
295
-------
TABLE B-43. KENNECOTT PROCESS
TOTAL CAPITAL INVESTMENT
Case variation - 2.0% S
Direct Investment
Raw materials handling and preparation
Reactor area
Coal filtration area
Product agglomeration and handling
Neutralization and water handling
Settling pond
Subtotal
Services, utilities, and miscellaneous
Total direct investment
Investment. $
13,856,900
48,820,200
24,489,000
28.343,900
6,151,800
4,489.800
126,151,600
7.569.100
133,720,700
Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total indirect investment
Contingency
Total fixed investment
3,541,000
854,100
14.589,700
3.964.400
22.949,200
31,334.000
188.003.900
Other Capital Charges
Allowance for startup and modifications 18,800,400
Interest during construction 26.320.500
Total depreciable investment 233,124,800
Land 1,237,000
Working capital 24,833.600
Total capital investment 259,195,400
Dollars of total capital per kW of generating
capacity 129.6
Basis
Midwest location of coal-cleaning plant with project beginning
mid-1979, ending mid-1982; average basis for cost scaling,
end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs, and 7 weeks operating overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
296
-------
TABLE B-44. KENNECOTT PROCESS
ANNUAL REVENUE REQUIREMENTS
Direct Costs
Raw materials
Liroe
Oxygen
Sodium lignin sulEonate
Total raw materials cost
Conversion costs
Operating labor and supension
Utilities
Process Btu loss
Steam
Process water
Electricity
Maintenance, 6% of direct
investment
Analyses
Total conversion costs
Total direct costs
Case variation - 2.0Z S
Annual
quantity
118,495 tons
600,520 tons
155,985 tons
168,000 raan-hr
1,655,224 MBtu
12,458,440 MBtu
8,741,630 kgal
660,230,321 kWh
32,000 raan-hr
Unit
cost, $
43.31/ton
21.13/ton
83.17/ton
13.80/man-hr
1.36/MBcu
2. 54 /MBtu
0.07/kgal
0.039/kWh
18.70/man-hr
Total annual
cost, $
5,132,000
12 ,689 ,000
12j973,300
30,794,300
2,318,400
2,251,100
31,644,400
611.900
25,749,000
8,023,200
598.400
71,196,400
101,990,700
J.ndirect_Co.sts
Capital charges
Depreciation, interim replacement,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor
Administrative, 10% of operating
labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
Revenue
None
Total annual revenue requirements
C/lt
Kills/kWh sulfur removed
Equivalent unit revenue requirement 12.7
132.2
11,987.500
22,290,800
1.159,200
231.800
37.669,300
139.660,000
139,660.000
Basis
Midwest coal-cleaning plant location; time basis for scaling, mid-1982; plant life, 30 years;
operating time, 8,000 hr/yr.
Clean-coal production capacity for 2,000-MW coal-fired pover plant operating at 9,500
Btu/kWh and 5,500 hr/yr.
Total direct investment, $133,720,700; total depreciable investment, $233.124.800; and
total capital investment, $259,195,400.
Raw coal (moisture-free): 4,208,754 tons/yr, 2.OZ sulfur, U.5X ash, 13,OOO Bni/lb, nod
1 5 Ib S/MBtu.
Clean coal (moisture-free): 4,318,182 tona/yr, 0.73Z sulfur. V3.8Z ash. 12,100 Btu/lb, and
0.60 Ib S/MBtu.
297
-------
TABLE B-45. KENNECOTT PROCESS
TOTAL CAPITAL INVESTMENT
Case variation - 3.5% S
Investment. $
Direct Investment
Raw materials handling and preparation 13,856,900
Reactor area 48,820,200
Coal filtration area 24,489,000
Product agglomeration and handling 28,343,900
Neutralization and water handling 6,151,800
Settling pond 8,884,200
Subtotal 130,546,000
Services, utilities, and miscellaneous 7,832,800
Total direct investment 138,378,800
Indirect Investment
Engineering design and supervision 3,661,500
Architect and engineering contractor 866,100
Construction expense 14,958,200
Contractor fees 4,069,000
Total indirect investment 23,554,800
Contingency 32,386.700
Total fixed investment 194,320,300
Other Capital Charges
Allowance for startup and modifications 19,432,000
Interest during construction 27,204,800
Total depreciable investment 240,957,100
Land 2,107,800
Working capital 25.276.300
Total capital investment 268,341,200
Dollars of total capital per kW of
generating capacity 134.2
Basis
Midwest location of coal-cleaning plant with project
beginning mid-1979, ending mid-1982; average basis for
cost scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consump-
tion, 7 weeks direct revenue costs, and 7 weeks
operating overheads.
Pond site for sludge disposal located I mile from
coal preparation plant.
298
-------
TABLE B.-46. KENNECOTT PROCESS
ANNUAL REVENUE REQUIREMENTS
Case variation - 3.5% S
Direct Costs
Raw materials
Lime
Oxygen
Sodium lignin sulEonate
Total raw materials costs
Conversion costs
Operating labor and supervision
Utilities
Process Btu loss
Steam
Process water
Electricity
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
Annual
quantity
207,360 tons
706,886 tons
160,326 tons
168,000 man-hr
1,662,240 MBtu
12,458,440 MBtu
8,741,630 kgal
660,230,321 kWh
32,000 man-hr
Unit Total annual
cost, $
43.31/ton
21.13/ton
83.17/ton
13. 80 /man-hr
1.36/MBtu
2. 54 /MBtu
0.07 /kgal
0.039/kWh
18.70/raan-hr
cost, $
8,980,800
14,936,500
13.334,300
37,251,600
2,318,400
2,260,600
31,644,400
611,900
25,749,000
8.302,700
598,400
71,485,400
1U«,737.000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
14,457,400
23,077,300
1,159,200
231,800
38,925,700
147,66_>,700
Byproduct Sales Revenue
None
Total annual revenue requirements
C/lb
Mills/kWh sulfur romoved
Equivalent unit revenue requirements 13.4
)47,062,700
Basis
Midwest coal-cleaning plant location; time basis for scaling, mid-1982; plant life
30 years; opi-rnt Lug time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power plant operating at 9 500
Btu/kWh and 5,500 hr/yr.
Total direct investment, ?138,378,8QO; total depreciable investment, $240,957,100- and
total capital investment, $268,341,200.
Raw coal (moisture-free): 4,325,868 tons/yr, 3.5% sulfur, 14.07 ash I > 7oo
2.8 Ih S/MBtu. ' ' "'
Clean coal (moisture-free): 4,390,756 tons/yr, 1 . 34X svil fur , 13. •>% ash 11 a
and 1.13 Ib S/MBtu. " * •'
,
, and
299
-------
TABLE B-47. KENNECOTT PROCESS
TOTAL CAPITAL INVESTMENT
Base case - 5% S coal
Investment, $
Direct Investment
Raw materials handling and preparation 13,856,900
Reactor area 48,820,200
Coal filtration area 24,489,000
Product agglomeration and handling 28,343,900
Neutralization and water handling 6,151,800
Settling pond 13,961,900
Subtotal 135,623,700
Services, utilities, and miscellaneous 8,137,400
Total direct investment 143,761,100
Indirect Investment
Engineering design and supervision 3,777,600
Architect and engineering contractor 877,700
Construction expense 15,321,300
Contractor fees 4,188.700
Total indirect Investment 24,165,300
Contingency 33,585,300
Total fixed investment 201,511,700
Other Capital Charges
Allowance for startup and modifications 20,151,200
Interest during construction 28,211,600
Total depreciable Investment 249,874,500
Land 3,152,600
Working capital 29,188.800
Total capital investment 231,215,900
Dollars of total capital per kW of
generating capacity 140>6
Basis
Midwest location of coal-cleaning plant with project
beginning mid-1979, ending mid-1982; average basis
for cost scaling, end-1980; operating time 8,000
hr/yr.
Clean coal production capacity for 2,000-MW, coal-
fired power plant operating at 9,500 Btu/kWh and
5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal
storage capacities (power plant basis).
Working capital provides for 3 weeks raw coal con-
sumption, 7 weeks direct revenue costs, and 7 weeks
operating overheads.
Pond site for sludge disposal located 1 mile from
coal preparation plant.
300
-------
TABLE B-48. KENNECOTT PROCESS
ANNUAL REVENUE REQUIREMENTS
Base case - 5% S coal
Annual quantity
Direct Costs
Raw materials
Lime
Oxygen
Sodium lignin sulfonate
Total raw materials cost
Conversion costs
Operating labor and supervision
Process Btu loss
Steam
Process water
Electricity
Maintenance, 6% of direct investment
Analysis
Total conversion costs
Total direct costs
329,915 tons
868,504 tons
171,200 tons
168,000 man-hr
2,005,900 MBtu
12,458,440 MBtu
8,741,630 kgal
660,230,321 kWh
32,000 man-hr
Unit cost, S
43.31/ton
21.13/ton
83.17/ton
13.80/aan-hr
1.36 /MBtu
2. 54 /MBtu
0,07/kgal
0.039/kNh
18.70/man-hr
Total annual
cost, $
14,228,600
18,351,500
14.238,700
46,878,800
2,318,400
2,728,000
31,644,400
611,900
25,749,000
8,625,700
598,400
?2, 275, 800
119,154,600
Indirect Costs
Capital charges
Depreciation, interim replacement, and
insurance at 6% of total depreciable
investment
Average cost of capital and taxes at
8.6% of total capital investment
Overheads
Plant, 50% of operating labor and supervision
Administrative, 10% of operating labor and supervision
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
Byproduct Sales Revenue
None
Total annual revenue requirements
Mills/kWh
C/lb
sulfur removed
14,992,500
24.184.600
1,159,200
231,800
40,560,100
159,722.700
159.722,700
Equivalent unit revenue requirements 14.7
53.8
Basis
Midwest coal-cleaning plant location; time basis for scaling, aid-1982; plant life
30 years; operating time, 8,000 hr/yi. *
Clean coal production capacity for 2,000-MW coal-fired power plant operating at
9,500 Btu/kWh and 5,500 hr/yr. *
Total direct investment, $143,761,100; total depreciable investment, $249.874 500- and
total capital investment, $281,215,900.
Raw coal (moisture-free): 4,619,275 tons/yr, 5.0Z sulfur, 16.71 ash. 12 000 Rtu/lk
and 4.2 Ib S/MBtu. ' tu'1D.
Clean coal (moisture-free): 4,623,894 tons/yr, 1.81X sulfur, 15.8X ash, 11 300 Btu/lb
and 1.60 Ib S/MBtu. '
301
-------
TABLE B-49. COMBINATION PCC-KVB PROCESS
TOTAL CAPITAL INVESTMENT
0.7X sulfur
Investment,_
Uircct Investment
Coal receiving and storage 8,799,000
Raw coal sizing 1,616,000
Coarse coal cleaning 1,575,000
Intermediate coal cleaning 2,234,000
Fine coal cleaning . 2,696,000
Refuse disposal as landfill 1,904,000
Interim storage area 4,513,000
Raw material handling and preparation 6,208,000
Sulfur oxidatio: 6,292,000
Reactor off-ga;, cleaning 11,448,000
Fine coal leaching 7,906,000
Coarse coal leaching 7,142,000
Product agglomeration and handling 12,212,000
Leach solution neutralization and water
handling 6,250,000
Settling pond __Jj963i?0|2.
Subtotal 84,758,000
Services, utilities, and miscellaneous 5,593,000
Total direct investment 90,351,000
_I nd i rec t_ Investment
Engineering design and supervision 8,817,000
Architect and engineering contractor 2,146,000
Construction expense 11,936,000
Contractor fees __JjJJLL.OOO
Total indirect investment 26,292,000
Contingency JLLIPI.PPP
Total fixed investment 139,846,000
01hcr Capita l_ Chaj-j;es
Allowance for startup and modifications 14,831,000
Interest during construction 20,763,000
Total depreciable investment 1/5,440,000
Land 3,296,000
Working capital _ f^OOT^OOO
Total capital in-'estment 197,743,000
Dollars of total capital per kW equivalent
of clean coal 98.9
Basis
Midwest location of coal-cleaning plant with project
beginning mid-1979, ending mid-1982; average basis for
cost scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating
overheads.
Pond and landfill sites for sludge and refuse disposal
located 1 mile from coal preparation plant.
302
-------
TABLE B-50. COMBINATION PCC-KVB PROCESS
ANNUAL REVENUE REQUIREMENTS
0.
,17. sulfur
Annual
quantity
. . —
Unit
cost, S
Total annual
cost , S
Direct Costs
Raw materials
Lime
Oxy gen
NO 2
NaOH (50X)
Sodium lignin sulfonate
Natural gas
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
Steam
Process water
Electricity
Process material: magnetite
Maintenance, 6% of direct Investment
Analyses
Total conversion costs
Total direct costs
22,200 tons
25,216 tons
952 tons
35,424 tons
81,200 tons
24,000 kft3
283,400 tons
43.il/ton
21.13/ton
665.28/ton
99.57/ton
83.17/ton
2.93/kft3
31.58/ton
962 ,000
533,000
633,000
3,527,000
6,753,000
7 1 ,000
8,949,000
296,000 man-hr 13.80/man-hr
21,428,000
4,085,000
97,000 gal
6,958,287 HBtu
2,946,438 kgal
257,358,453 kWh
2,720 tons
28,000 man-hr
0.70/f-al
2.54/MBtu
0.09/kgal
0.039/kWh
93.31/ton
18.70/man-hr
68,000
17,674,000
265,000
10,037,000
254,000
5,928,000
524,000
38,835,000
60,261,000
Indirect Costs
Capital charges
Depreciation, interim replacements
and insurance at 67. of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10X of operating labor
and supervision
Marketing, 1Q% of sales revenue
Total indirect costs
Gross annual revenue requirements
11,034,000
18,369,000
2,042,000
409.0OO
31,854,000
92,117,000
Byproduct Sales Revenue
None
Total annual revenue requirements
92,117,000
Equivalent unit revenue requirements
8.4
C/lb
fuJL.E<-<
258,0
Basis
Midwest coal-cleaning plant location; time basis for scaling, mid-198?- piant uf-
30 years; operating time, PCC-6000 hr/yr, KVB-8000 hr/yr.
Clean coal production capacity for 2,000-MU, coal-fired power plant operating at
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $90,351,000; total depreciable investment, $175,440,000- and
total capital investment, $197,743,000.
Raw coal (moisture-free): 4,683,536 tons/yr, 0.7X sulfur, 11.5Z ash, 11 700 Btu/lb
and 0.6 Ib S/MBtu. *
Clean coal (moisture-frro): 4,247,967 Cons/yr, Q.36I sulfur. 7,71 ash, 12 300 »tu/lh
and 0.29 Ib S/MBtu.
303
-------
TABLE B-51. COMBINATION PCC-KVB PROCESS
TOTAL CAPITAL INVESTMENT
27, sulfur
Investment. $
Direct Investment
Coal receiving and storage 8,529,000
Raw coal sizing 1,543,000
Coarse coal cleaning 1,512,000
Intermediate coal cleaning 2,132,000
Fine coal cleaning 2,573,000
Refuse disposal as landfill 2,558,000
Interim storage area 4,513,000
Raw material handling and preparation 5,685,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7,427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water 5,913,000
handling
Settling pond 8,321.000
Subtotal 85,534,000
Services, utilities, and miscellaneous 5,614.000
Total direct investment 91,148,000
Indirect Investment
Engineering design and supervision 8,856,000
Architect and engineering contractor 2,139,000
Construction expense 11,867,000
Contractor fees 3,399.000
Total indirect investment 26,261,000
Contingency 23.297.000
Total fixed investment 140,706,000
Other Capital Charges
Allowance for startup and modifications 14,474,000
Interest during construction 20,823,000
Total depreciable investment 176,003,000
Land 5,002,000
Working capital 25,481.000
Total capital investment 201,484,000
Dollars of total capital per kW equivalent
of clean coal 100.7
Basis
Midwest location of coal-cleaning plant with project
beginning mid-1979, ending mid-1982; average basis for
cost scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating over-
heads.
Pond and landfill sites for sludge and refuse disposal
located 1 mile from coal preparation plant.
304
-------
TABLE B-52. COMBINATION PCC-KVB PROCESS
ANNUAL REVENUE REQUIREMENTS
2% sulfur
Annual
quantity
Unit
cost, S
Total annual
cost, $
Direct Costs
Raw materials
Lime
Oxygen
N02
NaOH (50%)
Sodium lignin sulfonate
Natural gas
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
Steam
Process water
Electricity
Process material: magnetite
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
89,416 tons
117,232 tons
952 tons
70,224 tons
75,200 tons
24,000 kft3
315,600 tons
43.31/ton
21 . V3/ton
665. 28/ ton
99. 57 /ton
83.17/ton
2.93/kft^
31.58/ton
296,000 man-hr 13.80/san-hr
119,000 gal
5,352,009 MBtu
2,702,674 kgal
236,847,157 kWh
2,490 tons
0.70/gal
2.54/MBtu
0.09/kgal
0.039/kwh
93.31/ton
28,000 man-hr 18.70/aan-hr
3,873,000
2,477,000
633,000
6,992,000
6.254,000
70.000
9.966,000
10,265,000
4,085,000
83,000
13,594,000
243,000
9,237,000
232,000
5,950,000
524.000
33,948,000
64,213,000
Indirect Costs
Capital charges
Depreciation, interim replacements
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
and supervision
Marketing, 10% of sales revenue
Total indirect costs
Gross annual revenue requirements
11,066,000
18.482,000
2,042,000
409,000
31,999,000
96,212,000
Byproduct Sales Revenue
None
• Total annual revenue requirements
c/lb
Mills/kWh sulfur removed
Equivalent unit revenue requirements 8.8
71.4
96,212.000
Basis
Midwest coal-cleaning plant location; time basis for scaling, »id-1982; plant life,
30 years; operating time, PCC-6000 hr/yr, XVB-8000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired power plant operating at
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $91,148,000 total depreciable investment, $176.003,0X10; and
total capital investment, $201,484,000.
Raw coal (moisture-free): 4,354.530 tons/yr, 2Z sulfur, 14,5X ash, 13.000 Btu/lb, and
1.54 Ib S/MBtu.
Clean coal (moisture-free): 3,679,577 tons/yr, 0.53X sulfur, 6.8Z ash. 14,200 Btu/lb.
and 0.37 Ib S/MBtu.
305
-------
TABLE B-53. COMBINATION PCC-KVB PROCESS
TOTAL CAPITAL INVESTMENT
3.57. sulfur
Investment. $
Direct Investment
Coal receiving and storage 8,608,000
Raw coal sizing 1,564,000
Coarse coal cleaning 1,547,000
Intermediate coal cleaning 2,162,000
Fine coal cleaning 2,594,000
Refuse disposal as landfill 2,581,000
Interim storage area 4,513,000
Raw material handling and preparation 5,685,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7,427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water
handling 5,913,000
Settling pond 12.756.000
Subtotal 90,178,000
Services, utilities, and miscellaneous 5.B93.000
Total direct investment 96,071,000
Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total indirect investment
Contingency
Total fixed investment
8,980,000
2,154,000
12,244,000
3,530.000
26,908,000
24.400.000
147,379,000
Other Capital Charges
Allowance for startup and modifications 15,543,000
Interest during construction 21,759.000
Total depreciable investment 184,681,000
Land 5,915,000
Working capital 27.662.000
Total capital investment 212,343,000
Dollars of total capital per kW equivalent
of clean coal 106.2
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating
overheads.
Pond and landfill sites for sludge and refuse disposal
located 1 mile from coal preparation plant.
306
-------
TABLE B-54. COMBINATION PCC-KVB PROCESS
ANNUAL REVENUE REQUIREMENTS
3.5%
sulfur
Annual
quantity
Unit
coat, $
Total annual
cost. $
Direct Coats
Raw materials
Lime
Oxygen
NO
NaOH (50*)
Sodium llgnln sulfonate
Natural gas
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
Steam
Process water
Electricity
Process material: magnetite
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
137,952 tona
198,784 tons
952 tons
128,576 tons
75,200 tons
24,000 kft3
368,650 tons
43.31/ton
21. U/ ton
665.28/ton
99.57/ton
83.17/ton
2.93/kft3
31.58/ton
5.975,000
4,200,000
633,000
12.802,000
6,254,000
70,000
11.642,000
41,576,000
296,000 man-hr 13.80/man-hr 4,085,000
121,000 gal
5,350,723 MBtu
2,702,674 Vgal
237,076,157 MJh
2,550 tons
28,000 man-hr
0.70/gal
2.54/MBtu
0.09/kgal
0.039/kWh
93.31/ton
18.70/Mn-hr
85,000
13,591,000
243,000
9,246,000
238,000
6,246.000
524.000
34,258.000
75,834.000
jndlrect Costs
Capital charges
Depreciation, interim replacements
and insurance at 6X of total
depreciable Investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 501 of operating labor and
supervision
Administrative, 101 of operating labor
and supervision
Marketing, 10X of sales revenue
Total Indirect costs
Gross annual revenue requirements
11,563,000
19.463.000
2,042,000
409,000
33,477,000
109,311,000
Byproduct Sales Revenue
None
Total annual revenue requirements
109,311,000
C/lb
Mills/kVh sulfur removed
Equivalent unit revenue requirements 9.9
45.4
Basis
Midwest coal-cleaning plant location; tine basis for scaling, •14-1982; plant life
30 years; operating time, PCC-6000 hr/yr, KVB-8000 hr/yr. '
Clean coal production capacity for 2,000-MW,coal-fired power plant operating at
9,500 B /kWh and 5,500 hr/yr.
Total direct investment, $96,071,000} total depreciable investment, $184,681,000; and
total capital Investment, $212.343,000.
Raw coal (moisture-free): A,486,288 tons/yr, 3.5JE sulfur, 14.OX a«h, 12,700 Btu/lb
and 2.75 Ib S/MBtu. *
Clean coal (moisture-free): 3,705,674 tons/yr, 0.981 sulfur, 6.71 a»h, U 1OO Btu/lb
and 0.70 Ib S/MBtu. '
307
-------
TABLE B-55. COMBINATION PCC-KVB PROCESS
TOTAL CAPITAL INVESTMENT
5% sulfur
Investment, $
Direct Investment
Coal receiving and storage 8,841,000
Raw coal sizing 1,627,000
Coarse coal cleaning 1,585,000
Intermediate coal cleaning 2,249,000
Fine coal cleaning 2,696,000
Refuse disposal as landfill 3,058,000
Interim storage area 4,513,000
Raw material handling and preparation 5,685,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7,427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water
handling 5,913,000
Settling pond 16,203.000
Subtotal 94,625,000
Services, utilities, and miscellaneous 6,173.000
Total direct investment 100,798,000
jndirect Investment
Engineering design and supervision 9,161,000
Architect and engineering contractor 2,186,000
Construction expense 12,980,000
Contractor fees 3,668.000
Total indirect Investment 27,995,000
Contingency 25,525.000
Total fixed investment 154,318,000
Other Capital Charges
Allowance for startup and modifications 16,257,000
Interest during construction 22,761,000
Total depreciable investment 193,336,000
Land 7,297,000
Working capital 28,791.000
Total capital investment 229,424,000
Dollars of total capital per kW equivalent
of clean coal 114.7
Basis
Midwest location of coal-cleaning plant with project
beginning mid-1979, ending mid-1982; average basis for
cost scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating
overheads.
Pond and landfill sites for sludge and refuse disposal
located 1 mile from coal preparation plant.
308
-------
TABLE B-56. COMBINATION PCC-KVB PROCESS
ANNUAL REVENUE REQUIREMENTS
5% sulfur
Annual
quantity
Unit
cost, S
Total annual
cost, $
Direct Costs
Raw materials
Lime
Oxygen
NO 2
NaOH (50%)
Sodium llgnin aulfonate
Natural gas
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
Steam
Process water
Electricity
Process material: magnetite
Maintenance, 6% of direct investment
Analyses
Total conversion costs
Total direct costs
197,603 tons
297,600 tons
952 tons
152,880 tons
75,200 tons
24,000 tons
478,000 tons
43.31/ton
21.13/ton
665.28/ton
99.57/ton
83.17/ton
2.93/kft3
31.58/ton
296,000 man-hr 13.80/man-hr
8,558,000
6.288,000
631,000
15,222,000
6,254,000
70,000
15.098.000
52.123.000
4.085,000
145,000 gal
5,349,838 MBtu
2,708,374 kgal
237,849,157 kWh
2,760 tons
28,000 man-hr
0.70/gal
2. 54 /MBtu
0.09/kRal
0.039/kWh
93.31/ton
18.70/nan-hr
102.000
13.588,000
244,000
9,276,000
257,000
6.545,000
524,000
34,621,000
86,744,000
Indirect Coats
Capital charges
Depreciation, interim replacements
and insurance at 6% of total
depreciable investment
Average cost of capital and taxes
at 8.6% of total capital investment
Overheads
Plant, 50% of operating labor and
supervision
Administrative, 10% of operating labor
and supervision
Marketing, 10% of sales revenue
Total Indirect costs
Gross annual revenue requirements
12,096,000
20,536,000
2.042,000
409,000
35,081.000
121.827,000
Byproduct Sales Revenue
None
Total annual revenue requirements
121,827,000
Hills/kWh sulfur removed
Equivalent unit revenue requirements
11.0
31.5
Basis
Midwest coal-cleaning plant location; time basis for scaling, mid-1982; plant life,
30 years; operating time, PCC-6000 hr/yr, KVB-8000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired power plant operating at
9,500 Btu/kwh and 5,500 hr/yr.
Total direct investmnet, $100,798,000; total depreciable investment, $193,136,000; and
total capital investment, $229,424,000.
Raw coal (moisture-free): 4,796,394 tons/yr, 5* sulfur, 16.7X ash. 12,OOO.Btu/lb,
and 4.17 Ib S/MBtu.
Clean coal (moisture-free): 3,841,912 tons/yr, 1.261 sulfur, 8.0 ash, 13,600 Btu/lb,
and 0.93 Ib S/MBtu.
309
-------
TABLE B-57. PCC I PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
2% S - 1.2 lb S02/MBtu
Investment. $
Direct Investment
Raw material handling and preparation 12,104,000
Raw coal sizing 1,543,000
Coarse coal cleaning 1,512,000
Intermediate coal cleaning 2,132,000
Fine coal cleaning 2,573,000
Clean coal storage 8,028,000
Scrubbing 28,281,000
Waste disposal 9.602.000
Tota] areas 65,775,000
Services, utilities, and miscellaneous 3,947.000
Total direct investment 69,722,000
Indirect Investment
Engineering design and supervision 5,857,000
Architect and engineering contractor 1,395,000
Construction expense 8,297,000
Contractor fees 2,342.000
Total indirect investment 17,891,000
Contingency 15,733.000
Total fixed investment 103,346,000
Other Capital Charges
Allowance for startup and modifications 10,335,000
Interest during construction 14,469.000
Total depreciable investment 128,150,000
Land 4,100,000
Working capital 10,487,000
Total capital Investment 142,737,000
Dollars of total capital per kW of generating
capacity 71.37
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs (excluding Btu loss), and
7 weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
310
-------
TABLE B-58. PCC I PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
Direct Costs
Raw materials
Coal loss (Btu basis)
Limestone
2Z S - 1.2 Ib S02/MBtu
Annual
quantity
315,600 tons
83,100 tons
Unit
cost, $
31.58/ton
7.75/ton
Total annual
cost, $
9.966.00O
644,000
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Steam
Process material: magnetite, Grade E
Maintenance
Analyses
Total conversion costs
Total direct costs
168,700 man-hr 13.80/aan-hr
10,610,000
2,328.000
344.000 kgal
75,470,000 kWh
119.000 gal
879,800 klb
2,490 tons
7,600 man-hr
0.13/kga!
0.039/kUh
0.70/gal
2.35/klb
93.31/ton
18.70/nan-hr
45,000
2,943,000
83,000
2,068,000
232,000
4,183,000
142.000
12,024,000
22,634,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
7,689,000
12,275.000
2,434,000
233,000
22,631,000
45,265,000
Byproduct Sales Revenue
None
Total annual revenue requirements
45,265,000
Equivalent unit revenue requirements
Mills/kWh
4.12
C/lb
S removed
40.49
Basis
Midwest coal-cleaning plant location; time basis for scaling, •id-1982; plant life,
30 yr; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired power plant operating at
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $69,722,000; total depreciable investment, $128,150,000; and
total capital investment, $142,737,000.
Raw coal (moisture-free): 4,362,000 tons/yr, 2X S, 14.51 ash, 12,800 Btu/lb, and
1.56 Ib S/MBtu.
Clean coal (moisture-free): 3,749,000 tons/yr, 1.36X S, 7.45X ash, 14,000-Btu/lb, and
0.97 Ib S/MBtu.
311
-------
TABLE B-59, PCC I PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
3.52 S - 1.2 Ib S02/MBtu
Investment, S
Direct Investment
Raw material handling and preparation 15,073,000
Raw coal sizing 1,564,000
Coarse coal cleaning 1,547,000
Intermediate coal cleaning 2,162,000
Fine coal cleaning 2,594,000
Clean coal storage 8,048,000
Scrubbing 43,681,000
Waste disposal 20.061.000
Total areas 94,730,000
Services, utilities, and miscellaneous 5.684.000
Total direct investment 100,414,000
Indirect Investment
Engineering design and supervision 8,434,000
Architect and engineering contractor 2,009,000
Construction expense 11,949,000
Contractor fees 3.374,000
Total indirect investment 25,766,000
Contingency 23,431.000
Total fixed investment 149,611,000
Other Capital Charges
Allowance for startup and modifications 14,961,000
Interest during construction 20.945,000
Total depreciable investment 185,517,000
Land 5,922,000
Working capital 12.051.000
Total capital investment 203,490,000
Dollars of total capital per kW of generating
capacity 101.74
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs (excluding Btu loss), and
7 weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
312
-------
TABLE B-60. PCC I PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
3.5* S - 1
Direct Costs
Raw materials .
Coal loss (Btu basts)
Limestone
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Steam
Process material: magnetite, Grade E
Maintenance
Analyses
Total conversion costs
Total direct costs
.2 Ib S02/MBtu
Annual
quantity
366,650 tons
315,900 tons
180,000 man-hr
726.000 legal
133,000,000 kWh
121,000 gal
1,662,100 k.lb
2,550 tons
9.300 Mn-hr
Unit
cost. $
31.58/ton
7.75/ton
13.80/Mn-hr
0.11/kgal
0.039/kWh
0.70/kgal
2.35/klb
93.3l/to»
18,70/man-hr
Total annual
cost. $
11,642,000
2.448.000
14,090,000
2.484,000
80.000
5,187.000
85,000
3,906.000
238,000
6,024,000
174,000
18,178,000
32,268,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
Byproduct Sales Revenue
None
Total annual revenue requirements
11.131.000
17.500.000
3,441,000
249.000
32,321,000
64.589.000
64.589.000
Equivalent unit revenue requirements
Milla/kWh S removed
5.87 25.74
Basis
Midwest coal-cleaning plant location; tine basis for scaling, mid-1982; plant life,
30 yr; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired power plant operating at
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $100,414,000; total depreciable Investment, $185,517,000; and
total capital Investment, $203,490,000.
Raw coal (moisture-free): 4,480,000 tons/yr, 3.5Z S, 14.OX ash, 12.500 Btu/lb, mat
2.79 Ib S/MBtu.
Clean coal (moisture-free): 3,862.000 tons/yr, 2.55X S, 7.99X ash, 13.400 Btu/lb, and
1.91 Ib S/MBtu.
313
-------
TABLE B-61. PCC I PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
5% S - 1.2 Ib S02/MBtu
Investment, $
Direct Investment
Raw material handling and preparation 17,612,000
Raw coal sizing 1,627,000
Coarse coal cleaning 1,585,000
Intermediate coal cleaning 2,249,000
Fine coal cleaning 2,696,000
Clean coal storage 8,261,000
Scrubbing 51,033,000
Waste disposal 29,840,000
Total areas 114,903,000
Services, utilities, and miscellaneous 6,894,000
Total direct investment 121,797,000
Indirect Investment
Engineering design and supervision 10,231,000
Architect and engineering contractor 2,436,000
Construction expense 14,494,000
Contractor fees 4,093,000
Total indirect investment 31,254,000
Contingency 28,725,000
Total fixed investment 181,776,000
Other Capital Charges
Allowance for startup and modifications 18,177,000
Interest during construction 25,449,000
Total depreciable investment 225,402,000
Land 8,262,000
Working capital 13,698,000
Total capital investment 247,362,000
Dollars of total capital per kW of generating
capacity 123.68
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs (excluding Btu loss), and
7 weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
NSPS emission level - 1.2 Ib S02/MBtu. For this 5% sulfur
coal, this is also the emission level allowed for the
proposed 85% removal NSPS which has a 1.2 Ib S02/MBtu
upper limit.
314
-------
TABLE B-62, PCC I PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
52 & - 1.2 lb S02/MBtu
Annual
quantity
Direct Costs
Raw materials
Coal loss (Btu basis) 478,100 tons
Limestone 588,500 tons
Total raw materials cost
Conversion costs
Operating labor and supervision 185,100 raan-hr
Utilities
Process water 987,000 kgal
Electricity 158,810,000 kWh
Diesel fuel 145,000 gal
Steam 1,902,000 klb
Process material: magnetite, Grade E 2,760 tons
Maintenance
Analyses 10,100 man-hr
Total conversion costs
Total direct costs
indirect Costs
Capital charges
Depreciation, interim replacements,
and Insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
Unit Total annual
cost, $ cost, $
31.58/ton 15,098,000
7.75/ton 4,561,000
19,659,000
13.80/raan-hr 2,554,000
0.11/kgal 109,000
0.039/kWh 6,193,000
0.70/gal 102,000
2.35/klb 4,470,000
93. 31 /ton 257.000
7,308,000
18.70/man-hr 189.000
21,182,000
40,841,000
13,524,000
21,273,000
4,087,000
256,000
39,140,000
79,981,000
ttyjroduct Sales Revenue
None
Total annual revenue requirements
79,981,000
Equivalent unit revenue requirements
Mills/kVlh
c/lb
S removed
7.27
18.99
Basis
Midwest coal-cleaning plant location; time basis for scaling, mid-1982; plant life,
30 yr; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fited power plant operating at
9 500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $121,797,000; total depreciable investment, $225,402,000; and
total capital investment, $247,362,000.
Raw coal (moisture-free): 4,840,000 tons/yr, 5Z S, 16.7Z ash, 12,000 Btu/lb, and
4.17 lb S/MBtu.
Clean coal (moisture-free): 4,073,000 tons/yr, 3.67Z S, 10.091 ash, 13,000 Btu/lb, and
2.84 lb S/MBtu.
MSPS emission level - 1.2 lb S02/MBtu. For this 5X S coal, this is also the emission
level allowed for the proposed 85% removal NSPS which has a 1.2 lb S02/MBtu upper
limit.
315
-------
TABLE B-63. PCC I PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
0.7% S - 85% removal
Investment. $
Direct Investment
Raw material handling and preparation 12,147,000
Raw coal sizing 1,616,000
Coarse coal cleaning 1,575,000
Intermediate coal cleaning 2,234,000
Fine coal cleaning 2,696,000
Clean coal storage 8,459,000
Scrubbing 52,063,000
Waste disposal 9,950.000
Total areas 90,740,000
Services, utilities, and miscellaneous 5.444.000
Total direct investment 96,184,000
Indirect Investment
Engineering design and supervision 8,079,000
Architect and engineering contractor 1,923,000
Construction expense 11,446,000
Contractor fees 3,232.000
Total indirect investment 24,680,000
Contingency 22,356.000
Total fixed investment 143,220,000
Other Capital Charges
Allowance for startup and modifications . 14,322,000
Interest during construction _2jOJ_0_51_L000
Total depreciable investment 177,593,000
Land 3,316,000
Working capital 13,346.000
Total capital investment 194,255,000
Dollars of total capital per kW of generating
capacity 97.13
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs (excluding Btu loss), and
7 weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
316
-------
TABLE B-64. PCC I PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
0.7% S -
Direct Coats
Raw materials
Coal loss (Btu basis)
Limes tone
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Steam
Process material: magnetite, Grade E
Maintenance
Analyses
Total conversion costs
Total direct costs
85* removal
Annual
quantity
283,400 tons
98,400 tons
172,100 nan-hr
646.000 kgal
151,870,000 kWh
97,000 gal
1,803,000 klb
2,720 tons
8.200 man-hr
Unit
cost. $
31.58/ton
7.75/ton
13.80/aan-hr
0.11/kgal
0.039/kWh
0.70/gal
2.35/klb
93.31/ton
18.70/man-hr
Total annual
cost. $
8,949,000
763.000
9,712,000
2.375,000
71,000
5,923,000
68,000
4,237,000
254.000
5.771.000
153,000
18.852.000
28,564,000
Indirect Costa
Capital charges
Depreciation, interim replacements,
and insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total Indirect costs
Gross annual revenue requirements
10,656,000
16,706,000
3,244,000
238.000
30,844,000
59,408,000
Byproduct Sales Revenue
None
Total annual revenue requirements
Equivalent unit revenue requirements
C/lb
MiUs/kWh S removed
5.40
'05
Basis
Midwest coal-cleaning plant location; tine basis for
30 yr; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000 MH, co.<
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $96,184,000; total de; • e.
total capital investment, $194,255,000.
Raw coal (moisture-free): 4,777,000 tons/yr, 0.7X S, 11.5X ash, 11,700 Btu/lb and
0.60 Ib S/MBtu.
Clean coal (moisture-free): 4,354,000 tons/yr, 0.62X S, 7.MX ash. 12;200 Btu/lb and
0,51 Ib S/MBtu.
DSPS emission level - 0.20 Ib S02/MBtu.
•8, •id-1982; plant life,
-ower plant operating at
investment, $177,593,000, and
317
-------
TABLE B-65. PCC I PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
2% S - 85% removal
Investment, $
Direct Investment
Raw material handling and preparation 14,439,000
Raw coal sizing 1,543,000
Coarse coal cleaning 1,512,000
Intermediate coal cleaning 2,132,000
Fine coal cleaning 2,573,000
Clean coal storage 8,028,000
Scrubbing 47,083,000
Waste disposal 14,204.000
Total areas 91,514,000
Services, utilities, and miscellaneous 5,491,000
Total direct investment 97,005,000
Indirect Investment
Engineering design and supervision 8,148,000
Architect and engineering contractor 1,940,000
Construction expense 11,544,000
Contractor fees 3,259,000
Total indirect investment 24,891,000
Contingency 22,590.000
Total fixed investment 144,486,000
Other Capital Charges
Allowance for startup and modifications 14,449,000
Interest during construction 20,228.000
Total depreciable investment 179,163,000
Land 4,813,000
Working capital 11,571.000
Total capital investment 195,547,000
Dollars of total capital per kW of generating
capacity 97.77
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs (excluding Btu loss), and
7 weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
318
-------
TABLE B-66. PCC I PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
2Z S
Direct Costs
Raw materials
Coal loss (Btu basis)
Limestone
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Steam
Process material: magnetite. Grade
Maintenance
Analyses
Total conversion costs
Total direct costs
- 85Z removal
Annual
quantity
315,600 tons
172,200 tons
177,000 man-hr
670,000 kgal
140,990.000 kWh
119,000 gal
1,819,000 klb
E 2,490 tons
8,900 naa-hr
Unit
cost, $
31.58/ton
7.75/ton
13.80/Mn-hr
0.11/kgal
0.039/kWh
0.70/g»l
2.35/klb
93.31/ton
18.70/Mn-hr
Total annual
cost, $
9,966,000
1,335,000
11,301,000
2,443,000
74,000
5,498,000
83,000
4,275,000
232,000
5,820.000
166.000
18,591,000
29,892,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Cross annual revenue requirements
Byproduct Sales Revenue
None
Total annual revenue requirements
10.750.000
16.817,000
3.321,000
245,000
31,133,000
61.025,000
61,025.000
Equivalent unit revenue requirements
C/lb
Mills/kWh S reaoved
5.55
41.1
Basis
Midwest coal-cleaning plant location; time basis for scaling, Mid-1982; plant life
30 yr; operating time, 6,000 hr/yr. '
Clean coal production capacity for 2,000-MW, coal-fixed power plant operating at
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $97,005,000; total depreciable InvratMBt, $179,163,000; and
total capital investment, $195,547,000.
Raw coal (moisture-free): 4,362,000 tons/yr, 2X S, 14.5X **h, 12,800 fttu/lb. and
1.56 Ib S/MBtu.
Clean coal (moisture-free): 3,749,000 tons/yr, 1.36X S, 7.45X aah, 14.000 Btu/lb and
0.97 Ib S/MBtu,
HSPS emission level - 0.47 Ib S02/MBtu.
319
-------
TABLE B-67. PCC I PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
3.5% S - 85% removal
Investment, $
Direct Investment
Raw material handling and preparation 15,667,000
Raw coal sizing 1,564,000
Coarse coal cleaning 1,547,000
Intermediate coal cleaning 2,162,000
Fine coal cleaning 2,594,000
Clean coal storage 8,048,000
Scrubbing 48,678,000
Waste disposal 21,668.000
Total areas 101,928,000
Services, utilities, and miscellaneous 6,115,000
Total direct investment 108,043,000
Indirect Investment
Engineering design and supervision 9,075,000
Architect and engineering contractor 2,161,000
Construction expense 12,857,000
Contractor fees 3,630,000
Total indirect investment 27,723,000
Contingency 25,348,000
Total fixed investment 161,114,000
Other Capital Charges
Allowance for startup and modifications 16,111,000
Interest during construction 22,556,000
Total depreciable investment 199,781,000
Land 6,187,000
Working capital 12,321,000
Total capital investment 218,289,000
Dollars of total capital per kW of generating
capacity 109.14
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs (excluding Btu loss), and
7 weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
320
-------
TABLE E-68. PCC I PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
3.52 S -
Direct Coses
Raw materials
Coal loss (Btu basis)
Limestone
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Steam
Process material: magnetite, Grade E
Maintenance
Analyses
Total conversion costs
Total direct costs
85Z removal
Annual
quant ity
368,650 tons
355,700 tons
181,700 man-hr
812,000 kgal
147,960,000 kWh
121,000 gal
1,871,000 klb
2,550 tons
9,600 man-hr
Unit
cost, $
31.58/ton
7.75/ton
13."80/man-nr
0.11/kgal
0.039/kWh
0.70/gal
2.3S/klb
93.31/ton
18,70/nan-hr
Total annual
cost, $
11,642,000
2,757,000
14,399,000
2,508,000
89,000
5,770,000
85,000
4,397,000
238,000
6,482,000
180,000
19,749,000
34,148,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
11,987,000
18,773,000
3.685,000
251,000
34,696,000
68,844,000
Byproduct Sales Revenue
None
Total annual revenue requirements
68,844,000
Equivalent unit revenue requirements
Mills/kWh
6.26
C/lb
S removed
25,83
Basis
Midwest coal-cleaning plant location; time basis for scaling, •id-1982; plant life,
30 yr; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired power plant operating at
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $108,043,000; total depreciable investment, $199,781,000; and
total capital investment, $218,289,000.
Raw coal (moisture-free): 4,480,000 tons/yr, 3.53! S, 14.OZ ash, 12,500 Btu/lb, and
2.79 Ib S/MBtu.
Clean coal (moisture-free): 3,862,000 tons/yr, 2.55X S, 7.99Z ash. 13,400 Btu/lb, and
1.91 Ib S/MBtu.
NSPS emission level - 0.84 Ib S02/MBtu.
321
-------
TABLE B-69. PCC I PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
5% S - 852 removal
Investment, $
Direct Investment
Raw material handling and preparation 17,612,000
Raw coal sizing 1,627,000
Coarse coal cleaning 1,585,000
Intermediate coal cleaning 2,249,000
Fine coal cleaning 2,696,000
Clean coal storage 8,261,000
Scrubbing 51,033,000
Waste disposal 29,840.000
Total areas 114,903,000
Services, utilities, and miscellaneous 6,894,000
Total direct investment 121,797,000
Indirect Investment
Engineering design and supervision 10,231,000
Architect and engineering contractor 2,436,000
Construction expense 14,494,000
Contractor fees 4,093,000
Total indirect investment 31,254,000
Contingency 28,725,000
Total fixed investment 181,776,000
Other Capital Charges
Allowance for startup and modifications 18,177,000
Interest during construction 25,449,000
Total depreciable investment 225,402,000
Land 8,262,000
Working capital 13,698,000
Total capital investment 247,362,000
Dollars of total capital per kW of generating
capacity 123.68
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption,
7 weeks direct revenue costs (excluding Btu loss), and
7 weeks operating overheads.
Landfill site for refuse disposal located 1 mile from coal
preparation plant.
NSPS emission level - 1.2 Ib SO2/MBtu. For this 5% sulfur
coal, this is also the emission level allowed for the
proposed 85% removal NSPS which has a 1.2 Ib S02/MBtu
upper limit.
322
-------
TABLE B-70. PCC I PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
5X S
- 35* removal
Annual
quantity
Unit
cost, $
Total annual
cost, $
Direct Costs
Raw materials
Coal loss (Btu basis)
Limestone
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Process water
Electricity
Diesel fuel
Steam
Process material: magnetite, Grade E
Maintenance
Analyses
Total conversion costs
Total direct costs
678,100 tons
588,500 tons
185,100 toan-hr
987,000 kgal
158,810,000 kWh
145,000 gal
1,902,000 Vlb
2,760 tons
10,100 man-hr
3l.58/ton
7.75/ton
13.80/wan-hr
0.11 /kgal
0.039/kWh
0.70/gal
2.35/klb
93.31/ton
18.70/man-ht
15,098,000
4.561,000
19.659,000
2,554,000
»09,000
6,193,000
102,000
4,470,000
257.000
7,308,000
\ 89, 000
21,182,000
40,841,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Cross annual revenue requirements
13,524,000
21,273,000
4,087,000
256,000
39.140,000
79.981,000
Byproduct Sales Revenue
None
total annual revenue requirements
79,981,000
Equivalent unit revenue requirements
C/lb
Mills/fcWh S removed
7.27
18.99
Basis
Midwest coal-cleaning plant location; time basis (or seeling, •14-1M2; plant life,
30 yr; operating time, 6,000 hr/yr.
Clean coal production capacity for 2,000-tW. coal-fired power plant operating *t
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $121,797,000; total depreciable Investment, $225,402,000: and
total capital investment, $247,362,000.
Raw coal (moisture-free): 4,840,000 tons/yr, SZ S, 16.71 ash, 12,000 Itu/lb, «nd
4.L7 Ib S/MBtu.
Clean coal (moisture-free): 4,073,000 tons/yr, 3.67X S, 10.09X ask, 13.000 Btu/lb, and
2.84 Ib S/MBcu.
NSPS emission level - 1.2 Ib S02/MBtu. For this 5X S coal, this la also the emission
level allowed for the proposed 85Z removal NSPS which haa a 1.2 Ib. SOj/MBtu upper
limit.
323
-------
TABLE B-71. KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
3.5% S - 1.2 Ib S02/MBtu NSPS
Investment, $
Direct Investment
Raw material handling and preparation 11,819,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7,427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water handling 5,913,000
Scrubbing 16,583,000
Waste disposal 16.194.000
Subtotal 92,764,000
Services, utilities, and miscellaneous 5.155.000
Total direct investment 97,919,000
Indirect Investment
Engineering design and supervision 8,595,000
Architect and engineering contractor 1,579,000
Construction expense 12,430,000
Contractor fees 3,692.000
Total indirect investment 26,296,000
Contingency 24.843.000
Total fixed investment 149,058,000
Other Capital Charges
Allowance for startup and modifications 14,906,000
Interest during construction 20,868,000
Total depreciable investment 184,832,000
Land 3,352,000
Working capital 19,356.000
Total capital investment 207,540,000
Dollars of total capital per kW of generating
capacity 103,8
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kVh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs, and 7 weeks operating overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
324
-------
TABLE B-72. KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
3.5%
S - 1.2 Ib S02/MBtu NSPS
Annual
quantity
Unit
cost, $
Total annual
cost, $
Direct Costs
Raw materials
Limestone
Lime
Oxygen
NOj
NaOH (502)
Sodium llgnin sulfonate
Natural gas
Total raw materials cost
Conversion coats
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance
Analyses
lotal coaver&ion costs
Total direct costs
31,303 tons
137,952 tons
198,784 tons
952 tons
128,576 tons
75,200 tons
24,000 kft3
7.75/ton
43.3l/ton
21.13/ton
665.28/ton
99. 57 /ton
83.17/ton
2.93/kft3
243,000
5,975,000
4,200,000
633,000
12,802,000
6,254,000
70,000
165,878 raan-hr 13.80/n«n-hr
5,350,723 MBtu
2,807,020 kgal
253,335,413 kWh
27,274 man-hr
30,177,000
2,289,000
2.54/MBtu
0.09 /kgal
0.039/Kwh
18.70/»an-hr
13,591,000
253,000
9,880,000
5,998,000
510,000
32,521,000
62,698,000
Indirect Coats
Capital charges
Depreciation, interim replacements, and
Insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
I 7,848,00(1
1,899,000
229,000
9 <,?<<.;,noo
Byproduct Sales Revenue
Hone
Total annual revenue requirements
Equivalent unit revenue requirement
Mills/kWh
e/lb
sulfur removed
Baals
Midwest coal-cleaning plant location; time basis for scaling, mid-1982- plant life
30 years; operating time, KVB - 8,000 hr/yr; FGD - 5,500 hr/yr. '
Clean coal production capacity for 2,000-MW coal-fired power plant operatine at
9,500 Btu/kWh and 5,500 hr/yr. 6
Total direct Investment, $97,919,000; total depreciable investment, $184 932 000- anri
total capital Investment, $207,640,000. '
R«W coal (moisture-free): 4,211,525 tons/yr, 3.5Z sulfur, 14.Ot ash, 12 700 Btu/lv, .»,.
2.8 Ib S/MBtu. »«»/«», and
Clean coal (moisture-free): 3,988,549 tons/yr, 0.98X sulfur, 10.3* ash, 13,100 Btu/lb
and 0.8 Ib S/MBtu. * *
NSPS emission level - 1.2 Ib S02/MBtu.
325
-------
TABLE B-73. KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
5% S - 1.2 lb SOa/MBtu NSPS
Investment. $
Direct Investment
Raw material handling and preparation 13,852,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7,427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water handling 5,913,000
Scrubbing 31,628,000
Waste disposal 23.396.000
Subtotal 117,044,000
Services, utilities, and miscellaneous 5,749.000
Total direct investment 122,793,000
Indirect Investment
Engineering design and supervision 10,466,000
Architect and engineering contractor 1,586,000
Construction expense 16,210,000
Contractor fees 4.785,000
Total indirect investment 33,047,000
Contingency 30,920.000
Total fixed Investment 186,760,000
Other Capital Charges
Allowance for startup and modifications 18,676,000
Interest during construction 26.146.000
Total depreciable investment 231,5R2,000
Land 4,726,000
Working capital 21.685.000
Total capital investment 257,993,000
Dollars of total capital per kW of generating
capacity 129.0
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs, and 7 weeks operating overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
326
-------
TABLE B-74. KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
5:
S - 1.2 Ib S02/MBtu USPS
Annual
quantity
Unit
cost, $
Total annual
cost. $
Direct Costa
Raw materials
Limestone
Lime
Oxygen
N02
NaOH (50%)
Sodium llgnln sulfonate
Natural gas
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance
Analyses
Total conversion costs
Total direct costs
90,004 tons
197,603 tons
297,600 tons
952 tons
152,880 tons
75,200 tons
24,000 Wt3
7.75/ton
43.31/ton
21.13/ton
665.28/ton
99. 57 /ton
83. 17 /ton
2.93/kft3
698,000
8,558,000
6,288,000
633,000
VS. 222,000
6,254,000
70.000
174,694 aan-hr 13.80/aan-hr
37,723.000
2,411.000
5,349,838 MBtu
3,005,871 kgal
293,591,132 kWh
27,338 man-hr
2.54/KBtu
0.09/kgal
0.039/kWh
18.70/aan-hr
13.589.000
271.000
11.450.000
7,460,000
511.000
35.692,000
73,415,000
Indirect Costs
Capital charges
Depreciation, Interim replacements, and
Insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
13.895.000
22,187,000
2,595.000
241.000
38.91K.OOO
112,333,000
Byproduct Sales Revenue
None
Total annual revenue requirements
112,333,000
Equivalent unit revenue requirement
Mills/kWh sulfur
10.2
29.9
Basis
Midwest coal-cleaning plant location; time beela for scallM, sttd-lW2- Bleat life
30 years; operating tlae, KVB - 8,000 hr/yr; FGD - 5.500 te/yr. '
Clean coal production capacity for 2,000-MH coal-fired power plant o»ejatlua at
9,500 Btw/kWh and 5,500 hr/yr. ^^ ^
Total direct investment, $122.793,000; total depreciable Imastmeiii $231.2*4 OOfi- m,
total capital investment, $257,695.000. * '
Raw coal (moisture-free): 4.378,650 tons/yr, 5.0X aulfur, 16.n aah. 12.000 Btu/lh
4.2 Ib S/MBtu. "*
Clean coal (moisture-free): 4,146,825 tons/yr, 1.3X sulfur, 11.Ut a«ti 1
and 1.0 Ib S/MBtu.
NSPS emission level - 1.2 Ib S02/MBtu. For this 5X eulfur cotl, tKU la
level allowed for the proposed 8SX removal HSPS which has • 1.2 Ib
327
-------
TABLE B-75. KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
0.7% S - 85% Removal NSPS
Investment. $
Direct Investment
Raw material handling and preparation 13,223,000
Sulfur oxidation 6,292,000
Reactor off-gas cleaning 11,448,000
Tine coal leaching 7,906,000
Coarse coal leaching 7,141,000
Product agglomeration and handling 12,212,000
Leach solution neutralization and water handling 6,250,000
Scrubbing 33,507,000
Waste disposal 8,797,000
Subtotal 106,776,000
Services, utilities, and miscellaneous 5,755.000
Total direct investment 112,531,000
Indirect Investment
Engineering design and supervision 10,226,000
Architect and engineering contractor 1,568,000
Construction expense 15,317,000
Contractor fees 4,553,000
Total indirect investment 31,664,000
Contingency 28.838.000
Total fixed investment 173,033,000
Other Capital Charges
Allowance for startup and modifications 17,303,000
Interest during construction 24,225.000
Total depreciable investment 214,561,000
Land 1,760,000
Working capital 17.747,000
Total capital investment 234,068,000
Dollars of total capital per kW of generating
capacity 117.0
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs, and 7 weeks operating overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
328
-------
TABLE B-76. KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
0.7% S -
85% Removal NSPS
Annual
quantity
Unit
cost, $
Total annual
cost, $
Direct Coata
Raw materials
Limestone
Lime
Oxygen
H02
NaOH (50%)
Sodium lignin sulfonate
Natural gas
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance
Analyses
Total conversion costs
Total direct costs
39,600 tone
22,200 tons
25,216 tons
952 tons
35,424 tons
81,200 tons
24,000 kft3
7.75/ton
43.31/ton
21.13/ton
665.28/ton
99.57/tot»
83. 17 /ton
2.93/kft3
307,000
962,000
533,000
633,000
3,527,000
6,753,000
70,000
176,948 man-hr 13.80/man-hr
6,958,287 MBtu
3,303,406 kgal
336,478,753 kWh
2.54/MBtu
0.09/kgal
0.039/kWh
27,672 man-hr 18.70/man-hr
12,785,000
2,442,000
17,674.000
297,000
13,123,000
7,596,000
517.000
41,649,000
54,760,000
Indirect Costs
Capital charges
Depreciation, interim replacements, and
insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
12.ft74.000
20,129.000
2,956,000
244,000
36.203.000
90,963.000
Byproduct Sales Revenue
None
Total annual revenue requirements
90,963.000
Equivalent unit revenue requirement
C/lb
Mills/kWh sulfur removed
8.3
197.8
Basis
aoA.0
Midwest coal-cleaning plant location; time basis for scaling, mid-1982- nlant
30 years; operating time, KVB - 8,000 hr/yr; FGD - 5,500 hr/yr. '
ii ..»— «A«t m-ftrtnf+t-4f\n f*anne+4+*t ff\'f 9 QQQ«"MUf ^~~~^ *"* -* -- • ~
,000; total
Raw coal (moisture-free): 4,715,468 tona/yr, 0.7X sulfur, 11.5X M)> 11
0.6 Ib S/MBtu. '
Clean coal (moieture-free): 4,465,812 tons/yr, 0.36Z sulfur, U.2J: a*h
and 0.3 Ib S/MBtu.
NSPS emmission level - 0.20 Ib S02/MBtu..
lif.
m»..Mv
»n»/lb.
329
-------
TABLE B-77. KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
2,0% S - 85% Removal NSPS
Investment. $
Direct Investment
Raw material handling and preparation 12,119,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7,427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water handling 5,913,000
Scrubbing 25,471,000
Waste disposal 12,542.000
Subtotal 98,300,000
Services, utilicies, and miscellaneous 5.361,000
Total direct investment 103,661,000
Indirect Investment
Engineering design and supervision 9,431,000
Architect and engineering contractor 1,569,000
Construction expense 13,753,000
Contractor fees 4,091,000
Total indirect investment 28,844,000
Contingency 26,501.000
Total fixed investment 159,006,000
Other Capital Charges
Allowance for startup and modifications 15,901,000
Interest during construction 22,261,000
Total depreciable investment 197,168,000
Land 2,572,000
Working capital 18.220.000
Total capital Investment 217,960,000
Dollars of total capital per kW of generating
capacity 109.0
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs, and 7 weeks operating overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
330
-------
TABLE B-78. KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
2* S -
85Z Removal flSPS
Annual
quantity
Unit
coat, $
Total annual
coat, $
Direct Costs
Rav
Limestone
time
Oxygen
N02
NftOH (50%)
Sodium lignln aulfonate
Natural gas
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance
Analyses
Total conversion costs
Total direct costs
36,883 tons
89.416 tons
117,232 tons
952 tons
70,224 tons
75,200 tons
24,000 WtS
7.75/too
43. 31 /ton
21.13/ton
665.28/ton
99. 57 /ton
83.17/too
2.93/kft3
286,000
3,873,000
2,477,000
633,000
6,992,000
6,254,000
70.000
171,577 n*n-hr
13.80/nan-hr
2.54/NBtu
5,352,009 HBtu
2,965,076 kgal
290,438,594 kVh 0.039/kVh
26,884 man-hr 18.70/«en-ht
20,585,000
2,368,000
13,594,000
267,000
11,327.000
6,726,000
503.000
34.765.000
55.370,000
Indirect Costa
Capital charges
Depreciation, interim replacements, and
Insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
11 .« Ift.lWI
2,451,000
237,000
Byproduct Sales Revenue
None
Total annual revenue requirements
SS.frJS.OOO
Equivalent unit revenue requirement
Mills/kVh sulfur removed
8.1 42.6
Basis
Midwest coal-cleaning plant location; tin* basis for scaling, add-1982; plant life
30 years; operating time, KVB - 8,000 hr/yr; FGD - 5,500 hr/yr. *
Clean coal production capacity for 2,000-MW coal-fired power plant OD.ratln* *t
9,500 Btu/kWh and 5.500 hr/yr. !-«"»* «c
Total direct Investment, $103,661,000; total depreciable InveataMnt. S197 1M ooo- .^
total capital investment, $217,960,000. ,w,uw, and
Raw coal (molstura-free): 4,117,238 tons/yr, 2.OX sulfur, 14.51 ash, 13,000 Rtu/l\>, and
1.5 lt> S/MBtu.
Clean coal (molature-free): 3,899.254 tons/yr, 0.53Z «ulfur, II.6J *,h, ^j 4(xj «tu/lb
and 0.4 Ib S/MBtu. " '
NSPS emission level - 0.45 Ib S02/MBtu.
331
-------
TABLE B-79. KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
3.5% S - 85% Removal NSPS
Investment. $
Direct Investment
Raw material handling and preparation 12,361,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7,427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water handling 5,913,000
Scrubbing 21,850,000
Waste disposal 19.049.000
Subtotal 101,429,000
Services, utilities, and miscellaneous 6,086,000
Total direct investment 107,515,000
Indirect Investment
Engineering design and supervision 10,969,000
Architect and engineering contractor 1,701,000
Construction expense 16,431,000
Contractor fees 4.926,000
Total indirect investment 34,027,000
Contingency 28.308^000
Total fixed investment 169,850,000
Other Capital Charges
Allowance for startup and modifications 16,985,000
Interest during construction 23,779,000
Total depreciable Investment 210,614,000
Land 3,828,000
Working capital 20,223.000
Total capital investment 234,665,000
Dollars of total capital per kW of generating
capacity 117.3
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs, and 7 weeks operating overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
332
-------
TABLE B-80. KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
3.5%
S - 8551 Removal NSPS
Annual
quantity
Unit
cost, $
Total annual
cost, $
Direct Coats
Raw materials
Limestone
Lime
Oxygen
N02
NaOH (50%)
Sodium lignin sulfonate
Natural gas
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance
Analyses
Tetal conversion coats
Total direct costs
70,888 tons
137,952 tons
198,784 tons
952 tons
128,576 tons
75,200 tons
24,000 kft3
7.75/ton
43.31/ton
21.13/ton
665.28/ton
99. 57 /ton
83. 17 /ton
2.93/kft3
549,000
5,975,000
4.200,000
633,000
12,802,000
6,254,000
70,000
174,227 man-hr 13.80/man-hr
30,483,000
2,404,000
5,350,723 MBtu
2,988,275 kgal
290,819,931 kWh
27,274 man-hr
2. 54 /MBtu
0.09/kg«l
0.039/kWh
18.70/nan-hr
13,591,000
269,000
11,342,000
h,i.M , OOU
510,000
Ji, 56 7. 000
bS, 050. 000
Indirect Costs
Capital charges
Depreciation, Interim replacements, and
insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Markecing
Total indirect costs
Gross annual revenue requirements
U.MT.OOO
2,509,000
241,000
Byproduct Sales Revenue
None
Total annual revenue requirements
100. f. is, ooo
Equivalent unit revenue requirement
C/lb
Mills/kWh sulfur removed
9.1
40.1
Basis
Midwest coal-cleaning plant location; time basis for scaling. aid-1982- olant Uf.
30 years; operating time, KVB - 8,000 hr/yr; FGD - 5,500 hr/yr. *
Clean coal production capacity for 2,000-MW coal-fired cover plant
9,500 Btu/kWh and 5,500 hr/yr.
>r
,t
Total direct investment, $V07, 515, r>00; total depreciable investment SMO 6X4 iXX)- ~»
total capital investment, $234,665,000. ' ' '
Raw coal (moisture-f tee) : 4,211,525 tons/yr, 3.5Z sulfur, 14. OX ash, 12 700 »t,,Mv. .
2.8 Ib S/MBtu. ' »••'"".
Clean coal (moisture-free): 3,988,549 tons/yr, 0.98X sulfur. 10. 3Z ash 13 10
and 0.8 Ib S/MBtu. *iu
NSPS emission level - 0.84 Ib S02/MBtu.
333
-------
TABLE B-81. KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
57, S - 85% removal NSPS
Investment. $
Direct Investment
Raw material handling and preparation 13,852,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7,427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water handling 5,913,000
Scrubbing 31,628,000
Waste disposal 23,396,000
Subtotal 117,044,000
Services, utilities, and miscellaneous 5,749,000
Total direct investment 122,793,000
Indirect Investment
Engineering design and supervision 10,466,000
Architect and engineering contractor 1,586,000
Construction expense 16,210,000
Contractor fees 4,785,000
Total indirect investment 33,047,000
Contingency 30,920,000
Total fixed investment 186,760,000
Other Capital Charges
Allowance for startup and modifications 18,676,000
Interest during construction 26.146.000
Total depreciable investment 231,582,000
Land 4,726,000
Working capital 21.685,000
Total capital investment 257,993,000
Dollars of total capital per kW of generating
capacity 129.0
Basis
Midwest location of coal-cleaning plant with project begin-
ning mid-1979, ending mid-1982; average basis for cost
scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW coal-fired power
plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides for 3 weeks raw coal consumption, 7
weeks direct revenue costs, and 7 weeks operating overheads.
Pond site for sludge disposal located 1 mile from coal
preparation plant.
334
-------
TABLE B-82. KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
5% S - 85% removal NsrS
Annual
quantity
_
Unit
cost, $
Total annual
cost, $
Direct Costs
Raw materials
Limestone
Lime
Oxygen
N(>2
NaOH (50%)
Sodium lignin sulfonate
Natural gas
Total rav materials cost
Conversion costs
Operating labor and supervision
Utilities
Steam
Process water
Electricity
Maintenance
Analyses
Total conversion costs
Total direct costs
90,004 to'ns
197,603 tons
297,600 tons
952 tons
152,880 tons
75,200 tons
24,000 kft3
7.75/ton
43.31/ton
21.13/ton
665.28/ton
99.57/ton
83.17/ton
2.93/kft3
698.000
8,558,000
6,288,000
633,000
15,222,000
6,254,000
70,000
174,69A man-hr 13.80/man-hr
37,723,000
2.411,000
5,349,838 MBtu
3,005,871 kgal
293,591,132 kWh
27,338 man-hr
2. 54 /MBtu
0.09/kgal
0.039/kHh
18. 70 /man-hr
13,589,000
271,000
11,450,000
7,4*0,000
511,000
35,692.000
73,415,000
Indirect Costs
Capital charges
Depreciation, interim replacements, and
insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
1 !,*<»> ,000
_'->, I.S7.0OO
2,595,000
241.000
18,-MS,000
1U\1 I i.00(1
Byproduct Sales Revenue
None
Total annual revenue requirements
IU.lil.iKW
Equivalent unit revenue requirement
Mills/kWh sulfur removed
10.2 29.9
Basis
ISi-a
Midwest coal-cleaning plant location; time basis for scaling, mid-1982; plant ltf«
30 years; operating time, KVB - 8,000 hr/yr; FGD - 5,500 hr/yr. *
Clean coal production capacity for 2,000-MW coal-fired power plant oMratln* mt
9,500 B«u/kWh and 5,500 hr/yr. *-««««
Total direct investment, $122,793,000; total depreciable InvastMnt $231 284 000- and
total capital investment, $257,695,000. ' *
Raw coal (moisture-free): 4,378,650 tons/yr, 5.OX sulfur, 16.71 ash, 12,000 Btu/lh and
4.2 Ib S/HBtu. " ™~
Clean coal (moisture-free): 4,146,825 tons/yr, 1.3X sulfur, U.4X ash U 60O
and 1.0 Ib S/MBtu. ' '
NSPS emiasion level - 1.2 Ib S02/MBtu. For this 5X milfur eoal, thi« U also
level allowed for the proposed 85X removal NSPS whtch has a 1.2 Ib "
335
-------
TABLE B-83. COMBINATION PCC-KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
3.5% S - 1.2 Ib S02/MBtu NSPS
Investment, $
Direct Investment
Coal receiving and storage 8,608,000
Raw coal sizing 1,564,000
Coarse coal cleaning 1,547,000
Intermediate coal cleaning 2,162,000
Fine coal cleaning 2,594,000
Refuse disposal as landfill 2,581,000
Interim storage area A,513,000
Raw material handling and preparation 6,737,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7,427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water 5,913,000
handling
Scrubbing 11,219,000
Waste disposal 14,909,000
Subtotal 104,599,000
Services, utilities, and miscellaneous 6,470,000
Total direct investment 111,069,000
Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total indirect investment
Contingency
Total fixed investment
10,330,000
2,154,000
14,644,000
4,280,000
31,408,000
28.300.000
170,777,000
Other Capital Charges
Allowance for startup and modifications 17,078,000
Interest during construction 23.909,000
Total depreciable investment 211,761,000
Land 6,209,000
Working capital 28.186,000
Total capital investment 246,156,000
Dollars of total capital per kW equivalent
of clean coal 123.1
Basis
Midwest location of coal-cleaning plant with project
beginning mid-1979, ending mid-1982; average basis for
cost scaling, end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000 MW, coal-fired
power plant operating at 9,500 Btu/kwli and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating
overheads.
Pond and landfill sites for sludge and refuse disposal
located 1 mile from coal preparation plant.
336
-------
TABLE B-84. COMBINATION PCC-KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
3.5X S -
Direct Costa,
Raw materials
Limestone
Lime
Oxygen
N02
NaOH (50%)
Sodium lignin sulfonate
Natural gas
Coal loss (Btu basis)
Total raw materials coat
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
Steam
Process water
Electricity
Process material: magnetite
Maintenance
Analyses
Total conversion costs
Total direct coses
1.2 Ib S02/KBtu NSPS
Annual
JluantUy
17,894 tons
137,952 tons
198,786 tons
952 tons
128,576 tons
75,200 tons
24,000 tons
368,650 tons
304,350 man-hr
121,000 gal
5,350,723 MBtu
2,790,058 kgal
255,823,565 kWh
2,550 tons
29,072 man-hr
Unit
cost, $
7.75/ton
43.31/ton
21.13/ton
665.28/ton
»9.57/ton
83.17/ton
2.93mt3
31.58/ton
13.80/man-hr
0.70/gal
2. 54 /MBtu
0.09/kgal
0.039/kWh
93.31/ton
Total annual
cost, $ _
139,000
5,975,000
4,200,000
633,000
12,802,000
6,254,000
70,000
U, 642,000
41,715,000
4,200,000
85,000
13,591,000
2M,000
9,977,000
238,000
IS. 201,000
18.70/»an-hr 544,000
44,089,000
85,804,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance
Average cost of capital toxps
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
2,557,000
421.000
Byproduct Sales Revenue
None
Total annual revenue requirements
I22.fc57.000
Equivalent unit revenue requirements
11.2
47.4
Basis
Midwest coal-cleaning plant location; time basts for scaling, atd-lM?; plant life,
30 yr; operating time, PCC-6,000 lir/yr, KVB-8.0OO hr/yr, n:D-S.50O Ur/yt.
Clean coal production capacity for 2,000-MH, conl-fIred power plant o,H-rjtinK ^t
9,500 litu/klfli, and 5,500 hr/yr.
Total direct investment, $111,069,000 total depreciabl* Investment. $21J.6'»5>OOO, »nd
total capital investment, $248,090,000.
Raw coal (moisture-free): 4,589,372 tons/yr, 3.5X sulfur. V4.0X ash, 12,700 Uu/lb,
and 2.75 Ib S/MBtu.
Clean coal (moisture-free): 3,786,232 tons/yr. 0.98X sulfur. S.9I ash, U.tQO Hu/Jb,
and 0.7 Ib S/MBtu.
NSPS emission level: 1.2 Ib S02/MBCU.
337
-------
TABLE B-85. COMBINATION PCC-KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
5Z S - 1.2 lb S02/MBtu NSPS
Investment. $
Direct Investment
Coal receiving and storage 8,841,000
Raw coal sizing 1,627,000
Coarse coal cleaning 1,585,000
Intermediate coal cleaning 2,249,000
Tine coal cleaning 2,696,000
Refuse disposal as landfill 3,058,000
Interim storage area 4,513,000
Raw material handling and preparation 8,250,000
Sulfur oxidation 5,985,000
Reactor off-gas cleaning 10,889,000
Fine coal leaching 7.427,000
Coarse coal leaching 6,625,000
Product agglomeration and handling 11,329,000
Leach solution neutralization and water
handling 5,913,000
Scrubbing 25,683,000
Waste disposal 22.060,000
Subtotal 128,730,000
Services, utilities, and miscellaneous 7,541,000
Total direct investment 136,271,000
Indirect Investment
Engineering design and supervision 12,354,000
Architect and engineering contractor 2,186,000
Construction expense 18,656,000
Contractor fees 5,442,000
Total indirect investment 38,638,000
Contingency 34.748.000
Total fixed Investment 209,657,000
Other Capital Charges
Allowance for startup and modifications 20,966,000
Interest during construction 29,332,000
Total depreciable investment 259,975,000
Land 8,135,000
Working capital 30.0_85.000
Total capital investment 298,195,000
Dollars of total capital per kW equivalent
of clean coal 149-1
Basis
Midwest location of coal-cleaning plant with project beginning
mid-1979, ending mid-1982; average basis for cost scaling, end-1980;
operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired power plant
operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage capacities
(power plant basis).
Working capital provides 3 weeks raw coal consumption, 7 weeks
direct revenue costs, and 7 weeks operating overheads.
Pond and landfill sites for sludge and refuse disposal located
1 mile from coal preparation plant.
338
-------
TABLE B-86. COMBINATION PCC-KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
SX S -
1.2 lb S02/MBtu HSPS
Animal
quantity
Unit
cost. $
Total annual
coat, $
Direct Costs
Raw materials
Limestone
Line
Oxygen
N02
KaOH (50*)
Sodium llgnin sulfonate
Katural gaa
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
Steam
Process water
Electricity
Process material: magnetite
Maintenance
Analyses
Total conversion costs
Total direct costs
57.291 tons
197.603 tons
297,600 tone
952 tone
152,860 tons
75,200 tone
24,000 tons
478,000 tons
7.75/ton
43.31/ton
21 a3/ton
66S.28/ton
99.57/ton
83.17/ton
2.93/k€t3
31. SB/ton
444,000
8.SS8.000
6.288,000
633.000
15,222,000
6,254,000
70,000
IS.09%.000
52.567,000
317.872 Bin-hr 13.80/Mn-br 4.387.000
145,000 gal
5,349,838 HBtu
2,940,474 kgal
286,664.699 kWh
2,760 tona
30,806 van-hr
0.70/gal
2.54/MBtu
0.09/kcal
0.039/kMk
91. 31 /ton
18.70/aan-hr
102.000
13,588,000
265,000
11.180.000
257.000
8.862.000
576,000
39.217.000
91.784,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total Indirect costs
Gross annual revenue requirements
15,599,000
25.645.WW
3,377.000
439.000
4%.060 .000
136,844,000
Sales
None
Total annual revenue requirement a
Mllls/kWh S
C/lb
Equivalent unit revenue requirements 12.4
35.1
136,844.000
Jaais
Midwest coal -cleaning plant location; time baaia tor •c*ll*».
30 yr; operating tia». PCC-6000 hr/jrr, KT*-«,000 fcc/yt,
lit.
'
Total direct Investment, $136,271,000; total depreciable
and total capital Investment, $300,176,000.
Saw coal (moisture-free): 4,531,224 tons/yr, 5X tulfui, li.n artu tt.UO
and 4.17 lb S/MBtu.
Clean coal (moisture-free): 3,928,571 tone/7*, 1.J1 aaltvr. «.K «ati. 13.MO
and 0,9 lb S/MBtu. "^
NSPS emission level: 1.2 lb S(>2/MBtu. For tKle SS-coal, thta *» «4«a> Uw
level allowed for the proposed 4SZ removal IMPS Vbich ha* « V»l Ik
limit.
339
-------
TABLE B-87. COMBINATION PCC-KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
0.72 S - 85Z removal MSPS
Investment, $
Direct Investment
Coal receiving and storage 8,799,000
Raw coal sizing 1,616,000
Coarse coal cleaning 1,575,000
Intermediate coal cleaning 2,234,000
Fine coal cleaning 2,696,000
Refuse disposal as landfill 1,904,000
Interim storage area 4,513,000
Raw material handling and preparation 8,753,000
Sulfur oxidatidn 6,292,000
Reactor off-gas cleaning 11,448,000
Fine coal leaching 7,906,000
Coarse coal leaching 7,142,000
Product agglomeration and handling 1?,212.000
Leach solution neutraliEation and water
handling 6,250,000
Scrubbing 41,054,000
Waste disposal 8,636.000
Subtotal 133,030,000
Services, utilities, and miscellaneous 7,431,OOP
Total direct investment 140,461,000
Indirect Investment
Engineering design and supervision 13,327,000
Architect and engineering contractor 2,146,000
Construction expense 19,954,000
Contractor fees 5,898,000
Total indirect investment 41,325,000
Contingency 36,232,000
Total fixed investment 218,018,000
Other Capital Charges
Allowance for startup and modifications 21,802,000
Interest during construction 30,523.000
Total depreciable investment 270,343,000
Land 3,908,000
Working capital 21,090,000
Total capital Investment 295,341,000
Dollars of total capital per kW equivalent
of clean coal 147.7
Basis
Midwest location of coal-cleaning plant with project beginning
mid-1979, ending mid-1982; average basis for cost scaling,
end-1980; operating time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired
power plant operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage
capacities (power plant basis).
Working capital provides 3 weeks raw coal consumption,
7 weeks direct revenue costs, and 7 weeks operating
overheads.
Pond and landfill sites for sludge and refuse disposal
located 1 mile from coal preparation plant.
340
-------
TABLE B-88, COMBINATION PCC-KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
0.7% S -
Direct Costs
Raw materials
Limestone
time
Oxygen
N02
NaOH (50%)
Sodium lignin sulfonate
Natural gas
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
Steam
Process water
Electricity
Process material: magnetite
Maintenance
Analyses
Total conversion costs
Total direct costs
Indirect Costs
Capital charges
Depreciation, interim replacements,
and insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total Indirect costs
Gross annual revenue requirements
Byproduct Sales Revenue
None
Total annual revenue requirements
Equivalent unit revenue requirements
85% removal NSPS
Annual
quantity
36,995 tons
22,200 tons
25,216 tons
952 tons
35,424 tons
81,200 tons
24,000 tons
283,400 tons
321,309 man-hr
97,000 gal
6,958,287 MBtu
3,359,753 kgal
353,916,849 kWh
2,720 tons
11,724 man-hr
Mills/kVh S
10.4
Unit
cost, $
7.75/ton
43.31/ton
21.13/ton
665.28/ton
99. 57 /ton
83. 17 /ton
2.93/kft3
31.58/ton
13.80/nan-hr
0.70/gal
2.54/MBtu
0.09/kgal
0.039/kWh
93. 31 /ton
18.70/man-hr
-------
TABLE B-89. COMBINATION PCC-KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
2% S - 85% reduction NSPS
Direct Investment
Coal receiving and storage
Raw coal sizing
Coarse coal cleaning
Intermediate coal cleaning
Fine coal cleaning
Refuse disposal as landfill
Interim storage area
Raw material handling and preparation
Sulfur oxidation
Reactor off-gas cleaning
Fine coal leaching
Coarse coal leaching
Product agglomeration and handling
Leach solution neutralization and water
handling
Scrubbing
Haste disposal
Subtotal
Services, utilities, and miscellaneous
Total direct investment
Investment, $
8,529,000
1.5A3.000
1,512,000
2,132,000
2,573,000
2,558,000
4,513,000
8,202,000
5,985,000
10,889,000
7,427,000
6,625,000
11,329,000
5,913,000
25,620,000
11.737.000
117,087,000
7.011.000
124,098,000
Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total indirect investment
Contingency
Total fixed investment
11,822,000
2,139,000
17,139,000
5,047.000
36,147,000
31.864,000
192,109,000
Other Capital Charges
Allowance for startup and modifications
Interest during construction
Total depreciable investment
Land
Working capital
Total capital investment
Dollars of total capital per kW equivalent
of clean coal
19,211.000
26.895.000
238,215,000
5,417,000
26,673,000
270,305,000
Basis
Midwest location of coal-cleaning plant with project beginning mid-1979,
ending mid-1982; average basis for cost scaling, end-1980; operating
time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired power plant
operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage capacities
(power plant basis).
Working capital provides 3 weeks raw coal consumption, 7 weeks direct
revenue costs, and 7 weeks operating overheads.
Pond and landfill sites for sludge and refuse disposal located
1 mile from coal preparation plant.
342
-------
TABLE B-90. COMBINATION PCC-KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
2Z
S - 8SZ reduction HSPS
Annual
quantity
Unit
cost, S
Total annual
coat. $
Direct Coats
Raw materials
Limestone
Lime
Oxygen
N02
NaOH (50%)
Sodium lignin sulfonate
Natural gas
Coal loss (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
Steam
Process water
Electricity
Process material: magnetite
Maintenance
Analyses
Total conversion costs
Total direct costs
21,858 tons
89,416 tons
117,232 tons
952 tons
70,224 tons
75,200 tons
24,000 tons
315,600 tons
7.75/ton
43. 31 /ton
21.13/ton
665.28/ton
99.57/ton
83.17/ton
2.93/kft3
31.58/ton
314,700 man-hr 13.80/Mn-hr
169.000
3,873,000
2,477,000
633,000
6.992.000
6,234,000
70.000
9.966.000
30,4)4.000
4.384,000
119,000 gal
5,352,009 MBtu
2,909,150 kgal
284,860,387 kUh
2,490 tons
30,402 aan-hr
0.70/gal
2. 54 /MBtu
0.09/kgal
0.039/kWh
93.31/ton
18.70/«*n-hr
83.000
13.594.000
262,000
11,110,000
232,000
8,191,000
569,000
3t.425.000
6S.8S9.000
Indirect Costs
Capital charges
Depreciation, Interim replacements,
and insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total indirect costs
Gross annual revenue requirements
14,293,000
23,246.000
3.314.000
134,000
40.987,000
109.846.000
Byproduct Sales Revenue
None
Total annual revenue requirements
Mills/kWh
C/lb
S removed
Equivalent unit revenue requirements 10.0
72.3
109,646,000
Basis
Midwest coal-cleaning plant location; time basis for scaling, Bid-1982; plant life
30 yr; operating tine, PCC-6,000 hr/yr, KVB-8.000 hr/yr, FGD-S.SOO hr/yr, *
Clean coal production capacity for 2,000-MW, coal-fired power plant operating at
9,500 Btu/kWh and 5,500 hr/yr.
Total direct investment, $124,098,000; total depreciable inveatawnt. $239,736.000.
total capital investment, $271,826,000.
Raw coal (moisture-free): 4,401,408 tons/yr, 21 sulfur. 14.SJ ash. 13.000 Bcu/lK.
and 1.54 Ib S/MBtu. **
Clean coal (moisture-free): 3,679,577 tons/yr. 0.49X sulfur, 6.0X aah. 14.200
and 0.35 Ib S/MBtu.
NSPS emission level: 0.462 Ib SOj/MBtu
343
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TABLE B-91. COMBINATION PCC-KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
3.5* S - 85* removal NSPS
Direct Investment
Coal receiving and storage
Raw coal sizing
Coarse coal cleaning
Intermediate coal cleaning
Fine coal cleaning
Refuse disposal as landfill
Interim storage area
Raw material handling and preparation
Sulfur oxidation
Reactor off-gag cleaning
Fine coal leaching
Coarse coal leaching
Product agglomeration and handling
Leach solution neutralization and water
handling
Scrubbing
Haste disposal
Subtotal
Services, utilities, and miscellaneous
Total direct Investment
Investment, $
8,608,000
1,564,000
1,547,000
2,162,000
2,594,000
2,581,000
4,513,000
7,730,000
5,985,000
10,889,000
7,427,000
6,625,000
11,329,000
5,913,000
29,337,000
18.5A5.000
127,349,000
6,024,000
133,373,000
Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total indirect Investment
Contingency
Total fixed Investment
12,443,000
2,154,000
18,400,000
5,454.000
38,451,000
34,404.000
206,228,000
Other Capital Charges
Allowance for startup and modifications
Interest during construction
Total depreciable Investment
Land
Working capital
Total capital Investment
Dollars of total capital per kW equivalent
of clean coal
20,623,000
28.872.000
255.723.000
6,787,000
29.267.000
291,777,000
145.9
Basis
Midwest location of coal-cleaning plant with project beginning mid-1979,
ending mid-1982; average basis for cost scaling, end-I980; operating
time, 8,000 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired power plant
operating at 9,500 Btu/kUh and 5,500 hr/yr.
Fifteen-day raw coal and fifteen-day clean coal storage capacities
(power plant basis).
Working capital provides 3 weeks raw coal consumption, 7 weeks direct
revenue costs, and 7 weeks operating overheads.
Pond and landfill sites for sludge and refuse disposal located 1 mile
from coal preparation plant.
344
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TABLE B-92. COMBINATION PCC-KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
3.
,5Z S - 851 removal NSPS
Annual
quantity
Unit
cost. $
Total annual
coat, $
Direct Coats
Raw materials
Limestone
Lime
Oxygen
N02
NaOH (507)
Sodium lignin sulfonate
Natural gas
Coal loss (Btu basis)
Total raw materials coat
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
Steam
Process water
Flectriclty
Process material: magnetite
Maintenance
Analyses
Total conversion costs
Total direct costs
63,954 tons
137,952 tons
198,784 tons
952 tons
128,576 tons
75,200 tons
24,000 tons
368,650 tons
7. 75 /ton
43. 31 /ton
21.13/ton
665.28/ton
99.57/ton
83.17/ton
2.93/Wt3
31.58/ton
496,000
5,975.000
4.200.000
633,000
12.602.000
6.254,000
70.000
11.642.000
317.193 nan-hr 13.80/aan-hr
42,072.000
4,377,000
121.000 gal
5,350,723 MBtu
3,015,488 kgal
302,893.233 Mfti
2,550 tons
31,118 nan-hr
0.70/gal
2. 54 /MBtu
0.09 /kgal
0.039/kUh
93.31/ton
18.70/van-hr
85,000
13,591,000
271,000
11,813.000
238,000
8. 702 .000
582,000
39,659.000
81,731,000
Indirect Costs
Capital charges
Depreciation, interim replacements,
and Insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total Indirect costs
Gross annual revenue requirements
IS,143.000
25,n«n,0
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TABLE B-93. COMBINATION PCC-KVB PROCESS AND FGD
TOTAL CAPITAL INVESTMENT
5% S - 85% removal NSPS
Direct Investment
Coal receiving and storage
Raw coal sizing
Coarse coal cleaning
Intermediate coal cleaning
Fine coal cleaning
Refuse disposal as landfill
Interim storage area
Raw material handling and preparation
Sulfur oxidation
Reactor off-gas cleaning
Fine coal leaching
Coarse coal leaching
Product agglomeration and handling
Leach solution neutralization and water
handling
Scrubbing
Waste disposal
Subtotal
Services, utilities, and miscellaneous
Total direct investment
Investment, $
8,841,000
1,627,000
1,585,000
2,249,000
2,696,000
3,058,000
4,513,000
8,250,000
5,985,000
10,889,000
7,427,000
6,625,000
11,329,000
5,913,000
25,683,000
22.060.000
128,730,000
7.541.000
136,271,000
Indirect Investment
Engineering design and supervision
Architect and engineering contractor
Construction expense
Contractor fees
Total indirect investment
Contingency
Total fixed Investment
12,354,000
2,186,000
16,656,000
5,442,000
38,638,000
34,746,000
20?,657,000
Other Capital Charges
Allowance for startup and modifications
Interest during construction
Total depreciable investment
Land
Working capital
Total capital investment
Dollars of total capital per kW equivalent
of clean coal
20,966,000
29.33Z.OQO
259.975,000
8,135,000
30_,OR5,000
298,195,1100
149.1
Basis
Midwest location of coal-cleaning plant with project beginning
mid-1979, ending mid-1982; average basis for cost scaling, end-1980;
operating tine, 8,000 hr/yr.
Clean coal production capacity for 2,000-MB, coal-fired paver plant
operating at 9,500 Btu/kWh and 5,500 hr/yr.
Fifteen-day rav coal and fifteen-day clean coal storage capacities
(power plant basis).
Working capital provides 3 weeks raw coal consumption, 7 weeks
direct revenue costs, and 7 weeks operating overheads.
Pond and landfill sites for sludge and refuse disposal located
1 mile from coal preparation plant.
346
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TABLE B-94. COMBINATION PCC-KVB PROCESS AND FGD
ANNUAL REVENUE REQUIREMENTS
5X S -
85Z removal NSPS
Annual
quantity
Vnit
costj S
Total annual
comt . $
Direct Costs
Raw materials
Limestone
Lime
Oxygen
N02
NaOH (505S)
Sodium llgnln sulfonate
Natural gas
Coal lose (Btu basis)
Total raw materials cost
Conversion costs
Operating labor and supervision
Utilities
Diesel fuel
fteam
Process water
Electricity
Process material: magnetite
Maintenance
Analyses
Total conversion costs
Total direct coats
57,291 tons
197,60) tons
297,600 tons
952 tons
152,880 tons
75,200 tons
24,000 tons
478.000 tons
7.75/ton
43.31/ton
21,13/ton
665.287 ton
99.57/ton
83.17/ton
2.93/kft3
31.58/ton
444.000
8.558.000
6.2M.OOO
633.000
IS. 222,000
6.254.000
70,000
15.098.000
317.872 nan-hr 13.80/Mi>-hr
52.567,000
*,387,000
145,000 gal
5.349,838 MBtu
2.940,474 kgal
286,664,699 kWh
2,760 tons
30,806 nan-hr
0.70/gal
2.54/MBtu
0.09/kg«l
0.039/kVh
93.31/ton
18.70/s*n~hr
102,000
13,588,000
265.000
11,180.000
257.000
8,862,000
576.000
39.217,000
91,784,000
Indirect Costs
Capital charges
Depreciation, Interim replacements,
and Insurance
Average cost of capital and taxes
Overheads
Plant
Administrative
Marketing
Total Indirect costs
Gross annual revenue requirements
IS.S99.000
25,6*5,000
3.377,000
439,000
ll«i.K44,fMIO
Byproduct Sales Revenue
None
Total annual revenue requirements
C/lb
Hllls/kHh S removed
Equivalent unit revenue requirements 12.4
15.1
Basis
Midwest coal-cleaning plant location; time basis for scaling, mid-1982; plant llf«
30 yr; operating time, PCC-6000 hr/yr, KVB-8,000 hr/yr, F<3>-5,500 hr/yr.
Clean coal production capacity for 2,000-MW, coal-fired povcr plant op*ratlnK «t
9,500 Btu/kHh and 5,500 hr/yr.
Total direct investment, $136,271,000; total depreciable Invcstnnt, $261,956,000-
and total capital Investment, $300,176,000. *
Raw coal (moisture-free): 4,531,224. tons/yr, 51 sulfur, 16.7S ash, 12.000 Btu/lb
snd 4.17 Ib S/MBtu.
Clean coal (moisture-free): 3,928,571 tons/yr, 1,21 sulfur, 6.9X ash, 13,300 Btu/lb
and 0.9 Hi S/MBtu. '
NSPS emission level: 1.2 Ib S02/MBtu. Tor this 5Z coal, this Is also the mission
level allowed for the proposed 85X removal NSPS which has • 1.2 Ib SOj/MBtu upper
limit.
347
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/7-79-250
. RECIPIENT'S ACCESSION-NO.
4. TITLE ANDSUBTITLE
Evaluation of Physical/Chemical Coal Cleaning
and Flue Gas Desulfurization
REPORT DATE
November 1979
PERFORMING ORGANIZATION CODE
7. AUTHORIS)
T. W. Tarkington, F. M. Kennedy, and J. G. Patterson
. PERFORMING ORGANIZATION REPORT NO.
ECDP B-5
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.
IAG-D9-E721-BI
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
Final; 6/78 - 10/79
14. SPONSORING AGENCY CODE
EPA/600/13
15. SUPPLEMENTARY NOTES
IERL-RTP project officer is C. J. Chatlynne, Mail Drop 61, 919/541-2915.
T6. ABSTRACT
The report gives results of evaluations of physical coal cleaning (PCC),
chemical coal cleaning (CCC), and coal cleaning combined with flue gas desulfuriza-
tion (FGD). It includes process descriptions, cleaning performances, comparative
capital investments, and annual revenue requirements when four coals (with sulfur
levels of 0.7% to 5.0%) are cleaned by each of seven conceptual coal cleaning
processes. In the three commercial-type PCC processes, coal is treated in dense-
medium equipment and by froth flotation or concentrating table. The three CCC
processes are KVB, TRW Gravichem, and Kennecott. The seventh process combines
PCC and CCC. Economics are provided also for three coal cleaning/FGD combinations
to meet the pre-1978 1.2 Ib S02/MBtu NSPS and the 85% S02 reduction NSPS proposed
in September 1978. All processes are compared on a 2000-MW power generation basis.
PCC is cost effective for meeting the 1.2 Ib S02/MBtu emission level with coals
having sulfur levels below about 1.2%. Coal cleaning/FGD is cost effective for
S02 emissions control in many specific cases. The CCC processes studied are
generally higher in both capital investments and annual revenue requirements; the
KVB process is the least expensive.
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
Pollution
Coal
Desulfurization
Sulfur Oxides
13. DISTRIBUTION STATEMENT
Release to Public
b.lQENTIFIERS/OPEN ENDED TERMS
Pollution Control
Stationary Sources
Coal Cleaning
19. SECURITY CLASS ( This Report )
Unclassified
20. SECURITY CLASS (This page)
Unclassified
. COSATi Field/Group
13B
08G, 21D
07A, 07D
07B
21. NO. OF PAGES
378
22. PRICE
gPA Form Z220-1 (9-73)
349
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