PB83-117366
Acid Rain Mitigation study. Volume II
PGD Cost Estimates (Appendices)
Radian Corp.
Austin, TX
Prepared for
Industrial Environmental Research Lab,
Research Triangle Park, NC
Sep 82
U.S. DEPARTMENT OF COMMERCE
National Technical Information Service
-------
PB83-117366
EPA-600/2-82-070b
September 1982
ACID RAIN MITIGATION STUDY
Volume IL FGD Cost Estimates
(Appendices)
bv
J.G. Ball and W.R. Menzies
Radian Corporation
8501 Mo-Pac Blvd
Austin, Texas 78766
EPA Contract No: 68-02-3171
Work Assignment 12
William Baasel and P.P. Turner
Technical Support Staff
Industrial Environmental Research Laboratory
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
Prepared for:
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
RESEARCH TRIANGLE PARK, NC 27711
-------
TECHNICAL REPORT DATA
(Please read Inunctions on the reverse before completing)
1 REPORT NO.
EPA-600/2-82-070b
2.
3. RECIPIENT'S ACCESSION- NO.
117566
4. TITLE AND SUBTITLE _
Acid Rain Mitigation Study: Volume II FGD Cost
Estimates (Appendices)
5 REPORT DATE
September 1982
6 PERFORMING ORGANIZATION CODE
7 AUTHOR(S)
J. G. Ball and W. R. Menzies
8 PERFORMING ORGANIZATION REPORT NO
DCN 81-203-001-12-23
9 PERFORMING OROANIZATION NAME AND ADDRESS
Radian Corporation
8501 Mo-Pac Boulevard
Austin, Texas 78766
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-3171, Task 12
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 PEHIOI
Task Final;2/80-2/81
IOO COVERED
14. SPONSORING AGENCY CODE
EPA/600/13
is. SUPPLEMENTARY NOTES IERL-RTP project officer William D. Baasel is no longer with
EPA. For details, contact P.P. Turner, Mail Drop 62, 919/541-2826. Volume III is
the industrial boiler technical report. Volume I is the estimates technical report.
is. ABSTRACT -pne repOrt gives results of work to provide a consistent set of capital in-
vestment and operating costs for flue gas desulfurization (FGD) systems retrofitted
to existing industrial boilers. The investigation of wet limestone scrubbers and lime
spray drying FGD systems included: (1) the apparent discontinuities in both FGD
system capital investment and operating costs; (2) FGD retrofit factors applied to
existing boilers based on published reports; and (3) differences between PEDCo
Environmental, Inc. and TVA cost estimates for utility boiler FGD systems. These
costing issues were examined on the bases of design scope, costing factors (for
equipment installation, indirect investment, etc.), year of costs, inherent strengths
and weaknesses, and published data of actual system costs. Recommendations are
made for the cost bases to use in further acid rain studies.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Croup
Pollution
Flue Gases
Desulfurization
Cost Estimates
Boilers
Industrial Processes
Calcium Carbonates
Limestone
Calcium Oxides
Rain
Acidity
Pollution Control
Stationary Sources
Lime
Acid Rain
13B
21B
07A,07D
05A,04A
13A
13H
07B
08G
04B
13. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (Tha Report)
Unclassified
21. NO OF PAGES
20. SECURITY CLASS (Thapage!
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
-------
NOTICE
THIS DOCUMENT HAS BEEN REPRODUCED
FROM THE BEST COPY FURNISHED US BY
THE SPONSORING AGENCY. ALTHOUGH IT
IS RECOGNIZED THAT CERTAIN PORTIONS
ARE ILLEGIBLE, IT IS BEING RELEASED
IN THE INTEREST OF MAKING AVAILABLE
AS MUCH INFORMATION AS POSSIBLE.
-------
NOTICE
This document has been reviewed in accordance with
U.S. Environmental Protection Agency policy and
approved for publication. Mention of trade names
or commercial products does not constitute endorse-
ment or recommendation for use.
11
-------
ABSTRACT
The U.S. EPA has initiated a multiphased study of the acid rain problem.
As part of Phase I, Radian Corporation investigated 862 emissions and controls
in the industrial sector. The primary objective of this work was to provide
a consistent set of capital investment and operating costs for flue gas
desulfurization (FGD) systems applied to both industrial and electric
utility boilers. Retrofit factors as well as the cost for FGD systems
applied to new boilers were addressed. Wet limestone scrubbing and lime
spray drying FGD systems were evaluated.
In conducting the work to provide a consistent set of capital invest-
ment and operating costs for FGD systems retrofitted to existing boilers,
the following issues were investigated:
• The apparent discontinuities in both FGD system capital
investment and operating costs as a function of boiler
capacity -in the region between industrial boilers and
small utility boilers,
•• FGD retrofit factors applied to existing boilers based
on published reports, and
• The differences between PEDCo Environmental, Inc. and
TVA cost estimates for utility boiler FGD systems.
These costing issues were examined on the bases of design scope, costing
factors (for equipment installation, indirect investment, etc.), year of
costs, inherent strengths and weaknesses, and published data of actual system
costs. Recommendations are made for the cost bases to use in further acid
rain studies.
iii
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TABLE OF CONTENTS
VOLUME I
Abstract iii
List of Tables ix
List of Figures xiii
1 INTRODUCTION AND SUMMARY 1-1
1.1 Introduction 1-1
1.2 Summary of Results 1-4
1.2.1 Utility and Industrial Boiler FGD System
Costs 1-4
1.2.2 FGD System Retrofit Factor Evaluation. . . . 1-15
1.2.3 TVA & PEDCo Environmental, Inc. FGD
System Cost Comparison 1-16
2 FLUE GAS DESULFURIZATION SYSTEM COST COMPARISONS FOR
INDUSTRIAL AND UTILITY BOILERS 2-1
2.1 Wet Limestone FGD System Cost Estimates 2-2
2.1.1 Process Description 2-2
2.1.2 Limestone FGD System Capital Investment. . . 2-7
2.1.2.1 Utility Boiler FGD System Capital
Investment Estimates 2-9
2.1.2.2 Industrial Boiler FGD System Capital
Investment Estimates 2-13
2.1.2.3 Comparison and Integration of Utility
and Industrial Boiler FGD System
Capital Investment Estimates 2-17
2.1.2.4 Comparison of TVA Utility Boiler FGD System
Capital Investment Estimates with Actual
Installed FGD System Investment 2-32
2.1.2.5 Equipment on Actual Installed FGD Systems. . 2-36
2.1.3 Limestone FGD System Annual Operating
Cost Estimates 2-39
2.1.3.1 Utility Boiler FGD System Annual Operating
and Maintenance Cost Estimates 2-39
2.1.3.2 Industrial Boiler FGD System Annual
Operating and Maintenance Cost Estimates . . 2-44
2.1.3.3 Comparison and Integration of Utility and
Industrial Boiler FGD System Annual O&M
Cost Estimates 2-48
Preceding page blank
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TABLE OF CONTENTS (continued)
SECTION
2.2
Refe
FLUE
FOR
3.1
3.2
3.3
2.1.4 Use of the Cost Estimate Results
Lime Spray Dryer FGD System Cost Estimates
2.2.1 Process Description
2.2.2 Lime Spray Dryer FGD System Capital
2.2.2.1 Utility Boiler Lime Spray Dryer Capital
2.2.2.2 Industrial Boiler FGD System Capital
2.2.2.3 Comparison and Integration of Utility
and Boiler FGD System Capital
Investment- E
-------
TABLE OF CONTENTS (continued)
SECTION PAGE
4 COMPARISON OF TENNESSE VALLEY AUTHORITY AND PEDCO
ENVIRONMENTAL, INC. CAPITAL INVESTMENT AND ANNUAL COST
ALGORITHMS FOR UTILITY BOILER FGD SYSTEMS 4-1
4.1 Equipment Configuration Basis 4-1
4.2 Economic Premises 4-2
4.3 Capital Investment Algorithms 4-2
4.4 Comparison of TVA and PEDCo Capital Investment . . . 4-2
4.5 Annual Operating Cost and Revenue Algorithms .... 4-8
4.6 Comparison of TVA and PEDCo Annual Operating Cost
and Annual Revenue Requirement 4-11
4.7 Summary 4-11
References 4-15
VOLUME II
APPENDICES
A Utility Boiler Limestone FGD System Premises A-l
B Industrial Boiler Limestone FGD System Premises B-l
C Utility Boiler Limestone FGD System Premises on an
"Industrial Basis" C-l
D Utility Boiler Lime Dry Scrubbing FGD System Premises. . . . D-l
E Industrial Boiler Lime Dry Scrubbing FGD System Premises . . E-l
F Description of TVA and PEDCo Environmental, Inc.
Investment/Cost Components F-l
G Utility Boiler Lime FGD System Costs Comparison of TVA's Old
and New Premises and PEDCo Environmental, Inc. Costs .... G-l
Vll
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LIST OF TABLES
NUMBER PAGE
1.2.1-1 Industrial Boiler Limestone FGD System Capital Investment. . 1-7
1.2.1-2 Industrial Boiler Limestone FGD System First Year
Operating and Maintenance Costs 1-8
1.2.1-3 Utility Boiler Limestone FGD System Capital Investment
(1980$) 1-9
1.2.1-4 Utility Boiler Limestone FGD System First Year Operating
and Maintenance Costs (1981$) 1-10
2.1.2-1 TVA Utility Boiler Wet Limestone FGD System Investment
Bases 2-10
2.1.2-2 TVA Utility Boiler Wet Limestone FGD System Design Scope . . 2-11
2.1.2-3 Utility Boiler Wet Limestone FGD System Capital Investment
(1980$) 2-12
2.1.2-4 Industrial Boiler Wet Limestone FGD System Investment Bases. 2-14
2.1.2-5 Radian Industrial Boiler Wet Limestone FGD System Design
Scope 2-15
2.1.2-6 Radian Industrial Boiler Limestone FGD System Investment . . 2-16
2.1.2-7 Impact of Different Design Scope on TVA Utility Boiler FGD
System Capital Investment 2-20
2.1.2-8 Utility Boiler Limestone FGD System Investment on an
Industrial Basis 2-21
2.1.2-9 Industrial Boiler Limestone FGD System Investment Using
Industrial Installation Factors and Based on TVA Indirect
Investment Algorithm 2-24
2.1.2-10 Limestone Wet Scrubbing FGD System Installation Factors. . . 2-26
2.1.2-11 Industrial Boiler Limestone FGD System Investment Using TVA
Costing Algorithm for Both Equipment Installation and
Indirect Investment 2-27
2.1.2-12 Comparison of PEDCo Adjusted Capital Investment with TVA
Estimates for Comparable Operating FGD Systems 2-33
2.1.2-13 Comparison of Final Adjusted PEDCo Capital Investment to
TVA Estimates for Similar Operating FGD Systems 2-34
2.1.2-14 Equipment Summary for 62 Operational Utility FGD Systems . . 2-37
2.1.3-1 TVA Utility Boiler Limestone FGD System Economic Premises
and Assumptions 2-40
2.1.3-2 Utility Boiler Limestone FGD System First Year Operating
and Maintenance Costs 2-41
Preceding page blank
IX
-------
LIST OF TABLES (continued)
NUMBER PAGE
2.1.3-3 Radian Industrial Boiler Limestone FGD System Economic
Assumptions 2-45
2.1.3-4 Industrial Boiler Limestone FGD System First Year Operating
and Maintenance Costs Using Radian Material and Operating
Costs and Overhead Algorithm 2-46
2.1.3-5 Utility Boiler Limestone FGD System First Year Operating
and Maintenance Costs on an Industrial Basis 2-49
2.1.3-6 Industrial Boiler Limestone FGD System First Year Operating
and Maintenance Costs Using TVA Material and Operating Costs
Plus Overhead Algorithm (Radian Investment Basis) 2-52
2.1.3-7 Industrial Boiler Limestone FGD System First Year Operating
and Maintenance Costs Using TVA Material and Operating Costs
Plus Overhead Algorithm (TVA Investment Basis, i.e.
Installation Factors) 2-54
2.1.4-1 Summary of Limestone FGD System Cost Studies 2-59
2.2.2-1 Utility Boiler Lime Spray Dryer FGD System Capital
Investment 2-67
2.2.2-2 Radian Industrial Boiler Lime Dry Scrubbing FGD System
Capital Investment Estimates 2-69
2.2.2-3 Utility Boiler Lime Dry Scrubbing FGD System Capital
Investment on an Industrial Basis 2-72
2.2.2-4 Industrial Boiler Lime Dry Scrubbing FGD System Investment
Calculated Using Industrial Installation Factors (Radian)
and TVA Indirect Investment Algorithm 2-75
2.2.2-5 Industrial Boiler Lime Dry Scrubbing FGD System Investment
Using TVA Costing Algorithms for Both Equipment Installation
and Indirect Investment 2-77
2.2.3-1 TVA Utility Boiler Dry Scrubbing FGD System Economic
Premises and Assumptions 2-82
*
2.2.3-2 Utility Boiler Lime Dry Scrubbing FGD System First-Year
Operating and Maintenance Costs 2-83
2.2.3-3 Industrial Boiler Lime Dry Scrubbing FGD System First-Year
Operating and Maintenance Costs Using Radian Material and
Operating Costs and Overhead Algorithm 2-86
2.2.3-4 Utility Boiler Lime Dry Scrubbing FGD System First-Year
Operating and Maintenance Costs on an Industrial Basis . . . 2-89
2.2.3-5 Industrial Boiler Lime Dry Scrubbing FGD System First-
Year Operating and Maintenance Costs Using TVA Material and
Operating Costs Plus Overhead Algorithm (Radian Investment
Basis) 2-91
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LIST OF TABLES (continued)
NUMBER PAGE
2.2.3-6 Industrial Boiler Lime Dry Scrubbing FGD System First-Year
Operating and Maintenance Costs Using TVA Material and
Operating Costs Plus Overhead Algorithms (TVA Investment
Basis, i.e., Installation Factors) 2-94
2.2.3-7 Summary of Lime Dry Scrubbing FGD Cost Studies 2-99
3.1-1 1972 M.W. Kellogg FGD System Retrofit Study 3-3
3.1-2 Retrofit Factors From TVA Analysis (3.5% S Coal, 90% S02
Removal, On-site Solids Disposal) 3-5
3.1-3 PEDCo Power Plant FGD Capital Investment Retrofit Factors. . 3-7
3.2-1 Investment Retrofit Factor Evaluation 3-15
3.3-1 Capital Investment Components 3-17
4.1-1 Comparison of TVA and PEDCo Equipment Configuration and
Operating Conditions 4-3
4.2-1 Comparison of TVA and PEDCo Economic Premises 4-5
4.3-1 Comparison of TVA and PEDCo Capital Investment Algorithms. . 4-6
4.4-1 Design Bases for TVA and PEDCo Total Capital Investment
Comparison 4-7
4.4-2 500 MWe Lime Slurry FGD System Capital Investment (3.5% S
Coal, 90% S02 Removal, 1980$) 4-9
4.5-1 Comparison of TVA and PEDCo Annual Operating Cost and
Revnue Algorithms 4-10
4.6-1 500 MWe Lime Slurry FGD Annual Costs and Revenue (3.5% S
Coal, 90% S02 Removal) 4-12
4.6-2 500 MWe Lime Slurry FGD Annual Costs on Same Unit Cost and
Operating Basis (3.5% S Coal, 90% S02 Removal, 0.63 Capacity
Factor) 4-13
XI
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LIST OF FIGURES
FIGURE PAGE
1.2.1-1 Capital Investment for Industrial and Utility Boiler
Wet Limestone FGD Systems 1-13
1.2.1-2 First Year O&M Costs for Industrial and Utility Wet
Limestone FGD Systems 1-14
2.1.1-1 Limestone FGD Process Flow Diagram 2-3
2.1.2-1 Comparison of Total Capital Investment for Small
Industrial and Large Utility Boiler FGD Systems 2-8
2.1.2-2 Difference in Capital Investment for Utility and
Industrial Boiler Limestone FGD Systems 2-18
2.1.2-3 Impact of Major Equipment Components on Costs of Large
Utility Boiler FGD Systems 2-22
2.1.2-4 Impact of Using a Utility Indirect Investment Algorithm
on Small Industrial Boiler FGD Systems 2-25
2.1.2-5 Impact of Using Large System Installation Factors and
Utility Indirect Investment Algorithm on Small
Industrial Boiler FGD Systems 2-28
2.1.2-6 Comparison of All Cases for Limestone Wet Scrubbing
FGD System Investment 2-30
2.1.2-7 Equipment on 62 Operational Utility Boiler FGD Systems . . . 2-38
2.1.3-1 Utility Boiler Limestone FGD System First-Year Operating
and Maintenance Costs 2-42
2.1.3-2 Differences in First-Year Operating and Maintenance Costs
for Utility and Industrial Boiler FGD Systems 2-47
2.1.3-3 Impact of Putting Large Utility Boiler FGD Systems on an
Industrial Basis 2-50
2.1.3-4 Impact of Putting Small Industrial Boiler FGD Systems
on a Large Utility Boiler FGD System Basis 2-53
2.1.3-5 Impact of Putting Small Industrial Boiler FGD Systems
on a Large Utility Boiler FGD System Basis, Including
Investment 2-55
Preceding page blank
Xlll
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LIST OF FIGURES (continued)
FIGURE PAGE
2.1.3-6 Comparison of All Cases for Wet Limestone Scrubbing FGD
System First-Year Operating and Maintenance Costs 2-56
2.2.1-1 Lime Spray Dryer Process Flow Diagram 2-61
2.2.2-1 Differences in Capital Investment for Utility and
Industrial Boiler FGD Systems 2-71
2.2.2-2 Impact of Major Equipment Components on Costs of Large
Utility Boiler FGD Systems 2-73
2.2.2-3 Impact of Using Utility Indirect Algorithm on Small
Industrial Boiler FGD Systems 2-76
2.2.2-4 Impact of Using Large System Installation Factors and a
Utility Indirect Investment Algorithm on Small
Industrial Boiler FGD Systems 2-78
2.2.2-5 Comparison for All Low ,Sulfur Cases for Lime Dry
Scrubbing FGD System Investment 2-79
2.2.3-1 Utility Boiler FGD System First-Year Operating and
Maintenance Costs 2-84
2.2.3-2 Difference in First-Year Operating and Maintenance Costs
for Utility and Industrial Boiler FGD Systems 2-87
2.2.3-3 Impact of Putting Large Utility Boiler FGD Systems on
an Industrial Basis 2-90
2.2.3-4 Impact of Putting Small Industrial Boiler FGD Systems on
a Large Utility System Basis 2-92
2.2.3-5 Impact of Putting Small Industrial Boiler FGD Systems on
a Large Utility Boiler FGD System Basis, Including
Investment 2-95
2.2.3-6 Comparison of all Low Sulfur Cases for Lime Dry Scrubbing
FGD System First Year Operating and Maintenance Costs. . . . 2-96
xiv
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VOLUME II
INTRODUCTION
There is a growing concern about the acidity of precipitation in the
northeastern United States and Canada. Acidic precipitation is thought by
many scientists to kill aquatic and plant life, damage crop-growing soil,
and accelerate erosion and damage to buildings. Although the mechanisms
producing acid rain are not clearly understood, sulfur dioxide (SO.) and
oxides of nitrogen (NO ) are thought to be the precursors of the chemicals
X
that cause acid rain. Large quantities of SO. and NO are produced by
£ X
various combustion and non-combustion processes in both the utility and
industrial sectors. 1 Reducing these SO. a
fc
should reduce the potential for acid rain.
industrial sectors. 1 Reducing these SO. and NO emissions to the atmosphere
fc 2C
Because this concern is increasing, the United States Environmental
Protection Agency (EPA) initiated a multi-phased study of the acid rain
problem. As one part of Phase I, Radian Corporation investigated
SO. emissions and controls in the industrial sector, while Teknekron, Inc.
made a similar study of the utility sector. The results of these studies
would provide direction for additional phases. The objectives of the
later phases are to investigate SO. sources in more detail than Phase I,
to investigate NO sources, and to model source/receptor relationships.
In support of the Phase I efforts, Radian Corporation was asked to
provide a consistent set of capital investment and operating costs for flue
gas desulfurization (FGD) systems applied to both industrial and electric
utility boilers. Since existing SO. sources are the primary targets for
reducing the impacts of acid rain, retrofit factors as well as the cost for
-------
FGD systems applied to new boilers were addressed. This report summarizes
the results of that cost work.
The cost estimates used as the basis for this study are:
• Utility boiler FGD systems by TVA and PEDCo Environmental, Inc., and
• Industrial boiler FGD systems by Radian Corporation.
Wet limestone scrubbing and lime spray drying FGD systems were evaluated.
The U.S. EPA has recognized that there appear to be discrepancies in these
published cost estimates in two areas:
• Utility boiler limestone FGD system costs prepared by TVA
and PEDCo Environmental, Inc., and
• FGD system costs in the capacity transition from industrial
boilers to small utility boilers.
To achieve the primary objective of the study (provide a consistent
set of capital investment and operating costs for FGD systems retrofitted
to existing boilers), the following issues were investigated:
• The apparent discontinuities in both FGD system capital
investment and operating costs as a function of boiler
capacity in the region between industrial boilers and
small utility boilers,
• FGD retrofit factors applied to existing boilers based
on published reports, and
• The differences between PEDCo Environmental, Inc. and
TVA cost estimates for utility boiler FGD systems.
-------
The above costing issues are examined on the bases of design scope,
costing factors*, year of costs, inherent strengths and weaknesses, and
published data of actual system costs.. Recommendations are made for the
cost bases to use in further acid rain studies.
This report contains two volumes. Volume I is divided into four major
sections. Section 1 contains an introduction and summary of results. The
three issues described above are addressed in Sections 2, 3, and 4, respec-
tively. Volume II, Appendices, contains the technical support for the study.
*For equipment installation, indirect investment, etc,
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APPENDIX A
UTILITY BOILER LIMESTONE FGD SYSTEM PREMISES
MATERIAL BALANCES
EQUIPMENT LIST
CAPITAL INVESTMENT ESTIMATES
ANNUAL O&M COSTS
ANNUAL REVENUE REQUIREMENTS
A-l
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APPENDIX A
TVA estimated the capital and operating costs for new limestone FGD
systems applied to 100, 250, 500, and 1000 MW boilers. The computer
output from TVA's cost estimating program for each case is presented in this
Appendix. There are 16 pages of output for each case, and the following
information is included:
1. Plant heat rate
2. Coal analysis
3. Flue gas characteristics
4. Limestone analysis
5. Complete FGD system design scope
6. Material and energy balances
7. FGD system operating conditions
8. Sludge pond design criteria
9. FGD system process stream characterization
10. Equipment list and costs
11. Equipment installation costs
12. Indirect investment costs
13. Annual O&M costs
14. Annual revenue requirements
In order to facilitate use of these outputs, the process capacity
(100, 250, 500, or 1000 MW) is stamped on each page.
A-2
-------
100 MW
EXAMPLE I'TlllTVj HHESTUNE* HEW ECUIIUMIC PREMISES CASE O08
••• INPUTS •••
BOILER CHARACTERISTICS
MEGAVATT! «—lo*. UTILITY suit - NEH PONB BUM
BOILER HEAT RATL • 9500.
EXCESS AIM • 191 PERCENT* INCLJDIUB LEAKAGE
HOT GAS TEMPERATURE • JUO» OEG F
CUAL ANALYSIS* IIT • AS FIRED I
C H 0 M S CL ASH H20
66.70 l.BO 5.60 I.la ».i6 O.ltf il.in A.BB
1ULFUR QVERIItAD • 9».Q PERCENT
ASM avERHEAU • 10.0 PERCENT
HBATIM6 VALUE OP COAL • 11700. BTU/LS
JPFICIE«V, EMISSION
ISSION,
S/M BTU
HFHOVAL«II
UPSTREAM Of SC»U»BtR 99. T 0.03
M1THIN SCBUUBER »0.3 0.0»
COST UP UPSTREAM FLYASH REMOVAL EXCLUDED
AL.KAL!
LIHESTOIIE I
97.iS HT t OHV BASIS
*4
J7o
SULUhLE MGU • U.
HURTS • Z.8»
MOISTURE CUllTENT • SiOO LI HtO/100 LBS DRV LIMESTONE
_..._.-
LIHEiTUHt bECRCE OF OP I HI) FACTOR • I ti
PLV ASH I
SULUHLE CAO • fl.O Ml S
SOLUBLE MUD • 0.0
RAH HATEHI«t HAIIIILIHIf
NUHBER OF REDUNDANT ALKALI PREPAR^TIUN UNITS •
Reproduced from
best available copy.
A-3
-------
100 MW
1CMJBBER SYSTEM VARIABLES
NUMBER Or nrfcRATIHn SCRURnlllG TR«|r'5
NUMBER OF REDUNDANT SCRUBBING TRAINS •
NUMBER UP BIDS •
NUMBER OF GUIUS •
HEIGHT np SPHEPES PER BED • ».o MICHES
LIOUID»TO«CAS RATIO • tit GAL/1000 ACF(SATD)
SCRUBBER GAS VEtut|TV • 12.3 FT/SEC
INDUCED DRAFT SCRUBBER FAN
ICRUBBCR PRESSUHE • 1*.7 PS IA
STUICHIQHETHV • 1.29 HOLE CAC03 ADUCD AI LIMESTONE
PER HOLE (S02«aMCLI ABSORBED
I0a REMOVAL • 90. PERCENT
INTRAIMHEHT LEVEL • O.iO XT 1
EHT RPSIPENCE TINE • 12.0 MIN
SOI OXlOltEO Iti 5YSTJH • 3O.O PERCfcHT
sntina IN RtciRciiitTgn SLURRY • 15.0 MT «
SOLIDS OISPUSAL SfSTCH
COST UF LAMP • 80OO.OO DOLLARS/ACRE
SOL IPS IN SYSTEM smoue DISCHARGE • »».o WT »
MAXIMUM POHO AREA • 9<99. ACRES
MAXIMUM EXCAVATION • M.oo FT
PUTAltfE TO POWi • 5ZBO. FT
POMP LlHfO MITH 12.0 IHCHES CLA»
STiAH REMEATER MN-tlMtl
SATURATED STEAH TF»:PERATUPE • *7o, DEC F
HEAT OF VAPURIZATIPN OF STEAM • 751. RTU/LB
OUTLET FLUE GAS TEMPERATURE • 179, bEG F
SUPERFICIAL GAS WEI IK i TV IF ACE VCLIICITVI • ««o FT/SEC
A-4
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100 MW
EXAMPLE UTHITYj L1MESTUNF, NCX fCflHOMIC PREMISES CASE 00>
••• OUTPIIIS •••
HOT C.AS TU 5CRUBBM
HOLE PERCENT IB-HHLE/HR
CHI 12.33B
HCL 0.006
sos olli*
U2 9.960
HI 79,227
H20 6,694
Sat CONCENTRATION
0.4S09E*04
0.2200E*01
0.78>Ji»02
0.2P32E*0*
U.27*9E»OS
0.2O2E«04
IH &CRURHER IMLET (US
Li/HR
0.19B9K+06
0.|33IE«02
o.Joiie+oJ
0.6J02£*g9
0.776U+54
0.43B1E»0»
^ ii«..ggn.
/ MILLION ITU
FLYASM t-HISSinil • 0.03 IBS/MILLION »TU
• 0.019 GRAIHS/SCF (UtTI OR 2*. LB/HR
SOLUBLE CAP HI FLY ASH • 0. LB/HR
CAP 111 FLY AS
rid) |h l^tV Ai
AH •
HOT GAS FLOW RATI • .23096*06 SCFH (60 DEC fi 14,7 PSU)
• .13746*06 >CFH IJUO. DEC t, t».T PSU>
CORBESPO»4DHI6 COAL FIRIH6 R«TF • .BUOE*09 LB/HR ._
HOT CAS HUMIDITY • O.P42 LB H20/LP ORV CAi
HBT BULB TEMPERATURE • I2<. OE6 F
MET GAS man
HOLE PCHCtNT LB-MOLE/HR . LB/HR
ejH 11.716 0.*9B»i«Q4 0.1017E+06
"HElO.POO0.1M)t+UO0«4179E*01
SIM 0.020 0.7B29E+01 0.5019E+03
02 9,ln9 0.2021E1
H2 70.300 0.27»9E<
»E*09 0.770*6*06
H2I) IZV7'«9
S02 CUMCEHTRATIUN |H SCRUBBER UJTLET DAS • 200. PPM
FLVASH Enissiuri • n.oz IBS/MILL inn BTU
• 0.007 URAIIIS/SCF CKET1 OR 19. LB/HR
TOTAL *ATER PtC»UP • 9>. r.PH
MET OA5 PLOW RAT" • .2*7OF.»06 StfM (60 OEB ft 14.7 PSIAI
• .27796*06 ACFM 1124. UE6 F» 14.7 PSIAI
WET CAS SATURATION HUMIUITY • 3.11*7 LR H2Q/LB nRv CAS
Reproduced from
best available copy.
A-5
-------
FLUE GAS TO STACK
100 MW
PERCENT
LH-HOIE/HR
LB/HR
f" 4»**T
HCL O.nun
•WWW-
•tf-
O.flf
0.79?9E»Ul
•*
I.lbO
0.2021E*04
q.274«E»OS
04«0i>
HJO
SPECIFIED 5P2 DCHUVAL EFHCIrNCY • 9O.O I
CALCULATED >U2 EMISSION • Otli POUNDS FEII HILLIUK »TU
CALCULATED SUZ CnNCtHTKATTON IN STACK CAS •
200. PPh
FLVASH EMUSIDM •
BTO
TI.
STACK CAS FlOW PATE •
'
,2*7*E*0» SCFN (60 DE6 ft 1».7 PSIA)
.30ME+06 ACFN 1178. PEB ft 14.7 P1IAI
STEAH HEHEATIK
JUPEHFUUI 6A3 VEHIC1TV (FACE »El"CITV> • 13.0 FT/SEC
SQUARE PIPE PITCH • » TIMES ACTJAt PIPE 0.0.
SATURATED STEAH TEMPERATURE • »70. DEO F
OUTLET FLUF CAS TEMPERATURE • 173. DtO F
REQUIRED HEAT INPUT TO REMATCH • 0.13i6E*0« STU/H»
STEAH CnHSUIIFTlllH • O.l78»j»05 LSj/HR
OUTSIDE PIPE PRESSURE DROP,
ESSUH
I. IUU
HEAT TRANSFER
OIAIIETCR* Hit
I.no
a
0.6»
DEC F
RfcHEATER
OUTS ID
t W
S(l FT
Pf
1UMBER OF
PIPES PER
BANK
NUMBER
-£f_
(RUM
AKEA«
PER TRAIN
PER
TRAIfl
BANKS IRUHS)
Pt» TRAIN
I HE OMt L
0.12Z7E
COMTEN
TOTAL
0.7058E«03
bi
A-6
-------
100 MW
HATER BALANCE INPUTS
^T'~T "• •"•"• "" — —
RAINFALL'IIH/VCARI
POND SECPAriE(LII/SECI«10*«B
PUHD EVAPORATION! IN/YEAR)
SO.
94.
12.
HATER BALANCE OUTPUTS
HATER AVAILABLE
RAINFALL1 '
ALKALI
TOTAL
til.
1.
ii2.
GPN
PfH
GPH
119469.
461.
119946,
LB/HR
LB/HR
LB/HR
HATER REQUIRED
HUN ID IP 1C AT ION'
ENTRAPMENT
DISPOSAL WATER
HVDRATION NATFB
CLARIFIER EVAPOKATIUN
POHO EVAPORATION
SEEPAGE
TOTAL HATER REQUIRED
NET HATER REQUIRED
*9.
»•
44.
*•
0.
199.
19.
926.
94.
BPN
CPN
GPN
OPN
WH
GPN
BPH
GPN
GPN
1126.
2217A.
1197.
0.
77934.
1*99B,
1*2709.
46763.
LB/HR
LB/HR
LB/HR
LB/HR
LB/MR
LB/HR
LB/HK
LB/HR
LB/HR
A-7
-------
100 MW
SCRUBBER SVSTEII
TOTAL NUMBER UP SCRUBBING TRAINS f'IPERATINB+REDUNUANTI • 1
tat REMOVAL • fOtO PERCENT
PARTICULATE RENUVAL IN SCRUBBER SVSTfN • 99,0 PERCENT
TCA PRESSURE ORUP ACRIISS I BEDS • 8,6 IN. H2I1
TOTAl SVSTE'1 PRESSURE DROP • l».7 IN. H20
OVERRIDE TOTAL SYSTEM PRESSURE DKUP • 20*0 IN. HZU
SPECIFIED LIQUIO-TO-GAS-RATIU
• • •* CAL/IOOO ACF(SATPI
LIMESTONE AUDITION • U,9214E«04 IB/tlR ORV LIMESTONE
SPECIFIED LINESTUM6 5TOISHIOHSTBV •
1.29 NOLI CACD3 AOOEO Al LIMESTONE
PER MOLE ISO»«»HCL) ABSOKBfO
SOLUBLE CAB FROM FLY ASN • 0.0 HOLE PER MOLE ISM+IHCLI ABSORBED
TOTAL SULUBLE nco
• o.o HOLE P«R HOLE iso»»tHCLi ABSORBED
TOTAL STOICmOHETRV
1.29
ABSIIRBfeD
SCRUBBER IHLET LIvUUR PH • S>66
HAKE Or WATER •
CROSS-SECTIONAL AREA PER SCRUBBER • STOi SQ PT
SYSTEM SLUOGF DISCHARGE
""" — -~- ••
SPECIES
CAS03 .1/2 M2U
CAS04 .2H20
CACD3
INSOLUBLE*
H20
CA»*
M6«*
SIM—
Iii4—
CL-
••"•"••"
LB-HOLE/HR
o!2n8RE«02
0.17B8E402
0.1231E+04
0.|384E«01
0.0
0.3637E-01
0.2999E«00
O.Z176E+01
SOLID
COHP.
LB/HR MT S
0(6363E»04 12.92
0.35'Mi*0* 29.88
0.17901*04 14. 88
0.2T13E*O3 2.31
0.2218E»01
0.0
0.2911E*01
0. 24«»2l! ««2
LIQUID
CDMPi
PPM
148*.
0.
130.
1116.
149J.
TOTAL QISCHARCr PLOM RATE • 0.3436E«O» LB/HR
TOTAL niSSfllVBP SUM OS IN DISCHARGE LIOU1D • 7li».
DISCIURGE LIQUID PM •7.J7
Reproduced (rom
best available copy.
A-8
-------
100 MW
SCRURBER SLURRY
RLEED
.._»_ —
SPECIES
CAS03 .1/2 M2U
CASU4 .2H20
1MSOLUBLES
H2U
£***
J03--
CL-
AO.
TOTAL FLOH RATE
LB-HOLE/IIR
0.493(>E>02
!:ll!!!I!:
0.3796E«0«
0.4223E«01
0.0
O.U10E+00
0.7917E*OO
0,6639E»01
0.0
• O.B01BE+05
• 146.
LB/HR
0,6J65E»0*
O.399*E»O4
0.2T73E*OS
0.6766E*05
§.1693E*03
.0
o!z3S«E»03
O.U
LB/HR
GP1
•
TOTAL SUPERIIATE
SPFCIEf
H20
SOI—
SO*—
CL-
An»
TOTAL FLHH RATE
1UPERNATE TO WFT
PETURII
LR»HULE/HR
0.3B26E*04
0.4303E+OI
0.0
O.I130E«OO
0.8069E«UO
O,676*t*Ol
0.0
• P.6943E»OS
• 139.
BALL HILL
LB/HP
0.6B93E»09
0.0
0.9050C*Ol
0.77«7E«02
0.Z37Vt*0>
0.0
LB/HR
£••4
SPECIES
H20
CA»*
HG++
S03~
so*—
CL-
Ab.
TOTAL FLOU RATE
Lft-HQLE/IIR
0.33B1E*O3
0.3R07E*00
0.0
0.10UOE-OI
0.7139E-01
O.S984E*00
0.0
• O.6143E»04
• 12.
LB/HR
0.192ftE»02
0.0
0.8007E«00
o!2l21E»02
O.O
LB/HR
GP4
A-9
-------
100 MW
LIMESTOllE 1LUBRV Ttltl
SPECIES
CACH3
SOLUBLE NCO
INSOLUBLES
CA»«
MB*-*
S03—
CL-
AD •
TOTAL PIOM RATE
LR-NOLE/HR
O.B943E»U2
0.0
0.338SE.03
0.3B07EHIO
0.0
0.100»E»01
0.7133E-01
0.99B4C»00
0.0
• O.IS36E«05
IS/HP
0.0
Oi 262bi~*03
0.192»E*02
0.0
0.6B5«E»ni
o!o
LB/HR
GP1
1UP6RMATE HETURH TO SCRUBBER OR EHT
SPECIES
LB-NULE/HR LB/ttt
?!**
N6»*
S03—
S"-
.
O.J922E«01
0.0
0.1030E*00
0(7)3ZE»OO
0.6169E+01
0.0
8 .1972(403
!o
0.«Z49E*01
0. '06ZE*OZ
S.2IB6C«03
.0
TOfAt
RATE • n,632V6+05 LB/HK
127. OP1
RECYCLE SLURRT TO SCRUBBER
SPECIES
IB-HOtE/HR LB/HR
CASH* .1/2 1120
CASIM .2H2U
C AC 111
INSOLUBLE;
HZO
CA»*
MC»*
ln!H
CL-
AOi
TRTAL FLOW RATf
0.9I6SE*04
0.1B79E»0«
oT3937E»0
-------
100 MW
CAS cnniiHG SLURHV
SPECIES
LB-Htll.t/HR LB/HR
JM" •!/?
{ASM .SHZI
U20 0.37»?E*0
inaai 8;
s-«
•fc
JU°_
0.6T
-ii
A
AC01
0.1)611*03
36»E*03
NSOLUBLES
0
$03—
.
o.o
0.8*S9E»00 0.6772E«02
0.603iE*01 0.57976*03
CL-
AD*
0.0
0.0
TBTAL FLOM RATF • i».>mE*06 LB/HR
• I».61HE<
• llio.
OP1
A-11
-------
POND DESIGN
100 MW
OPTIMIZED TO HtNIHIZE TOTAL LOST PLUS OVERHEAD
Piirm 01 Mi us inns
— - — — — —
DEPTH OF POND
DEPTH OF EXCAVATION
LENGTH OF FUND PERIMETER
LFNGTH OF pIVinSR
LENGTH pgRiniTEli trN6E
IT.'S FT
4.69 FT
7»76t FT
14*1. FT
8vi7. Ft
AREA OF BOTTOM
HH»*
BH gf PON!;
ILS
161 •
THOUSAND TDI
MI 111"!*.".1 yM
47.THOUSAND V02
AIM STORAGE
*7.
I*
AREA OF POND SITE
»92.
USAND V01
AREA OF PONO SITE
VOLUHE OF EXCAVATI1H
VOLUHE OF RECLAIM STORAGE
VOLUHE OF SLUDGE TO BE
DISPOSED OVER LIFE OF PLANT
iaa.
• »4,
263.
148o!
ACRES
THOUSAND VD3
THOUSAND V01
TIlUUSANb V6i
ACRE FT
POMB COSTS ITHDUSANB8 OF DOLLARS I
LABOR
MATERIAL TOTAL
NG
,»«t
162*.
i;»i
1624.
«45.
DIKE CONSTRUCTIIIN
645.
LINlNGt 12. IN. CLAY)
snnoiHG oiur MALLS
SOAO cbiiSTRUCTIofl
PERINETER OUSTS, FENCE*
RECLAIMATIOH EXPENSE
MONITOR WELLS
412.
H.
.
44.
32?:
4.
28.
7.
19.
4.
432.
70.
iv.
1».
121.
a.
TRUCTION
1S40.
127.
612.
POND SITE
OVERHEAD
TOTAL
4279.
1132.
7411.
A-12
-------
100 MW
I»AMPLE UTILITY! L|HESTOHE« NEH ECUMDHIC PREMISES
CASE 008
UPSUl CONTENT "IBM
ASH CONTENT mil
BTU RATIIIGJ
BOILER TVPil
NO. Of SCRUBDiRSI
SCRUBBER VELOCITY IFT/HH
PLANT SUE iHWII
IIPEHATIMf HRS/VRI
puwlnft Ml icU/iooo AlHi
SCA RATIOl
(ACfUAL SO.FTt/CALC. JO. FT.)
PARTICULATk REMOVAL
9.3U
li.lo
1 1700
0»Y PULVERIIED COAL
\
790.0
10U
*711
2U.OO
1.1.10
INVESTMENT AND OPERATING COST
P ARTICULATE EH1SSILN PECULATION ILB ASM/HILL mil RTUII
FlUC 6AS tEHPERAfilRE UfllPl IPII
FLUE GAS TEHPERATURE IliOll Ifli
CUST OF ELECTRICITY 11/KkHPJi
CUiT fU iTEAH jl/THHUSMID LBII
rilSSI VE/6 tAPlTAL Ibifat FAMIIRi
BACHOUSE RATIO |OPfR. SO. FT. /ACTUAL Sq.FT.n
•AC COiT U/SQ.FT.II
BAG LIFEIYEARill
FLUE GAS REHEAT TEMPERATURE IF II
CHEMICAL ENGINEERING PLANT IHIUXI
O.lll
366.6
TOO.O
0.03
I. 00
o.iau
o.no
0.70
a. 00
17S.
26J.O
ELECTROSTATIC PRECIPlTATORS
•
REQUIRED REHUVAL EFFICIENCV (III
DRIFT VfLnCITy IfT/MJI
SPECIFIC tOfflCTinN IREA (So.FT./AtMn
COLLECTION AREA (S4.FT.il
TOTAL cnaniu PIIWER («wn
AUXILIAHV POUFR IKMII
FAN PUH!R JRCii
PUHP PUMER IKkll
TOTAL PU&EH lUil
OPERATING AIR/CLUTH RATIOl
INSTALLED AIR/CLOTH RATIOl
REQUIRED PRESSURE ORIIP 1 INCHES II
D!AHETEI> IFEETII
REQUIRED REHEAT IPIU/HRtl
STEAH SUPPLV/VR ITHflUSAND LHII
INSTALLED COST (197* PULLARSH •
FIRST VEiR CAPITALIZED COiTI »
ANIIUAL POWER CtlSTl 1
ANHUAJ. OPEHATII'C AMD
IIAIHTENAHCE COST ll»7» DOLLARS)! »
REPLACEMENT cftST Cl«9 b&LLAftSil
ANNUAL REHEAT COSTI
COLO
99.70
H-l4
.f«
91711.4
III. 7
H.4
.«
2J>.»
1.0
11M24SI
IB916V
mis
«6117
HOT
99.70
j°-go
J?».S9
19*46 2.1
202.6
191.6
la. e
416.11
1.0
• 2921863
» 92»«11
• 99V27
» 69213
BACHOUSE FABRIC FILTERS
99.70
171226. B
168.9
16*. 6
412.*
2.4
1.9
5.0
1 427TI9I
1 771120
1 99191
* 49JOT
I 93076
SCRUBBERS
99.70
32UB.O
691.6
3B6i.S
60. B
17
120S3B11.0
6756B.2
t S91T090
» 1067041
» 929800
6 310499
» 13S130
TOTAL ANIIUAL COST I
ANNUAL IZEO COST OF PCWERimLLS/HMHMI
16634I
0.77
6961173
1.3V
I.9T
2042476
4.32
-------
100 MW
KAN IIATEMU HANDLING AND PREPARATION
ITEM
UESCKIPTIU1
HU,
HATEHIAL
LABOR
MOBILE EQUIPMENT
RECLAIM HUPPER
RECLAIM VIBRATING FEEDER
RECLAIM BELT CUIIVtVOft
RECLAIM INCLINE BELT CONVEYOR
RECLAIM PIT DUST COLLECTOR
•(CLAIM PIT SUMP PUMP
Rf CLAIM BUCKET ELEVATOR
FEED BIN
BIN HEIGH FEEDER
GYRATORY CRUSHERS
•All HILL DUST CULUCTPRS
BALL HILL
HILLS PRODUCT TANK
HILLS PRODUCT TANK AGITATOR
HILLS PRODUCT TANK 5LUKUV
PUMP
SLURRY FEED TANK
BUCKET TRACTUR
TFT Hint* 4.2SFT HT* ZFT
NIDI BIITT3h. CS
l.SHP
100FT* 2HP
I91FT/ 40HP
POLYPROPYLENE BAG TVPI
60GPN. TOFT HEAD* SHP
90FT HIGH* TSHP
IJFJ BIA. I1FT STRAIGHT
llBE BT* lUVlRED* H
14FT PULLEY CENTERS* 1HP
TSHP
PUIYPRUPTLKNE »RG TTPB
2200 CFHf 7.3HP
».»TPM, kOO.HP
1500 GAL IOFT OlA/ 10FT
HJi FLAKEGIASS LINED CS
IOHP
I«.GPH« »OFT HEAD*
l.Hpj 1 OPERATING
AND I SPARES
10237
1
1
1
\
I
I
I
I
|
1
1
1
I
I
I
1
1
6S1T6,
lots.
46S7.
19618.
JI661.
664B.
aoTl.
*9>9|.
12170.
14169.
1490*.
M4*(
1*7071.
192*.
6J19,
4>10.
.
3170.
e.
67.*.
412.
11BB.
1U24.
2160.
64d<
5309.
6643.
641.
17*2.
216P.
16196.
102*i
p
1912.
1912.
42V7.
LINED CS
SLURRY FEED TANK AGITATOR
SLURRY FEED TANK PIMPS
TOTAL fOUIPHENT COST
19. HP
|9.GPHi 60 FT HEAP*
l.HP< 1 UPiRATING AND
z SPAR!
I
i
1082).
679S.
401634.
bj«.
226R.
347ZB.
A-14
-------
100 MW
SCRUB? IHG
INCLUDING I OPERATING AND 1 SPAKE SCRUBBING
IT(N
INSCRIPTION
TRAINS
UO. MATERIAL
LABflR
I.D. PAHS
SHELL
RUBBER LINING
HIST ELIMINATOR
SLUftRV HEADER AND NOZZLES
HioS
SPHERES
TOTAL TCA SCRUMER CllSTS
REHEATERS
SOnTRLDMERS
EFFLUENT HOLD TANK
EFFLUENT HOLD TANK ftGITATUB
CUULIN6 SPRAY PUHPS
20.0IN HJO. KITH 126B.
HP MOTOR AND UHIVE
•
20I4B9.0ALJ 3><>FT 01A*
13«>FT Mr* FLAKEGLAIS-
LINEO CS
17. HP
1110. GPN IOOFT HEAD*
2 1992064.
«S4999,
442949.
85091.
1046T9.
1*2020.
391O71.
2 1920361.
I 719393.
24 101141.
t B969S.
2 11B996.
4 11919.
2169T.
110173.
49007.
604K6.
70011.
1(862.
970tf.
91. HP* 1 OPERATING
A;
-------
100 MW
HASTE DISPOSAL
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
ABSORBER SLEEP RFCE1V1HG
TAM<
10320. GAL* 16.ZFT DIA«
M.8FT Hf» FLAHCLAIS-
17896,
M266.
ItEEO TANK AGITATOR
20Z19.
1601.
PONO ftlO SlUHRV
1*6.CPN« 110. FT HfAO %
4.HPi 2 OPERAT1HO
Z S9ARE
11702.
1991.
THD
SUPERNATE PUMPS
)99.CPN> T9J.FT Nfio* i
ll.llPf I nPERATINO
AND 1 SPAKE
TOTAL JQUIPMtNT CD1T
»99»«.
I07J*.
A-16
-------
100 MW
I
I—*
-^1
LlneST'lNE BLURRY PMICESS — BASISI I OP 1H UNIT. 19B1 STARTUP
PROJECTED CAPITAL IIIVESTHfllT RfOUIRtlltNIS - fcXACPLE UTILITY* LIMESTONE* HEM CCUhllHIC PREMSE&
-
INVESTMENT.
RAU MATERIAL
HANOI ING AND
PREPARATION
THOUSANDS UP
SCRUBBING
1*PU DOLLAR!
WASTE
DISPOSAL
Tiirti
CASE 009
DISTRIRIITIOU
f me em
at oihct
IHVESTHEiiT
EQUIPMENT
LABOR
PIPING
MATERIAL
UsBS
OUCJUIJRK
HAtEktAl
LABOR
FOUNDATIONS
MATERIAL
LABOR
POND CHNSTRUCTinil
STRUCTURAL
MATERIAL
ELECTRICAL
MATERIAL
LABOR
INSTRUHENTATION
MATERIAL
ABQR
BUlLOIUGS
MATERIAL
LABUR
SERVICES AND HISCELlAHEItUS
SUBTOTAL DIRECT INVESTMENT
ENGINEERING UESir.N AND SUPERVISION
CONSTRUCTION EXPENSES
CONTRACTOR FEES
CONTlNliEMCV
SUBTOTAL FIXED INVESTMENT
ALLOWANCE FOR STARTUP AND NIIDlFICATIIIIlS
INTEREST DURING CIlllSTHUCTinh
SUBTOTAL CAPITAL IMVLSTHSH1
I AMD
MORKINB CAPITAL
B3*
,.. '
B6.
0.
0.
lia.
lot!
0.
H.
.
94.
176.
49.
7.
14.
I9'
Si.
1738.
196.
271.
•7.
452.
2711.
209.
4o7.
3327.
9.
aa.
4600.
371.
lisa.
292.
746.
988.
».
.
O.
m.
.
223.
444.
297.
41.
0.
276.
9199.
•46.
1904.
470.
2444.
1466).
IIZ8.
2l99.
17940.
1.
477.
60.
21.
4)2.
186.
0.
0.
H.
!
3667.
1-
I.
122.
297.
9.
1.
0.
• o.
1*7;
9011.
491.
802.
1303.
7820.
601.
1171.
9J95.
624.
294.
9191.
4*6.
1RBA.
924.
saa!
169.
423.
»667.
142.
213.
439.
B76.
315.
97.
14.
13.
47*.
16149.
1493.
2»a*.
807.
4199.
2S192.
1918.
1779.
30909.
63*.
oZc.
31.9
2.8
1L.7
3.2
4.6
3.6
1.0
2.6
22.7
0.9
ill
2.7
9.4
2.0
0.4
0.1
O.I
2.9
100.0
".0
16. 0
9.P
26. 1)
1S6.0
12.0
2J.4
191.4
3.9
9.1
TOTAL CAPITAL |tiVEST"FNT
3424.
18468.
_U>473.
32363.
200.*
-------
100 MW
LlHESTUNE SLURRY PROCESS — II AS I SI 100 1H UNIT. 1911 STARTUP
PROJECTED REVENUE REMUI*LHE>'T* - EXAMPLE UTILITY* LIHESTUNEi HEW iCfltlOHIC PRtMISEl
CASE oat
O3
DISPLAY SHEtT FOR
AMUA.L UP E RAT
IT Fg« VfftR* L
'IUN KH-HR/KM • V
Til - 0.34 c«p factor
6.1)1 TtMS PER HOU*
TOTAL CAPITAL INVESTMENT
OBr
8IJ93000
TIJT4L
ANNUAL IHUMTITV
UHII CUSI»»
COST,*
DIRtCT COSTS
il.B K TONS
».00/TON
SUBTOTAL «iAW HATER IAL
ClIIIVFRSlO'l COSTS
OPERATIHC LABOR ANO
Supervision
I3T60.0 HAH-IIR
U.Stl/MAN-HR
mooo
ilEAH
PROCESS WATER
ELECTRICITY
MAlllTEHMICF
LABUR AND MATERIAL
AHALYSES
•2170.0 K LB •
16160.0 K CAL
90187*0.0 KWH
3060.0 HR.
ItOO/K IB
0.1I/K GAL '
O.Of/KMH
•x
17.00/HR
I6STOO
3100
163600
1108600
92300
SUBTIUAL CO'lvERSintl COSTS
SUBTOTAC OMECT COSTS
H39500
INDIRECT COSTS
OVE
LAIIT AUD AuMIUISrt'ATlVk ( 00.01 (IF CDNVERSIUN CIIJT5 LESS UTILITIESI
FIPST
LEVELllFD CAPITAL CHAR6fcS»
UPtf.ATINC ANU IIAlNrENiilCE COSTS
UF TOTAL CAPITAL IHVESTHtNT>
Z7J9JIOO
FIRST YEAP AMUUAL RgVEU'JE REQUlREMtMTS
7496A60
EQUIVfltENT FIKST TEA* UHH RtVEKUE RiOUIREMEHTS* HlLLS/MH
LEVEUZED OPFIIAriHC AND HA|!
-------
250 MW
EXAMPLE UTILITY* LIHESTOHF, NEM fCIII'IIIC PRLMI5FS CASE 006
••• HIPIITS •••
BHILER CHARACTERISTICS
HECArfATT* . «o: "Him BASIS - HEH POM) BASH
iniLER HEAT RATE •9500. BTU/KWM
EXCESS AIM • 39. PERCENT* IHCLJUIHG LEAKAGE
HOT CAS TEHHFkATllr.F • 300. UEG f
COAL ANALYSIS* NT * AS FlRCl) I
C H a N S CL ASH HZO
66.70 3.Bll 3.60 "1.10 a.3«» 0.10 H.10 4.OO
illLFUR UVERHEAO • 91.0 PiRCENT
AIM nVERHfcAO • tO.O PERCMT
HtATIHG VAtUF Of COAL • 11700. BTU/L*
EMISSION,
FLYASH REIIOVAL » LBS/H BTU
UMTRtAH IIP SCBUBBfP 99. T 0.01
WITHIN SCRUI'PEP »0.9 0.0»
CIKT UP UPSTREAM ftVA&M RtMOtfAL EXCLUDED
ALKALI
LIMESTHHt I
CAC03 . 97.15 HT t OKV BASIS
SHLUHLE MCU • 0.0
INERTS . 2.»»
MOISTURE CUII1EIIT • J.OJ Lh HZO/100 LBS DRV LIMESTONE
LIMF.STUNE HMIUHE55 HOHK INDEX FACTUR • IQiUP
OF GMINO FACTOR •T7I5
LIHEJTUHC
FLY ASH I
SULUBIE CAU •0.0 HT
SULUBIE UGU • 0.0
IflERTS • 100.00
RAH MATERIAL HAIIfiLllir. AhEA
NUMBER UF REbUlflAHT ALKALI !>R»PAkAT|llN UNITS •
A-19
-------
250 MW
ICPUBBtR SYSTEM VARIABLES
NUMBER Or OPERATING SCRUBBING THAI IIS •
NUMBER nr REDUNDANT ICRUBBTNG T**IIS •
HUH8ER UF BEDS •
NUMBER UF GRIDS •
HEIGHT llr SPHtRfi PER BID • 9.9 INCHES
IIQUIO-T[1-GA$ R4IIU • 99• GAL/lOOi) ACFISATD)
SCRUBBER CAS VEIDCITV • 12,3 FT/SEC
INDUCED DRAFT SCRUPBER FAN OPTION
SCRUBBED PKtSSURt • I*«7 PSIA
iTOICMIimETRV • 1.25 HOLE CAC01 AOOCD AS IIHESTOHE
PER 10LE
-------
250 HW
EXAMPLE UTILITY. LIMESTONEj NfcH ECPtlOHIC PREMISES CASE OOt-
^™~""""" ••• nurpuTS •••
HUT CAS TO SCRUBBER
RULE PFKCfcMT LBH4ULE/MP
C02 11.33*
HCL 0,00*
lot 6lll«
02 *'**P
N2 7S.227
H20 6.6S*
SOZ COHCENTRATlnN
O.U77E*OS
0.. 17266+01
0.1997E+0*
SiJOBPf*°i
.68V4E+0)
0.60H06+0*
IN SCRUBBER MLET GAS
LB/HR
Oi*96IE*06
o.2oaaE«o»
0.1ZS4E«0>
O.J626E«Ob
0.19262*0>
0.10«SE«06
• 2142. PPH
BTU
FLVASH fcHISSIUH • O.U3 LHS/MILLIUH BTU
• O.OU GKftlNS/jCf SIAI
CORRE5PUMOIIIG CUAL HRIII6 RATE • .20101*06 LB/HR
HOT CAS HUMIDITY • 0.0*2 LB MIO/LB ORV CAS
MET BULB TEIIPEBATUKC • 12*. OEC F
MET CAS FHIIH SCRUBBER
MOLF PFKCfHT . LB-HOLE/HR LB/HR
£02 11.716
CLo.nno
SII2 0.020 0.19>7E*02
02 5.169 O.SiJi4E+bi
1
N2 70.3UO 0.6874E*05 0.1926E+07
7*6*05 1*13
91E*OS0.2]
H20 12.799 O.U91E+OS 0.2294E+06
Sn2 CnMCEIITP.ATlUH III SCRUBRER OdTLFT GAS • 200. PPH
PLVASII EHISSIUM • 0.02 LBS/NlLLlUN BTU
• 0.007 CRAIIIS/SCF
-------
FLUE GAS TO STACK
250 MW
(
HOLE PERCENT
U-HIILE/HR
IB/HR
cnz
HCL
SOI
02
«
11.697
o.ooo
0.020
S.U6
70.138
0.11*66*05
0.28636*00
0.19S7E*02
0.50346*0*
0.687*6*05
0.5042C*06
0.10446*02
§.125*6*0*
.16116*00
0.1926E»07
SPECIFIEDSOZ REMOVAL EFFICIFNC* • 90tO X
CALCULATED 3UZ
Otai rfiunn r«R
CALCULATED 102 CnilCEIITMATION IN STACK CAS •
200. PPM
HYASH EMISSION • 0.02 L»«/HtlLlOH BTU
• 0.007 GRAINS/&CF (MET) OK
37. LB/NR
STACK CAS FLOH KATE • .OlB6F*06 5CFN (60 DEC ft l»,T PS1AI
• .755*6*06 ACRH 1175. DEC P« 14.7 PSlAt
STEAM REHEAW (IK-tINEI
SUPERFICIAL CAS VELOCITY (FftCE VELOCITY I • 25.0 PT/HC
SQUARE PIPP PITCH • 2 TIMES ACTJAL PIPE 0.0.
1ATURATEP STEAH TEMPERATURE « »70. [>CG F
OUTLET Hut 6A8 UMPERATIIP.E • 175. OEC f
jtiqUIREO HEAT INPUT TO REHEATER • Q.»»»9E»Ot BTU/HR
STEAM COHSUIirTIUM • Q.*3T9E*Q> LKS/tl*
B PIPC PRESSUHE PROP.
iieAT TBWISr E1T
ESSUR
I. HZO
COEFPICIEMT
"IT
O/HR FT2 DEC F
0.20966*02
DIAHETER*
• 1.00
Iff
U.65
REHEATER
(IUTSI06 PIPE
Af.EA« SO FT
PER TRAIN
NUHBbR UP
PIPES PER
HUMBtR OF
TRAIN
BANKS (KOWSI
PER TRAIN
0.1>33E*0*
TOTAL
91
A-22
-------
MATEK "ULANCE lllPUTS
HATER BALANCE OUTPUTS
HATER AVAILABLE
250 HW
RAiriFALLflH/VftR)
PUIID SEEPA6E((,H/SECI«|0»8
POND EVAPUFAT10NI1N/VEAMI
50.
SO,
12.
RAINFALL
*l**ll . '
TOTAL
1 *•*• 6PM
PH
..ll gPK
»9», GPU
in/HR
•m-
HATfR
IIUHIPIFICA1IIIN
2 It. CPH
119B4B, LP/HR
HYORATIUN »AT6P
6. GPU
1991. LB/HR
CLARIFIER FVAPORATION
0. GPN
0. LB/HR
TUTAL HATER REQUIRED
Tig. GPN
179771. LB/HR
MET VfATtR RtQIMHO
193. 6PM
U6476. LB/HR
A-23
-------
250 nw
SCRUBBER SYSTEM
TOTAL NUHBE* Of SCRUBBING TRAINS (flPERATING+REDUNUANTl • 3
102 REHIWAL • vOtO PERCENT
PARTICIPATE REHnVAl IN SCRUBBER SYlTSn •90,0 PFXCENT
TCA PRESSURE ORUP 'CROSS 1 BIOS •B.ft IN. Had
TOTAL lYSTEIi PRESSURE DRDP • 14.7 IN. HID
OVERRIDE TOTAL SYSTEM PRESSURE DROP • }0.0 IN. H20
SPECIFIEDLIOUIO-TU-GAS-RAT10
• 33. bAL/1000 ACP(SATO)
i
LIMESTONE JIOOITIDN • 0.230«E*03 L&/HR DRY LIMESTONE
SPECIFIED LIHrSTDMC STOICMIUHETRV • 1.21 HOLE CACOJ ADDED AS LIMkSTUNE
PER HOLE MO»»2HCL) ABSPRBEP
IDLUiLE CAP FROH FlY ASH • 0.0 HOLE Pt» HOLE
-------
250 MW
SCRUBBER SLUfcRV PLEEB
SPECIES
LB-NIILC/MR LB/i«
CAS03 tilt Hill
CASU4 .7M20
0.»
m&-*.
0.13716+03
CAC03
iNfOLUBLfS
E«0
B.93B9E*04oT
O.IOS6E+02 C.
H2U
CA+*
*
•WHHm-
MC**
Sill—
0.0
E«0
SIM—
0.1660E*0» 0.3884E*03
^
I7o
0.0
TOTAL FLdN RATE
0.2004E«06 IB/MR
164. CP1
TOTAL SUPERtlATE RETURN
SPECIES
LB-MULE/HR LB/HR
«"
MC»*
SOI—
•»=•
162BE*A
0.0
0.0
0.2670E+00
O.I90»E*01
U.1S9BE+02
0.0
.lB30Et
ADa
0.0
TOTAL PlUM R'ATi • O.I640E»06 LB/HR
0^
328.
SUPERNATE TO MET BALL MILL
SPECIES
H20
sos—
SU4—
CL-
AD*
TOTAL FLUN RAU
LP-HOLE/HR
0.7912E*03
U. 68971*00
0.0
0.233'E-OI
o!l!99E«01
0.0
• ' 29.
LB/HK
0.142»C«09
0.0
0.1871E*01
0. 16(^6*02
0.49SBP*II2
0.0
IB/MR
API
A-25
-------
LIMESTONE stuRPv Ften
250 NW
SPECIES
LB/HH
CACUS
0.2736f»03
0.0
;•; 8
E*03 0.
T*Ro"""™o7
0.223af*OS
t»
«r
c**
0.84ME*03
Hi
-»=•
•fch
*fc
>.233«E-010>IB71E»P1
0.166Bt*00 Q.i602E»02
».UV9E»O1 0.49!>«t»O2
AD*
0.0
0.0
TOTAL FlOM KATi » 0.16
/HR
lUPgfttUTt RETUHM TO StBUBBEB OH tHT
SPECIES
If-HUtB/HRIB/HR
HIO
C**«
*
92T4E*01
*
O.I93|i*02
0.ib/OE*ni
•fc"
HC**
SU4—
.0
0.2*
0.1«SSE«OI
£4
I7o
.516BC*03
TOTH FlUH KATI • 0.1*97E*06 IB/HR
• til. OP1
RECTCLE SLUKRV TO SCRUBBER
SPCCIES
IB-HniE/MR L8/HR
•fm
0«^6B7E*O^ 0«»»9|
~^^^^~^^^"™^""^"TiTyrT
,4*911*06
H20
CA**
HC«*
Sal—
fn»—
i-
An.
0.9B42E*06
0.1107E«04
0.0
U.2VOBS+OJ
0.2075E+03
0.1740E*04
0.0
O.I773E»OB
o!o
B(232bE»bA
O.I9<*3E*OS
o!o
TOTAt FLOW RATI » 0.2IOIi*C8 LB/HR
OP1
A-26
-------
HUE GAS cauLiNc SLURRY
250 MW
SPfCIES
LB-HOLE/UR LB/HK
CASH! .1/2 H20
CASH* .2H20
CAC03
INSiJlUBlES
H>0
CA+*
MG»»
S03~
S0*~
Cl-
0.9396E«03
0.39BOE*03
0.340«E«A>
0.71»BE«Oi
O.BO««E«02
0.0
U.2115E»01
O.I509E+02
0.1265E«01
0.0
0.12136*06
0.6«»OE«fl»
0.3»126»0§
O.»2»3t*0*
0.12906 »07
O.J226E»0«
0.0
0.169JE»0)
§.1449C»0«
•448611*04
0.0
TOTAL Pt-fm RATE
LR/HR
; "'twK4" w
A-27
-------
PQNO DESIGN
250 MW
OPTIHUEO TO NINIMlIt TOTAL COST PLUS UVtRMEAO
POHO DIMENSIONS
— - — —- — —
OfPTH MF POND
DEPTH nf EXCAVATION
LENGTH UP PUNU PERIMETER
LENGTH [IF DIVIDER
LENGTH PERIHETEil FENCE
!«.»» FT
4.26 fj
1169*. FT
2106. FT
12«Il. Ft
ARE* UF BUTTON
via.
THOUSAND 1DZ
EA OF PUNU SI
HI, THOU
>*3, ACRE!
RES
VOLUME UF EXCAVATION
THOUSAND VOJ
IF SLUDGE It
DISPOSED OVER LIFE OF PtAMT
»967T
1699.
KND
ACRE FT
FUND COSTS (THOUSANDS OF DOLLARS!
LABOR
MATERIAL TOTAL
CLEARING LAND 397.
EXCAVATION 121V.
DIKE CONSTRUCTION • 1633.
LIHIIIGI 12. IN, CLAY) 931.
SODDING. DIKE WALLS 71.
RUAU CONSTRUCTION }1«
PERIMETER COSTSj FFNCE* 63.
RECLAIMATIOII EXPENSE 64*.
NUN 1 TOR fELLS 4.
POND CONSTRUCT IUM 7035.
197.
121B.
1615.
46. tie!
10. 43.
126. 189.
H».
4. 8.
187. 7192.
LANU C'lST 122*.
FUND SITE
OVERHEAD
TOTAL
8419,
14997.
A-28
-------
NJ
250 MW
EXAMPLE umm» LUIESTUHEJ HEM tcnminic PREMISE* CASE one
NPSUL CONTENT l«|l
ASH enilTfHT U II
ITU RATHIGl
BOILER TVPEl
NO. OF SCRUBBERS 1
SCRUBBER VCLUCIIV IFT/MII
1 JlAHT Silt |HU||
OPERATING HPS/yftl
PUHPiriB RAH 1 LAL/IOOO ACFII
SCA RATIUI •
{ACTUAL SQ.FT./CALC. SQ.FT.]
PART Hill ATE HENUVAL
3.16
19,10
DRV PULVERUED COAL
ii
790.0
ZJO
4731
2H. OO
1.300
1
INVESTMENT AND (IPPPATING CUST
PARTICIPATE EMISSION PECULATION ILB ASII/N|LLinil MTUH
FLUE GAS TtHPERATUPE (COLOI IFII
FLUE GI.S UHPERATUPE lllOTI JDl
COST OF fllctftlClTV |i/KuHp.|i
CUST OF STEAN 18/THUUSAND LBll
FIRST YEAR CAPITAL CHARGE MLTIiRl
SAGHOIISE RATIU iaptR. SQ.FT. /ACTUAL SQ.FT. II
Al! CUST li/SQ.FT.II
BAO LirEIVEARSII
FLUE CAS PIHFAT TEKPERATUPE IFII
CHEMICAL ENGINEERING PLANT IIIOCXl
0,01
100.0
700.0
0.01
2,00
o.lBO
O.RO
0>70
1.00
I7».
269.0
ILECTRUlt AT K PReCIPITATlIRS
REQUIRED REhUViL EFFICIENCY 11)1
DRIFT WELOCITV JFT/Mll
SPECIFIC CnilECTIUII AREA (SO,FT./ilFH)|
COLLECTlliri ARfA (SQ.FT. II
TOTkL CCRDUA rUIR ikUll
AUXILIARY PdUER IKMll
FAN pnMER IPWIl
PUHP PlIWER (KVII
TOTAL POMEH (KV)I
(IP E RATING AIR/CLUTH RATIUI
INSTALLED AlK/dOTH RATIOI
REQUIRED PRISSllAE DROP (INCHFSII
DIAMETER irretn •• • »••
REQUIRED MMEAT IBTU/HRII
STEAH SUPKV/V* (THBulAHO Lttl
INSTALLED CUST 11*79 OMLLARSM »
FIRST 'YEAR CAPITALIIED COSTI 1
ANiUIAL POMEP tllJTl t
ANIIUAt npFr.ATlHft ANb
HA1HTINANCE COST 11979 DUILARSH I
RfFLACEHINT CUST (1979 DOLLARS)!
ANNUAL REHEAT COSTI
COLO
99.TO
27.19
ifT.f*
114281.6
lll.B
m.»
.6
692.7
l.U
1996969
641367
89347
76790
HUT
99.70
20.00
177.39
406199.2
906.4
424,3
ZO1.S
1112.2
1.0
6 61B300S
• IIB7499
» 19»42
» 119211
BAGHOUSE FABPIl FILTERS
99.70
411067.2
309.8
•60.0
969.1
?r»
1.9
9.0
8 9162336
1 1632274
» IJ1059
1 J76S1
1 132S64
SCRUBBERS
99.70
8020.0
1631.9
9691.4
60.8
30
12114344.0
Ui920.6
» 12732169
• 2296033
» 1324499
1 668121
» 337841
TOTAL AflHUAl CUST| { 807704 8 1498O60 I 1979948 I 4626496
AHHUALIIEP COST Of PUWERIIIILLS/KntiRn 0.68 1.23 1.67 1.91
-------
250 HW
PAM MATERIAL HANDLING AMD PREPARATION
ITEM
DfSCRIPTIUN
NO. MATERIAL
LAHOfi
NO* III EQU|PHE"T
RECLAIH HOPPER
RECLAIM VIBRATING FEIDER
RECLAIM BELT CUIIVEVOR
RECLAIM INCLIIIE BELT CONVEYOR
RECLAIM PIT DUST COLLECTOR
RECLAIH PIT SUMP PUttP
RECLAIM BUCKET ELEVATOR
PEED BIN
•IN UEIGH FEEDER
GYRATURY CRUSHEPS
•All H|ll DUST CIULECTOHS
•ALL HILL
HILLS PRODUCT TArm
MILLS PRODUCT TAW AGITATOR
HILLS PRODUCT TAHF HUfcRY
PUMP
SLU*RV FEED T*"K
BUCKET TRACTUR
7FT VIDE* 4.24FT MT» 2M
HIOF BOTTOM* CS
3.5HP
lOOfT* ZHP
193FT* »OHP
POLYPROPYLENE BAG TVPE
60GPNJ 70PT HEAD. 9HP
«OFT HIGH. T5HP
13FT DIA* 71FT STRAIGHT
SIDE lit* CUVEHill* CS
14FT PULLEY CENTERS* 2HP
79HP
PULVPROPYLEME BAG TYPE
2200 CFHj T.SMP
11.5TPH* 1S9.HP
1900 GAL 10PT OIA, IOPT
HT» PLAKEEUSS LINEB CI
10HP
4e.GPHf 60FT HEAD*
2.HP» 1 OPERATING
AND 1 SPA*tS
29I92.G4L* 1«.3FT DIA*
16.3FT HT* FLAKEGIASS-
1 69176.
1 1039.
1 4617.
1 19618.
1 B1661.
1 664B.
1 1071.
1 49991.
1 12370.
1 14169,
I 84904,
I M40.
I 162639.
1 3924.
1 6939,
I 46iO,
1 9691.
0.
679.
412.
11BB.
3024.
2160.
646.
990*.
6643.
648.
17*2.
2160.
18649.
3424.
U.I.
""'
7B96.
LINFD CS
SLURRY FEED TANK AGITATOR
SLURRY FEED TANK PUHFS
2B.HP
2«.Gi>n» w r\ ntAU>
l.HP* 2 OPERATING AIID
1 Z070I.
> 11400,
1641.
JfBU.
't SPARE
TOTAL EQUIPMENT COST
93B5B9.
62661.
A-30
-------
SOUBBMC
250 MW
INCLUDING2 OPERATING AND 1 SPAHE SCRUBBING TRAINS
ITEM
DESCRIPTION
HO. MATERIAL LABOR
1.0. FANS
10
MpKt m
1568.
I 16*9313.
3694*.
SHELL
MlStim*
SLURRV HEADER AND HOflttS
•Wfr-
_SLU
GRIl
* w— v vv
•Wttfc-
A79489.
IDS
SPMFRES
TOTAL TCA SCRUBBER COST*
1- 2749996. 192188.
REHEATER9
SUOTBLOMERS
EFFLUENT HOLD TAIIK
EFFLUENT HOLD TANK AGITATOR
COOLING SPRAV PUHPS
ABSORIIER RECVCLfc PUIifS
MAKEUP HATER PUMPS
291861. GAL* 39. OFT 01 A*
19. OFT NT* FLAKEGLASS-
LIHEO CS
66. IIP
13M.GPH 100FT HEAD*
64. HP* I OPfeHATINO
AMD 4 SPARE
9540. GPMf 10UFT HEAD*
442. IIP* 4 OPERATING
AMD i SPARE
Hfa.GPH* 200.PT HEAD*
7.MPf 1 IIP«RA+jHd
|
36
1
1
6
f
2
1283029.
191719.
196119.
208993.
91879.
919790.
19981.
77441.
90730.
121894.
49698.
16041.
9987d.
1742.
MID 1 SPARt
TOTAL EQUIPMENT COST
778549I.
642999.
A-31
-------
250 MW
WASTE IrtSPUSAt
ITIIT
DtSCRIPTIUN
IIU. MATERIAL
lAPUK
ABSDRftER BLEED RfCEIVI"G
TANK
6X096. 0*1* 17.JFT DIA*
33. OFT HT« FL*H6LAII-
LINED
20720*
163S*.
CS
ABSORBER BLEED TANK AGITATOR
18. IIP
21676.
1677*
PIINO FfEO SlURRV PUH»S
16*.CPM» 130.FT HEAD
22.IIP» I LIP8HATIN6
9108.
2980.
AtlO I SPARE
•UNO SUPERNATE POMPS
iie.cpH* 192.FT HEAD* 2
26.HP1 i OPERATING
939*,
102**
AND i SPARE
TOTAL EQUIPMENT COST
6IS9B.
12435.
A-32
-------
250 MW
>
u>
to
CI'MESTMNE SLURRY PROCESS -- BAMSl 1JO HM
' PROJECTED CAPITAL INVESTMENT Rt 1UIREMEMTS
fqUIPHENT
MATERIAL .
LABOR
MplNtt
MATERIAL
I ABU*
DUC TWURK
MATERIAL
LABOR.
rOUNDATIUNI
MATERIAL
LABOR
POND CONSTRUCT ION
STRUCTURAL
MATERIAL
LABOR ,
ELECTRICAL
filUSllt
LABUR
INSTRUMENTATION
MATERIAL
lABiifi
BUILDINGS
MATERIAC
. LABOR
SERVICES MID MISCELLANEOUS
SUBTOTAL DIRECT INVESTMENT
INOIHEERINi; DESIGN AND SUPERVISION
CONSTRUCTION EXPANSES
CONTRACTOR FEES
COIIIINGEUCV
SUBTOTAL FIXED INVESTMENT
ALLOWANCE FOM STARTUP AH|) MODIFICATIONS
INTEREST DUX I! 1C CUIISTPMCTIUM
SUBTOTAL CAPITAL INVESTMENT
LAND
MORKIIIO CAPITAL
UfllT, |9«| STARTUP
- t«AHPLE UTILITY, LIMESTONE* HEf
INVESTMENT.
PAH riATERIAL -
HANDLIhd lllO
PHIPARATIUN
939.
61.
m.
.
0.
0.
111.
106.
0.
H.
.
«••
IBT.
»!•
1.
IB.
19.
46.
IITI.
169.
100.
V4.
4B8.
2920.
115.
419.
3590.
9.
97.
THOUSANDS HF
SCRUBBING
7TB9.
641.
(012.
401.
list.
1079.
77.
162.
0.
17«.
290.
424.
BOB.
1B6.
Si.
0.
0.
19B.
16070.
1446.
2171.
B04.
4178.
2S069.
im.
3760.
40757.
2.
812.
ICUIUHIC PREI'ISFS
IfPU OULLARS
WASTE
PISPUSAL
61.
12.
669.
2lT.
0.
0.
17.
34.
7192.
1.
i.
124.
26|.
;.
•:
0.
b.
220.
BBI9.
797.
141B.
441.
2303.
13820.
106J.
2071.
16956.
1216.
4&9.
TOTAL
• iB7.
728.
2941.
748.
1311.
107V.
207.
SO?.
7192.
211.
12*.
645.
1256.
493.
7?:
i*.
19.
664.
2*80*.
2412.
4289.
1340.
6969.
41B16.
*217.
«272.
S130S.
1247.
I38B.
CASE 006
niSTRIBUTinil
PCRfEriT
UF nifcECT
ItlVESllifllT
11.3
2.7
11.0
2.8
1.
4.
o.
1.
2 A.
n.ft
1.2
7.4
4.7
1.7
fill
O.I
1.1
2.5
lon.o
•».o
IA.O
9.0
26.0
1S6.0
12.0
21.4
191.4
4.7
S.2
TOTAL CAPITAL INVESTIIFMT
3696.
3H91.
18611.
53932.
201.2
-------
250 MW
LJ
LIMESTONE SLURRV PROCESS — liASISl 2SO
-------
500 MW
EXAMPLE UTUITVf L1IUSTUNP, NEH ECOHU1K PREMISES CASE OO7
••• INPUTS •••
BOILER CHARACTERISTICS
*OOT UTILITY Mill - MM POND Mill
BOILER HEAT FATt • 9900, BTU/KrfH
EXCESS AIR • 39. PERCENT* INCLUDING LEAKAGE
MOT GAS TEPPIRAIURE • 300, DEC P
COAL A'IALVSIS* MT « AS FIREU i
e n n Ns ci AIM nan
bft.TO 1.80 I.6Q I.3Q 1.J6 J.IO H.1O 4.OO
SULFUR UVEUHFAP • 9z.o PERCENT
ASH qVFRHEAO • »0.0 PERCENT
HtATIIIC VAIUF UF COAL • 11700. 8TU/LB
EMISSION,
FLVASH REMOVAL « LIS/M
UP8TR6AH OF SCPUBBtR 9V. T 0.03
WITHIN SCIUIItBER 80.0 0.0»
COST UF UPSTREAM FLTASH HEMUVAl EXCLUDED
ALKALI
LIHESTnnE
4*£t
SQLU
. 97.IS WT « DRY SASIS
LUtflt rtCll • 07B
1MERTS • 2.83
HDISTURTCDMTENT • S.OO LB HIO/100 IBS DRV
HM!J!9"^ HARntlESS XORK INQJX flCTOR . 10.00
MFSTHMt DECREE OF GRINU FACTUR • T7H
PlV ASM I
SULUHLE CAU •0.0 XT •
SULUntE MCU • 0.0
• loo.oo
RAH MATERIAL HaniLIUG AREA
NUMBER UP RfcOUUIiANT ALKALI PRfPtRATIHN UIUTJ •
A-35
-------
500 MW
SCRUBBER SYSTEM VARIABLES
NUMBER UrOPEMTIIW SCRUBBING TRAINS •
NUMBER UF REDUHOAHT SCRUBBING TRAMS •
NUHBER UF BEDS •
NUMBER II' GRIDS •
HEIGHT UP SPHERES PER BED • 5»
-------
500 MW
MANPU UTILITY, LIMESTONE* HEM ECIIMUHIC PREMISES CASE 007
••• OUTPUTS •••
HOT CAS TU SCRUBBER
cnz
IJCL
$02
02
H2
H20
NC116 PERCENT
12.338
0.006
0.214
3, Sou
ra.jzr,
6,6)4
LB-MIILE/HR
0.2Z53E+US
0.1143E*02
§. 1016E+01
U.1216E»OS
IB/MR
0,9923E*06
0.417si*OJ
o.MOBitoi
0.3431E+06
o!ll91E*06
Sfl2 COMCEHTKATIUH III SCRUBBER MLET OAS
IBS / niLLIOM BTU
FLVASH EHISSIUN • O.Ul IRS/NllLIQM BTU
• 0.015 CRAINS/SCF CMBTI OR 147. LB/HR
SOLUBLE CAP IN FLY ASH • 0. LB/HR
IN FLY ASH •
IN FLY ASH •
SULUBE MCU
HOT GAS FLU* KITE
• ,H94C»07 SCFM 160 DEB ft 14,7 PSIAI
• .16BTE+Q7 ACFM OOP. OEO ft 14.T PSIA>
CnRRISPUHOIHr. CUAL FIHIIIG RATE • .4«I60E«06 LB/HR
HOT 0*8 HUM 101 TV • 0.042 LB H2H/IB DRY CM
HET BULB T6HPERATU>E • 124. OEC F
•CT C*» rRllil SCRUBBER
HULE PFBtEMT LB-MOLE/HR IB/HR
Cnz 11.716 0.2Z91EO!! 0.lQQBE*07
HCL o.nun
102 0.070
*
S.lol O.lOllE^n? 0.3234£«06
N2 79.3UO 0,l3T3t»06 0.>B9ZE*07
1.2SIIZE+99
SO2 COIICEIITRATIUH IH 5CHUBBER OUIUtT (•*& • ZOO. PPH
PLTASH t"IS5luri • 0.02 LBS/HILIIJ-' "HI
• 0.007 URAIUS/SCF IMtTI OR 74. LB/HH
TOTAL HATER PICKIIP • *7a. GPH
iritLUDirib ii«i fiPii eiiynAiriNENT
MET CAS t-LUW KATE • ,IJ3S«+07 Srpn (An DEC ft 14.7 PS I* I
• .13B6t*0> >tFN 11^4. PEG ft 14.7 PSIA)
MET OAS SATURATION ilHUIUITy , B.OB7 LB H20/LB DRY CAS
A-37
-------
FLUE GAS TO STACK
500 MW
HUIE PFRCEHT
LH-MIUE/HR
IB/MR
11.697
— m. —
sat
02
Ml
Mlo
O.noo
o.Q^n
a.ino
70.188
12.434
O.5726t*UO
0.31146*0?
H.IOU6»OS
0.13»E*06
u.i53H*trt
• 13.0 FT/iEC
scu»e PIPE PITCH » i Tinei KTJ*L pipe P.O.
SATURATED 8TJAH T6MpEl>A7URg • 470. OE6 F
OUTLET FLUE GAS TEMPEBATURE • 17». OEO F
REQUIRED HCAT INPUT TO REHEATER • 0.68786*08 87U/HH
ITEAH CUMSUHPTIOH • 0.87588*08 L8S/HH
OUTSIDE PIPE PRESSURE OKOP,
ES5UI
irTili
HEAT HANSFER
C-JEFFICIEMT.
BTO/HR FT2 DEC F
0.20981*02
DIAMETER* IN,
1.00
IN
U
a.as
REHEATFR
OUTSII1I;
A»fA< SO FT
PER TRAIN
PIPES PER NUMBER OF
AANK PER
TKAltl
BANKS IROMS I
PER TBAIII
O.Hi
CORTEH
TOTAL
4.181
0.2»loE*04
91
Reproduced from
best available copy.
A-3S
-------
MATER BALANCE INPUTS
500 MW
PUNU kEEPAfiE(CH/SECI*10*M
PIIHO EVAPURATIQHIIH/VEAIO
90.
32.
HATE* BALANCE OUTPUTS
HATER AVAILABLE
•RAINFALL
ALKALI
TuTAl
»?9» GPN
3. CPN
4*4. GPK
419934. l«/HR
23U4. LB/HR
441838! LB/HR
HATER REQUIRill
HUNiniMCATinN
FNTRAINHCIIT
•iHHBh
-4H^
2*1691. LB/HR
3630. LB/HR
30^.
78.
DISPOSAL HATER
HVORATION fATER
11U*78. LB/HR
5983. LB/HR
0, LB/HR
IEH EVAPUKATIUN
OHO EVAPORATION
CPN
• 6"
. OPN
WM
fc-Hflh
SEEPACE
109
TUTAL HATER RE9UIREO
1*17. OPN
700179. LB/HR
NET WATER R6qUI»EO
833. CPN
26633T. LB/HR
A-39
-------
500 MW
ICHUBBEB SYSTEM
TOTAL NUHttEK Of SCRUBBING TRAINS |ilPfcRATINC«MEUUNUANT) • 5
102 REMOVAL • 7O.O PERCENT
PARTICIPATE REMOVAL IN SCRUBBER SYSTEM • 90.0 PERCENT
TCA PRESSURE DHUP ACROSS 3 BEDS • H.6 IN. H2U
TUTAl SY5TEH PRESSURE UROP • l*,7 |N. HID
OVERRIDE TOTAL SVJTEN PRESSURE OKDP • 20.0 IN* HZD
SPECIFIED IIUUIU-TU-CAS-HATIO • 39* DAL/1000 iCFISATH)
llrtESTnilE AUDITION •
LB/riH PRV LIHESTOI4E
SPECIFIED LI HE STUNS 5TUICMIOHIIKT • 1.19 HUIE CACOI ADDED *» LIHESTDHE
pia MOLE »in»»»HCLi
SULUBte CAP FROM FlY ASH • 0.0 HOLE P6H HOLE |S02»»HCH ABSORBED
TOTAL SUtmiE MCO
• O.B MOLE >t» MOLE HOa*»HCLI ABiORBgO
TOTAL STOICHIOMETRV
1.29
AB30RAED
SCRUBBER INICT liqUOR PH •)(66
HAKE UP •»!«;* • »J1. CPU
CROSS-SECTIUNAI AHEA PER SCMyBBEft • 463* SQ FT
SYSTEM SLUDCC OISCMAR06
SULID
SPECIES
CASU3 .1/2 K2D
CASU4 .2H20
CACU3
IM3HLURLES
H?U
CA+*
MC»*
SOI—
SO*--
CL-
19-HaLC/HK
o!lO**E+03
0.89A2E+02
o!6"»ilE»01
0.0
0.181BE+OO
U. 12976+01
O.IOt8€»02
L8/H-
O.JIBJE+09
0.1797E+09
j.a4sie»o4
0.13a7E»O4
o!277»h+03
0.0
olj9576+03
"W «'
92.92
29.88
U.88
2.31
-PPH
2484.
0.
130.
1116.
3*93.
TUTAl DISCHARGE Finn BATE • D.1
/MR
TUTAL OISSOLVEO JULIUS IN uiscMtRCt LIQUID
7169. PPH
DISCHARGE LIQUID
• 7,37
A-40
-------
500 MW
SCRUBBER SLURRV
SPECIES
CASI13 .1/2 M2D
§AS04 .2H20
ACUJ
IIISdLUftLES
H2H
CA»«
«r.»»
jl)3—
et-
AO.
TUTAL FLnM KATE
TOTAL SUPEP'Ure
SPECIES
«a
»*
MC»»
sm—
su*~
CL-
TOTAL FLOM RATE
SUPERNATE TU WET
SPECIES
HJQ
CA*»
nr»*»
S03—
3o4—
CL-
in.
TOTAL FLDU RATE
•
1LEEO
LB-HULE/HR
0.246SE403
0.1044E*03
2:!!!!!!!!.
0.1B7BE*>I3
0.2112E»UX
0,0
S.3320E*02
.11
• 0.400VS+0*
• 728.
RETURN
LH-MOLE/HR
0.1734E*OJ
0.0
0,SI23E«00
0.365SE*01
0.0
• 0.3146E«06
' *Mi
BALL HILL
"™~~ •-••
LB-HOLE/HR
0. 19426*114
0.17f9E»DI
0.0
0.4679E-01
0.3J3AE*Qi)
0.2797E*01
•J.a
• 0.2871E+D»
• 37.
LB/HR
oil""*"*
o!l3H7E*04
0.0
0.44«2E«02
b.lBJ2k»Cli
S.117FE»U4
LB/HR
GP1
LB/HR
0.3124E*06
o!u
o.*iuiC*«i
0.)J11E»03
0.0
LB/HR
GP<4
LB/HR
§.M32E*>02
0.1743E»n|
d.J^
-------
LlMESTOllE SLURRY FPCO
SPECIESLH-Hnifc/UKIS/HP
CACU3
SHLUBLE nCO O.U Q.il
r»llLU?E*"1 °ij??9g*0?
0.17/9E+010.7I32E»02
0.4679E-01
E+00
SI14— 0.3336
~CT:0.2797
in« o.o o.o
THTAL FLOW RATE • O.T67BEO9 LB/HH
97,
8IIPEBIIATE fftURH TH 5C»U»B6R 0» 8HT
SPECIESLB-NQLc/HRLB/H«
Htao.i»76e*osi
CA*+ 0.1772E*02 0.71U1E+03
MC++ 0.0 I), I)
i03— Q.46»»E*'>0 O.VI7E+OI
H.2789E+02
0.0 O.U
TOTAL FLHM HATE • o.2BS9E+i6
• 372. CP1
RECYCLE JLUKRY JO SCRUBBER
SPECIES LB-MOLE/m LB/m
1/2 H20 0.2S84E+J9 0.3136t*07
TUJfl0.1099E+U90.ia84E»nT
0.9173E+04
!3E*il4 0.93HIE
—— 0.1453k
INSULUIIIES .......... 0.1453fc«0b
H2Q 0.196HE+07 0.314tE»ft8
CA++U.2213E«04O.B<72t*OS
0.0 0.0
S.I3—
SU4-.
CL-
0,S81SE+02
SiH49E+(H
.34BOE+04
O.U
0.4696E+O4
0.394iiE*09
O.II34E*06
O.U
TOTAL PLUM HATE • 0.42O2E+O8
• 0.4202E*
"i Mi21.
A-42
500 MW
-------
500 MW
HUE CAS CDUIING
SPECIES
LB-HOLE/m LB/HB
CASU3 .1/2 H2U
CAC03
• ZH2D
0.6817E*01
IHSOIUOLES
ZI1
HBBr
2S1E.O
g.tf ..,.
0.*2Z9E«01
O.lOijlE+02
U.2S1IE»01
0.0
*
.0
JIIJ—
i3lH6E*0)
0.28996*04
CL-
to*
O.U
TOTAL Ft OH RATE
IK/HR
6M
A-43
-------
500 MW
POND UESIG:I
OPTIMIZED TO MINIMISE TOTAL COST PLUS OVERHEAD
POND DIMENSIONS
-— — — — -
DFPTH IF POHD
DEPTH OF EXCAVATION
LENGTH IJF PUIIO PER|ilETER
LFMGTH UF OtyiPFR
LEIlGfM PEKlNglER tfHlt
AREA OF BOTTOM
ARFA Of INS 1 Of HALLS
AREA OF OUTSIDE HALLS
• AREA UF RECLAIH STORAGE
AREA UF PUNO
AREA UF POND SlTi
ARFA UF PUriU SITE
VOLUME IF EXCAVATION
VOLUME IIF RECLAM STORAGE
VULUHE UF SL'JOGE TO BE
DISPOSED OVeR LIFE JF PLAHT
22i«l
«.02
U»H4.
ZHI1.
tSSinJ
l*8A.
1&4.
las.
J2».
l«4Mi
ZU19.
416.
itast
928.
1193S.
T)9B.
FT
FT
FT
THOU1ANII
THOUSANU
tHUOJANO
THOUSAND
THOUSAND
THOUSAND
ACRES
THOUSAND
THUUSANU
THOUSAND
ACRE FT
voa
»D»
voi
VDl
VuJ
VD2
YDS
YOJ
VUI
pmin citsTS iTHimSAMns HF OULLARSI
LADOR
MATERIAL TOTAIT
(LEAR IMG LAUD
ISZXvATiOii
DIKE CnilSTRUCTIOM
LIHIHGI 12. IN. CLAVI
fnOOINC DIKE UALLS
KlIAU ClIllSTRJCTIOH
PkRi:iETER CllSfSi FFilCE«
RECLAIMATIOII EIPE'ISE
MUIIITOR MELLS
POHD CnNSTRUCltnN
LAUD C"ST
POND SITE
OVERHEAR
TOTAL
67*.
sU«:
i/ii.
I6SO.
10».
**:
43.
11M.
4.
118)7.
.•• ••*•••««
69.
Is!
163.
4.
2S1.
674.
54J4.
2711.
1630.
174.
J7I
740.
1113.
B.
12099,
2081,
14140.
10290.
24410.
A-44
-------
1300 MW
EXAMPLE UTILITY* LIMESTONE MEN tcimnnic PREMISES
C*SE OUT
-p-
Ul
UP Jilt CONTENT 1*11
ASH CIWTEHT IKII
•TU DATIHCI
BOILER TYPEI
mi. UF SCR"SBEHfl
SCRUBBER VELOCITY IP I/HI 1
PLANT SUE IHMI
UPEHATIhG NRS/VRI
PHHPI'IG H»I( (GAL/1OOO ACFII
SCA RATIO!
(ACTUAL SQ.FT./CAIC. IU.FT.
PAKfltULATC REMOVAL
4.16
IS. 10
1ITDU
DRY PULVtRIIED COAL
790.0
1IIU
5"l
Zfl.M
l.lllO
I
INVESTMENT AHU OPERATING COST
PART|C'IL*TE flllSStUM RrCULitTllM ILK ASII/HILLIII 1 RTUII
FLUE GAS TEi'lPERATUHE ICOLP) IFll
FLUE r.nJ TEMPERATURE IIHITI lf=li
COST UF KLECTRtCITV ll/KHMRIi
CUiT OF S1EAH j i/ THOUSAND IBM
FlltSI VHAH
-------
500 MW
R*rf MATERIAL HAHDLIMG AND PREPARATION
•
ITEH
DESCRIPTION NO.
MATERIAL
LABUf
CAR SHAKER AND HOIST
CAM PULLER
UNLOADING HOPPER
UNLOADING VIBRATING FEEDER
UNLOADING BELT CONVEYOR
UNLOADING INCLINE BELT
20HP 3H4KER T.»HP HOIST
2SHP PULLER* SHP RETURN
16FT 014* IOFT STRAIGHT
INCLUDES 6 IN SB GRATE1NG
-3. SHP
20FT HORIZONTAL* JHP
310FT* SOUP
1
1
1
,
}
1
61661.
9*099.
1329T.
4*87.
9B09.
71133.
10(01.
16207,
491J,
432.
ilia.
3996.
CONVEYOR
UNLOADING PIT OUST tOLLECTHR
UNLOADING PIT SUMP PUHP
STORAGE BELT CONVEYOR
STORAGE CONVEVMR TRIPPfR
NOBILP EQUIPMENT
RECLAIM HOPPER
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOR
RECLAIM INCLINE BELT CnnVtyOH
RECLAIM PIT DUST COLLECTOR
RECLAIM PIT SUMP PUHP
RECLAIM BUCKET ELEVATOR
FEED BIK
BIN MEIGH FEEUEM
6YRATHRY CRUSHERS
BALL HILL DUST COLLECTORS
BALL HILL
MILLS PHUDUCT TANK
POLYPROPYLENE BAGTYPE,
INCLUDES OUST HOOD
60GPN. TOFT HEAD. SHP
ZOOFTJ SHP
30FPM* IHP
SCRAPPER TRACTOR
TFT MIBB. 4.25FT HT. SPT
WIDE BOTTOM* CS
3. SHP
200FT* VHP
171FT* 40HP
P1LYPROPVLENE BAG TYPE
60GPiU 70FT HEAOf SHP
90FT HIGH* 79HP
13FT u|«* 21PT STRAIGHT
SIDE HT. CUVEREOi CS
14FT PULLEY CENTERS. 2HP
7SNP
PULYPROPYIEME BAG TYPE
Z20O CM/ 7, JHP
ll.JTPH, 11S.HP
3SOO liAL H'FT i|A< IOFT
Hit FLAKECLA'jS LINED CS
1
l
^
|
I
I
i
I
I
1
1
1
*
2
2
I
*
I
9191.
2071.
62670.
21124.
121633.
2071.
9373.
19099,
91661.
664B.
2071.
97002.
2*741.
21311.
169807.
13297.
329278.
78*7.
4120.
641.
1240.
T961.
0.
1390.
«64.
2176.
1024.
2160.
64 tf.
9909,
II2B9.
129(1.
1164.
432D.
J7Z90.
6041.
HILLS PRODUCT TAW AGITATO* IONP
11079.
102*.
A-46
-------
500 MW
MILLS PRODUCT TANK SLURRY
48.GPM.60FT HEAD,3 7245. 2268.
PU((P 2, IIP* I OPERA! INC
• • MIO 1 SPARCS
SLUKRV FEED TANK
SLUlRV FEED TAMK A6ITATU8
Sliaj.CALi IU,6FT OIA< 1 15700. 1ZSJ3.
20i6FT Hf* FLAKFGLASS*
LINE') CS
«i.ni» i JiBos. iteo.
ltU>IIV FCED TA*
-------
500 MW
• •
SCRUBBING
INCLUDING 4 OPERATING AND 1 SPARE SCRUBBING
ITEM
DESCRIPTION
TRAINS
NO. MATERIAL
LABUH
.
I.D. PAHS
•
SHELL
RURBER LINING
NISTBLIHINATUH
SLURRY HEADER AHO MUZZLES
GRIDS
SPHERES
TOTAL TCA SCRUBBER COSTS
REHGATERS
SOOTBLtWERS
EFFLUENT MOLD TA'IK
EFFLUENT HOLD TANK AGITATOR
COOLING SPRAV PUHPJ
ABSORRER RECVCLP. PUMPS
HAKEUP WATFR PUMPS
20.01N H20. p-ITM 1365.
itP iViTim *H6 6Rlv«!
2318*0. GAL« JJ.OFT OIA»
if. OFT HI* FLAKEGLASS-
LINED CS
6*. HP
DSa.GPN 10GFT HEAO<
64.HP« « OPERATING
A-IU b SPARE
9S40.GPN* 1HOFT HEAD<
M2.HP, • UPERATINi
AMD 7 SPARE
Z77J. GPH* 200. FT HEAD*
234. HP* 1 OPERATING
AND 1 IPAKE
S 4419922.
1)13496.
1*94623.
I6BU21.
326906.
S8110S.
T924H2.
S 4976993.
9 2139716.
60 292848.
5 260199.
9 348259.
10 89798.
19 B662SO.
2 24300.
61580.
320314.
I29Q69.
191216.
201196.
138091.
26739.
9*12«.
264*.
......... .........
TOTAL EgUIPNlNTCOST
12973471. 1129897.
A-48
-------
500 MW
HASTE OlSPHSAL
I TEH
UtiCRIPTlUN
HO. HATER IAL
EA60M
ABSORBER BLEED RECEIVING
TAN*
62898,GAL* 17.3FT DIA*
35.0FT HT» FLAKCLASS-
IINEO C3
20720.
ABSURBfH BLEEO TAIW ACITAK'R
38.IIP
IJ6T6.
1877.
•UNO PEED SLURRY PUMPS
7ZB.GPH* HO. ft HEAD 1
»4.HP| 1 OPERATING
I SPARE
19111.
403*.
AMD
PUND SUPIRUATE POMPS
63Q.GPH* 192.CT HEAD*1
Sl.HPi 1 OPERATING
l.HPi 1 T
I SPARE
11210.
1222.
AND
TOTAL JOUIPMEMT COST
70917.
216117.
A-49
-------
1300 MM
Ul
o
UNESTUNf SLURRY PROCESS — HASISl 503 IN UUIT« 1981 STAK1UP
..'
PROJECTED CAPITAL INVfSTMENT PEI'llRtME'US -
IQUIPMENT
HAURIAL
LABOR
MMNG
MATERIAL
lAillS
DUCTWORK
HATER IAL
LABUR
FOUNDATIilNS
HATERIAL
lABUR
POND ClUllTRUCTinil
ITPUCTIIRAl
MATERIAL
A60R
ELECTRICAL
HiTERiAl
LABUR
INSTRUMENTATION
HATERIAL
LABIIR
BUILPIUG!
MATERIAL
LABOR
SERVICES AND MISCELLANEOUS
SUBTUTAL DIRECT INVESTMENT
ENGINEERING DESIGN ADD SUPERVISION
COtlSTRtlCTlUN EXPENSES
CONTRACTOR FEES
tUNTlNGEUCY
1UHTOTAI FIXED INVESTMENT
ALLOWANCE FOR STARTUP MID muiiFICATinNS '
INTEREST DURING CONSTRUCTION
SUBTOTAL CAPITAL IHVFSTHLUT
lANO
hORKlNG CAPITAL
TOTAL CAPITAL INVESTMENT
fXAr
-------
500 My,
LIMESTONE SLURRV PROCESS — BASISI 500
-------
1000 MW
EXAMPLE UTIHTVj LIMiSTUHE« NEW ECONUSIC PREMISES CASE OQB
••• INPUTS **•
BOILER CHARACTERISTICS
• lood. unun auit - mt row BA»U
IdlLER MEAT RATE •9SOO. BTU/K4M
EXCESS AIM • 11 • PERCEHTf INCLUDING LEAKAGE
HOT OA1 TEMPERATURE • 100. OSO
COAL AHALYSISf HT » AS FIRED I
C M 0 M S CE ASH MSI
&6.7n l.BO i.6o 1.10 l.»6 0.10 11.IB ».n
JULFUR QVEKHtAD • 92.0 P6»Ct?tT
ASH OVERHEAO • 80.0 PERCENT
HtATlMC VAtUi OF COAL « 11TOO. BTU/LB
•WWfr
REMOVAL
UPSTREAM OF SCRUBBER 99.T 0.01
HITIIIH SCRUBBEH 50.9 0.01
COST OF UPSTREAM FlYASH REMOVAL tXCLUOEO
ALKALI
LIMESTONE I
• 37.13 WT I PRY BASIS
HGO •OiO
JNERTS • 2.BS
MOISTURE CONTENT • S(00 LB MJO/100 LBS ORT LIHESTUUE
!• i"!?!"?1! !!"S"SS.S.."?* 'Ng"."CTOR.'J"-00
LIMESTUUE DEGREE UF GRIND FACTO* • T7U
FLY ASH
SULUBLE CAD « 0,0 HT K
5ULUBLE H6U • 0.0
SULUBLE
INERTS
RAM HATCH IAl HAImllrib
nUHBGR
-------
1000 MW
SCRUBBER SYSTEM VARIABLES
NUMBER UF I1PCRATING SCRUBBING TRAMS •
NUMBER OF REPUNUANT SCRUBBING
NUMBER Of OEDS •
NUMBER llF GRIDS •
HEIGHT UF SPHERES PER, BED • 9,0 INCHES
LIQUIO-TU-GAS RATIO •91. GAL/1000 *CF(S*TOI
SCRUBBER GAS VELOCITY » 12.i FT/SEC
INDUCED DRAFT SCRUBBER FAN OPT I DM
SCRUBBER PRkSSURE • 14.7 PSIA
STOICHIUHETRV •i.zs inie CACOI ADDED AS LIMESTONE
PER MOLE (SOZ»aHCL> ABSORBED
iO» RgMOVAL • 90. PiKCEHT
ENTKAINMEHT LEVEL • 0.10
-------
1000 MW
EXAMPLE UTILITY. LMESTtlNEf NEW ECllNUHIC PREMISE! CASE OOJ
«•« OUTPUTS *••
• HOT GAS Til SCRUBBER
HULE PERCENT LB-HOLE/HR LB/HR
cm
HCL
102
na
H2
H20
in*
12.3J8
§.006
.214
§.360
79(227
6.614
CmiCENTRATIUN
0,4909E»95 0.1989E+07
0.2290E«02 O.S15|E»03
0(7K29E*Ui Oi*019E*01
0.2il32E«03 Q.6302E+06
0.2749fe*06 0*7704E*07
0.2432E*OS 0.4)B1E»06
III SCRURIER ISLET GAS • 1142. PPM
HillION BTU
FLV*IH ENISSION • 0.03 LOS/MILLION BTU
• 0.015 CIUIHi/iCF IMETI PR 29*. LB/HH
SOLUBLE C*0 IN FLY ASH • 0. LB/HR
BLE c*a IN FLY
HIE MGO IN FLY
SULUMLE MfiU IN FLY ASH • 0.
HOT GAS FLOW RATE • .230*JE*07 SCFH (60 DEC f» 14.7 PSIAJ
• .33746*07 tCFH (100. OE6 F« U.7 PS1AI
CORRESPONDING CUAL FIRIHG RATE • .BUne+06 LB/HR
HOT CAS HUMIDITY • 0.0*2 LB H23/LB ORY fltS
MET BULB TEHPiRATUHE • 12*. OEC f
WET CAS rHun SCKIJBBEII
HOLE PERCENT LB-MflLE/HR LB/HR
*
11.716 0.4982E+09 Q.aol7E»0
0(000 u«ll'»Se»Ol
Silt O.P80 O.78296*02
-Hlf
U2 . _ _. . _ .
_M2 70.300 0.2749b*06 0.770*E+07
12(795
CONCEHTHATIUII III SCRUB81R OJiLET HAS • lOO. PPM
FLYASM FHISalOrl • 0.02 LBa/HILLIQ'l '•Til
• 0.01)7 GftAINS/SCF CMETI OR l«7. LB/HH
TOTAL MATER
lilClUPI'lli 22.1
HET HAS FLnN RATE • .2*7Ot+07 SCF>- (6f> OE6 F» 14.7 PSIA)
• .27788*07 ACF1 <1?4. PEG F« J4.7 PSIA)
-------
FLUE GAS TO STACK
1000 MW
MOlt fERCE.'T
IP-HOLE/HR
la/nR
tat
HCL
102
OS
N2
H2U
11.647
o.ooo
0.020
S.lhO
70.IM
•1S.W4
O.OB2E«0*
'1. UOE+01
0.7RZ9fc«02
0./U21E*09
§.27*9t»O»
.*067E«0:t
0.20171! *07
O.*t75t1»oi
0,9019E*0«
0.64A9E+06
0.770*^*07
O.VlJUEtOb
SPFCIFIEO S02 REMOVAL EFFICIENCY • »n,0 >
CALCULATED SU2 EMISSION • 0,3) POUNDS PEH IILLIUH ITU
CALCULATED *uz CHIICEHTRATIOH IN STACK
200. PPM
PLVASH EHISSIOH • O.U2 L«5
0.007
ETI OR
147. LB/HR
STACK CiS FLOirgJTti .2*746*07 SCF4 (60 DEC Ft 14.7 PSIA)
ti7i. pee F« i*.7 PIIA»
REHEATE*
SUPERFICIAL 6A8 VELUCITV (FACE VELOCITVI • H.u FT/SEC
SQUARE PIPE PITCH • 2 TIMES ACTUAL PIPE 0.0.
SATURATED STEAM TEHPtBATURE • »70. QIC F
OUTLET FLUE CAS TEMPERATURE • ITS. 088 F
REQUIRED HEAT INPUT TO REHEATER • O.U16E*0» BTU/HR
STEAM CUNSUIIPTlUH • O.J7»2E»Q6 LBS/HR
OUTSIDE PIPE PRESSURE DROP*
DIAHETER« II
1.00
«. IM< H2ii
0.65
HEAT TRANSFER
COEFFICIENT*
BTU/HR FT2 DEC F
0.209SE+02
INCUMEL
CflRTEH
TOTAL
RtMEATER
nUTSIlX: P1PF.
AREA* SO FT
PER TRAIN
0.1SJJF.+0*
O.Nd21E*03
O.»416£«0«
1U1BI-R OF
PIPES PER
8Ar4K PER
TRAIN
91
VI
41
NUMBER OF
BAittS 1 ROMS I
PER TRAIN
*
2
6
"
Reproduced from
best available copy.
A-55
-------
1000 MW
MATIR HALAUCE INPUTS
RAINFAI
PUrlD SeEPAbblCM/SFC!«IO»«B an,
PUMP EVAPOPATlUmil/ViAHl it.
HATER BALANCE OUTPUTS
WATER AVAILABLE
RAIIIFAli:
ALKAL I
TOTAL
' 19454
*.
1SJ*.
GPN
OPH
GPH
TT2120.
4AOT.
TTATZTi
LB/HR
L»/HR
LB/HR
.
MATER REQUIRED
HUMID IMCATIDH
EltTRAINMKHT
DISPOSAL HATER
HVnRATION MATER
CLARIFIED EVAP1RATIUN
PUNO EVAPORATION
•IT.
11.
»»«.
24.
Ot
i?y*.
GPH
GPH
GPH
GPH
GPH
-ssa
463191.
11260.
22173?!
119o6.
0.
»"2?V
LB/HR
LB/HR
LB/HH
14/HR
I B /MR
ll/»
TOTAL HATER RFQUtkEO 24TO. GPH 1*14625. LB/HR
MET MATER KEOlllRtD HI'S. OPH 9S7B9B. Lfl/HR
A-56
-------
1000 MW
SCRUBBER SYSTEM
TOTAL' NUHBEK UF SCRUBS 11 In TRAINS IUPERATIN6*REUUMUAHTI • 10
SU2 REMOVAL • 9O«0 PERCENT
PARTICIPATE REIKIVAL IN SCRUURER SV5TEH • 50.0 PERCENT
TCA PRESSURE DPuP ACROSS 3 BEOS • «,* IN, H20
TOTAL SYSTF'I PPESSllME "RtlP • U.T IH. H20
OVERRIDE TOTAL SYSTEM PRESSURE OMUP • 20.0 IN, HIU
SPECIFIEDLl«0IU-1U-GAS-RAT10S S». GAL/1000 ACF(SATD)
LINCSTQIIE AUUITIDM • 0«92UE«09 L8/HR DRV LIMESTUIlE
SPECIFIED
STUICHIOriETKV
U>9 HOLE CACUJ ADDED AS LIHtSTUNf
PtR MOLE MO**iHCL> ABSOHBUI
SOLUBLE CAP FKI1I1 FLY ASH • 0.0 HOLE PER HOLE tll»»»HCLI ABSORBED
TOTAL SOLUBLE HCU
• 0.0 MULE PER HOLE HO»»»HCLI ABSORBED
TOTAL STOICHIOHETRY
• 1.29
ABSORBED
SCRUBBER INLET LIQUUR >H • j.66
HAKE UP "ATftR • 1Mb. GfH
CROSS-SECT IIIHAL AREA PER SCRUBBER • 469* SQ FT
SYSTEM SLUDGE DISCHARGE
SQL 10 LIQUID
COMPj COMP.
UT X ft
SPECIES
LB-MOLE/HR LB/HK
PPH
CAS01 .1/2 H2U
0.6>6SE»09 92.92
CASU1 .2M20
INSHLIIBLES
H20
CA»*
SU3—
SIM--
CL-
0.2088EtO)
0.17HHE»OJ
0.1231E+OS
. 0.138»E»02
0.0
0.2999E*01
0.2176E»02
O.H9*E»oJ
U.2771E«04
0.2218fe»06
O.S»4HE«01
0.0
0.291ie»fl2
0.2«42E*01
0.771«E*03
29.48
U.88
2.31
.
1*8*.
0.
130.
1116.
1491.
TUTAL OISCHABGE PITH RATE
/HR
TOTAL DISSOLVED SHI.IDS IH DISCHARGE LIOUIU • T169. PPH
DISC'IAHGE LIQUID rll • 7.37
Reproduced from
best available copy.
A-57
-------
1000 MW
SCRUBBER UUBRY Ugl-D
SPECIES
LB-HiJlE/HR L4/HR
CAS03 .1/2 HZU
CASQ4 .2H20
0.493C»E«II3
0.20886*1)1
igg'SJ4
.173SE*
IIISIILUBIES
731: »0«
•fcK
•fc
0|f*Jtii**i
0.rbO3fe*()3
CA**
O.J7J6E+05
601: *O6
11)3
0.0
0.1110EOI
*
0.66]9E*02
0.0
0.0
FLUM RATE • O.B01BE*06 IB/MR
• 1436. 6P<
TOTAL SlIPERNATB RETURN
LP-MULE/HR LB/HR
HfiBr
MC»«
0.33Z9E«OS
.5997E*06
0.13001
0.0
0.0
O4
IU3--
•«=•
0.983IE»00 0./B74E+02
0.70I7E*01 0.67»0fc*03
v.sad^fetoz g.
-------
1000 MW
LIMESTONE SLURRV
FEEO
— — — — —
SPECIES
CACO1
SOLUBLE ICO
IllSULUBLES
H20
CA»»
SII4—
CL-
*!)•
TOTAL FLOW RATE
I Vf G RNATE RETUIIH
LB-MULE/IIR
o!o
0.338JE»0«
0.33281: +01
0.0
0.9269F.-01
0.6613K+00
o.s!(««£«ai
0.0
• 0.1336E+06
• 19*.
TO SCRUBBER
IB/HR
0.0
olo
0.6J12€»n2
0.1?6ttk»0>
0.0
LB/HR
GP1
OR EHT
SPECIES
H20
c*t*
HC««
$03—
CL-
AD*
TOTAL FLIJH HATE
L4-MULE/HR
SI3390E+02
.0
0.490KE+OO
o!s330E+02
O.J
• *1099.
LB/IW
a'i«"!S*
0.0
O.oiOAC+ni
0.0
LB/HR
CP^
RECYCLE SLURRV TU SCRUBBER
SPECIES
(AS01 .1/2 II2U
JASO* ,2MZO
CACII1
INSULURLES
H20
CA«*
HC««
SH3—
CL-
AO*
TOJAL FLOJ HATE
LP-HOLE/HR
0.516«E+09
o.2li4e*nS
O.IH7SE*U!I
0.3937E+U7
0.4,*Z7b+0*
0.0
0.1161E»O3
0.0
• O.B*O
-------
1000 MW
FIUE GS?
SPECIES
LH-IIHI.E/HR
l .1/2 1120
t*w •>/;;
CASIH .2H2
0.«8S2E»06
CASIH .2
CACU3
0.13631= •fO*
0.274UI:«06
0.136SE«P6
INSULUBLES
2U
-SSr
O.
•fier
•«
O.O
M—
0.6033E*0
JLdL
0.6
0.6772fc»nl
0.0
•w
TOTAL Flflll tATg • O.fcH?g*07 Lt/H«
• I11OI, CPH
A-60
-------
1000 MW
•"UNO QeSIG"
UPTIHtZSO TO "IM1-IZE TOTi^
COST >LJS
OVERHEAD
-
PONO DIMENSIONS
~— -- --
OEPTH IF i"C'IQ
OfPTM If EXCAVATION
LENGTH Of 'UNO PERIMETER
LEMGTM OF I)I'M«SB
LENGTH PERIHiTiii FErlCc
AKEA Of SflTTUH
AP.Pl OF INSIDE UALIS
AREA OF OUTSIDE WALLS
AflfA OF ^ECLAI'l STHPAGS
ARUA OF PUNO SIT*
AREA OF PQNU SITE
VlUUIg OP RECLAIM STORAUE
VOLUME Ul" SLUOGe TIJ RE
01SPQSIO OVER LIFE JF 'LArIT
2S.7I
3.86
23*47.
2100*.
JOJ-J,
JdJ.
2B9».
9*29.
739,
f'??;
iJ«»:
PT
FT
PT
THOUSAND Y02
THOUSAND YD2
THOUSAND YU2
THOUSANO Y02
THUUSAHU YD2
THOUSAND Yi|2
ACRES
THOUSAND Y03
THOUSAND Y03
THUUSAMO YD]
ACRE PT
POHO er«T* iTMnuSAMoi qp ODLLAP.SJ
MJ- - - .— —
CLEARING LAflO
a IK 8 CONSTRUCTION
LINING! 12. 114. CLAY)
jnOOtNj OIK6 'IALLS
PPRIHPTC* COSTS, series*
RECLAMATION EXPENSE
Ml W I TOR WELLS
anno CONSTRUCTION
LAND C'JST
PONO SITE
OVSRH8AO
TOTAL
LAtUH
•••••
11*«.
4»38.
2900.
117-
IS9*.
4.
19993.
MATERIAL
102.
Jlft.
4.
1*O.
TOTAL
•MlBW
914*.
2900.
ZM.
12*.
II9«>
20333*
3S*J.
23B76.
17163.
41241.
Reproduced from J
best available copy. 1
£Ja
B^
A-61
-------
1000 MW
EKAHPLE UTILITVJ LIMESTONE, MEM ECOHIIUK. PREMISES
CASE l)i>B
WPSUL CUriTFNT |III
ASH COIITEHT III!
8TU RAT ING |
BOILE*. fyPJ:!
1 No. OF StRUbbERSI
SCRUBBER VElOCITV (FT/IUl
PLAIIT SUE IMHH
OPERATING HRS/YRI
PUMP |IIU RATE IbAL/IOOO ACFII
SCA RATlUl
(ACTUAL 9Q.FT./CALC. SQ.FT,
PART ICUl All REMOVAL
3.36
19.10
I1TPU
ORV PULVERIZED COAL
b
7SO.O
lonu •
*»ii
id. ou
1.100
1
INVESTMENT *.ID dl'FkATING CIIS1
PART ICUL ATE EMISSION REGULATION ILR ASII/IIILLIOU MTJII
riUJ 643 ftHPERStllRe JlUlOl 1 IFJI
FLUE CAS 1EHPF.RATIIHE (MHTI IP II
COST HI- riECTHlCITV li/KkURIi
COST Of iTkAM ll/TH(IUSANn LUII
FIRST VfcdR CAPITAL CHAkSE FACTIIRI
BAOIIIJIISK RATIO (UPER. SQ.fT. /ACTUAL So. FT. II
BAG COST U/SQ.FT.II
fAb'LIFEIVEARSIl
LUE CAS REHEAT TEHPERATUPE IFII
.CHEMICAL EHGINEERH-G PLANT INOEXI
O.U1
joj.o
TOO.O
O.Oi
2.00
o.laj
0,80
0.70
l.UU
IIS.
165.0
>
10
ELECTHUSTATIC PKECIPITATURS
COLO
HUT
BACHOUSE FABRIC FILTERS
SCRUBBERS
REQUIRED REMOVAL EFFICIENCY (III
DRIFT yfLOGlJV IfT/Mll
SPECIFIC CniLFCTIHN AREA (SQ.FT. /ACFN)I
COLLECTION ARIA ISQ.FT.H
TUTAL CORONA PUHER IKtfll
AUXILIARY pn|J'* iKMll
PUMP POWER IHMH
TOTAL P(lulH IKtill
OPERATING AIR/CLOTH RAlldl
INSTALLED AIR/CLOTH RATIOl
REQUIRED PRESSURE DROP (INCHESII
DIAMETER IFEITII
REQUIRED PEHEAT IRTU/HRII
STEAM SUPPLV/VR {THOUSAND IBM
INSTALLED COST (1979 DULLARSII B
FIRST YEAR CAPITALHEO COSTl I
ANNUAL POWER COSTl B
ANNUAL OPERATING AiJO
MAINTEIIANCE CIJST (1979 DULLARSII B
REPLACFtWT COST 11979 DULLARSII
ANNUAL REHEAT COSTl
99.70
H-l'
.f*
917191.9
1127,1
tit'9
Sii.u
1711.7
1.0
99,70
XO.OO
»"i»*
19*4619.0
1029.6
I91I'1
861.9
*BO».l
1.0
99.70
1712267.0
„. .
2640.2
1419.9
2.4
1.9
9.0
99.70
12079.9
ȣiM
60. B
10
128936012.
12109651
lUl7fl
17906*
169977
B 22914*96
1 40&011J
B 69927B
B 249066
1 29010704
1 9211996
1 46B669
f I10661
I Iio29f
»
1
B
B
B
6796Bl.»
40181)666
7919*92
9297999
2129900
1191161
TUTAL AlUHIA
ANUUALIIEO COST OF PUhEPIHILLS/KUHRII
272*11*
0.98
1.09
I 61*1180
1.9*
B 16098790
l.*0
-------
1000 MW
R«U MATERIAL HANDLING Al«l PREPARATION
.
ITEM
DESCRIPTION
NU.
MATERIAL
LABOR
•
CAR SHAKER AMD HQIST
CAR PULLIH
UIHUAIIIH6 HOrPER
UNLOAOIHO V1PRATIIIG FEEUER
UNLOAniNO BELT CONVEYOR
UNLOADING INCLINE BELT
CUNVIVOR
UNLOAOIHO PIT BUST COLLECTOR
UNLOAD IMC PIT SuHP PUMP
STOKAGE BELT CONVEVUR
STORAGE CONVEYOR TRIPPER
NUBlLF EOIIIPMFHT
RECLAIM HIIPPFR
RtCLAIN VIBRATIIIG FEEDER
RECLAIM BELT CONVEVUR
RECLAIM INCLINE BELT CUIIVEYIIR
RECLAIM PIT OUST COLLECTOR
RECLAIM PIT SU'tP PUMP
RECLAIM BUCKET ELfcVATUR
PE(D BIM
•IN WEIGH FtF.DER
6VRATURV CRUSHERS
BALL MILL DUST COLLECTORS
BALL HILL
HILLS PRODUCT TANK
20HP SHAKER 7, SHP HOIST
29HP PULLER* SHP RETURN
I6FT OIA* 10FT STRAIGHT
INCLUDES 6 IN SO CRATE ING
3. SHP
20FT HORIZONTAL* SHP
310FT* SOHP
POLYPROPYLENE BAGTYPE*
iriCLUDES OUST MUOO
60GPHj TOFT HEAD. SHP
100FT* THP
10FPH* IMP
SCRAPPER TRACTOR
TFT HIDEj «.a9PT IITj 2FT
HIDE BOTT3M, Ck
*t»Hp
JOOFT* THP
193FT/ »CHP
POLYPROPYLENE BAG TVPE
6U6PH« 70FT HEAD* SHP
tOff H|AM* 7 5 UP
13FT OIA* 2IFT STRAIGHT
SIDE Mil COVEHEOa CS
UFT PULLEY CklTFRSi 2HP
TiHP
PULVPROP>LENR BAG TVPE
220(1 CFHj 7.ii(P
O.OTPH* Jli.HP
SSOO GAL 1UFT DIA* |OFT
HTj FLAKEI.LASS LIMED CS
1
I
I
\
\
I
1
I
|
\
\
|
I
1
1
1
1
1
2
|
2.
2
2
1
61661.
54059.
13297.
4687.
9809.
71133.
9991,
2O71.
87*69.
23324.
121633.
3106.
140*0.
90971.
91661.
6648.
2071.
97002.
24741.
18338.
169807.
132V7.
417624.
7847.
10801.
16202.
4915,
432.
1186.
• 3996.
4320.
648.
4861.
7961.
O.
1025.
1296*
3964.
3U24.
2160.
64V.
9509.
13285.
1296.
3564.
4320.
41COZ.
604V.
MILLS PRODUCT TANK AGITATUR IHII'
13070.
3024.
A-63
-------
1000 MW
MILLS PRODUCT TANK SLURRY 97.GPM,60FT HEAD,3 10186. 2507.
T3R* 4.IIP/ ft OPERATING
__. AMI! 1
8LUMV FIEO TANK 10237O.CU/ 2».»FT OIA« I 249Z1.
25.9FT HT< FLAKEGIASS-
L1MLU CS
ilU«KV FEED TANK ACITATUR 72.IIP 1 53206. 4377.
SLUHRY FEED TAIIK PUMPS Z4.crMi 60 FT HEAD* 13 34458. 11341.
l.llfl 8 UPkRATING AND
7 SPAHfc
TOTAL I4UIPMENT CU3T 14ASJ90.Ib86ll.
A-64
-------
1000 MW
SCRUB* IMC
iridUDING B nPEKATING AND 2 SPARE SCRUBBING TRAINS
IT EN
DESCRIPTION
NO. MATERIAL
LABOR
1.0. FANS
SHELL
RUBBER LIMING
HIST ILlHINATOfl
SLURRV HEADER wo NUZZLES
SRI Os
SPMERfS
TOTAL TCA SCRUBRER CIISTS
REHEATERS
SODTRLO'JERS
IFPLUENT HOLD TANK
EFFLUENT HOLD TANK AOITATOR
COOLING SPRAV PUMPS
ABSORUR RECYCLE PU«PS
MAKEUP HATER PUMPS
ZO.OIN H20. tflTH 1983.
H» AliTllH AND CHI VI
2SI86I.OAL* M.OFT DIA«
39 .OFT HT» FL*KEGLA3S»
LINED CS
Ab.HP
IIBB.GPH 100FT HEAD*
64.MP* 8 UPEKATING
ADD 12 SPARE
?S40.GPHf 100FT HEAD.
42. IIP/ 16 OPERATING
AND 1* SPARE
5451. GPH» 200. FT HEAD*
10 M11091.
262641J.
29892*9.
596043.
A53B11.
1162211.
1984964.
10 9191196.
10 4274434.
120 909716.
10 520398.
10 696511.
20 179996.
30 17329O1.
2 97393.
12316U.
64062B.
25B136.
102432.
406312.
952204.
53470.
186299.
6292.
468. HPf 1 DPtHATING
AMD 1 SPARE
.._-._.._ .........
TOTAL EQUIPMENT CUST
25955664. 2«Bt)49.
A-65
-------
1000 MW
nlSPUSAL
ITfl HisCRIPTlUN HUi HATERIAL
ABSaRBCR BLEED RECEIVING62810.GAL* 17.9FT 01A* 1 20720. l*SS«.
TAM1 39.OFT HT« '
.
E
LINEO CS
ABIORHfR BLEED TAI4K AGITATOR3«,HP • ) 21676. 1877.
PUNO FfiO SIURR.V PU«PS 1*56.GPM» 13O.FT HfAO 2 20O30. »**l.
• -i u 67.IIP* I OPERATING -
1 SPARE
AIIO
PONU SUPlRI'ATE PUMPS 1209.CPH* 192.FT HIAU* 2 M599, 1391.
98.HP, I OPIRATIHG
AND 1 SPARE
TOTAL IQUIPMENT COST T9O«».
A-66
-------
1000 MW
• J/IMfSTflNE SLURRY PROCESS — nASISl IIIOU **
PROJECTED CAPITAL IHVE STHfcllT «EOUIH£MFIITS
UIIIT< 19»l STAR1UP
- fXAr-PLi UTILITY.
LUIF.STllNEr HEM
INVESTMENT/ THIIL'SANDS UF
EQUIPMENT
HATERlAt
LABOR
MPI'IG
HATERIAl
UaUB
PUCTUtWN
MATERIAL
FOUNOAT DNS '
fATEftli L
ABOR
POND CI1NSTRUCTILUI
STRUCTURAL
HATERIAL
LABOR
ELECTRICAL
HMER|A[
LABOR
INSTlUMEUTATinN '
HATER UL
lABoV
BUILDINGS
MATERIAL
LABOR
SERVICES AHO HISCELLANEDUS
SUBTnTAL DIRECT INVESTMENT
ENGINEERING DESIGN AH|» SUPE4VISIUN
CONSTRUCTION EXPENSES
CONTRACTOR FEES
CONTINGfMCV
SUBTOTAL FIMEO INVESTMENT
ALLOWANCE FUR STARTUP AMD MOIIIF ICATIIIM.
INTEREST DURING CHIISTRUCTIU'I
SUBTOTAL CAPITAL IMVESTMFNT
LAND
WORKING CAPITAL
TOTAL CAPITAL I'lVEhTHEIIT
RAH liATEHIAL
HANULING ANII
PREPARATIOll
l*6>.
ie«.
491.
lot. '
0.
0.
191.
178.
0.
I1I«
+i.
160i
i62.
14).
11.
IDi
s>.
61.
4941.
409.
TIT.
.W:
708S.
54S.
I06S.
8693,
11.
141.
8943.
ten ur> el no
299)6,
2329.
6707.
Iio3.
46«»4.
3827.
171.
570.
0.
S75.
968.
ma.
S14I.
1290.
2o4.
0.
0.
TIB.
81IT2.
4794. .
a»4. 1
2664.
15851.
83103.
6193.
12466.
101164 .
T.
2824.
1OA79S .
ICliNUHIC PREMISES
1910 DOLLARS
WASTE
DISPOSAL
7».
2S.
1114.
ill.
0.
0.
IT.
14.
2(1131.
2.
*;
in.
STt.
11.
1.
0.
0.
IIS.
2274J.
2047.
3619.
Ml:
13479.
^729.
5121.
43330.
3S3S.
1206.
48291.
lilTAL
27M)0.
2741.
aik«.
I860.
4b9«.
3827.
SM.
1376,
2P111.
K-,.
106.1.
162U.
197^.
LAOS.
2l*.
10.
Si.
1116.
R055A.
7210.
12889.
40 JO.
2094S.
'.12566.
9667.
iinj(>.
134184.
ISTt.
*27n.
162027.
CASE 008
OlSTRlPIITinN
PFRCEUT
OP UIRFCT
INVLS1MEUT
34.1
1.4
10.4
2.3
S.8
*.«
n.7
1.7
79.2
.).«
1.3
2.O
1.7
1.7
o.t
«.l
O.I
1.4
1(11.0
1.0
14.0
5.0
26.0
156.0
12.0
21.4
191.4
4.4
4.1
201.1
-------
1000 MW
cr>
oo
.t'lHESTONE SLURRY PRDLFSS — 4ASISI lUO'J "W UHlT* 19(1 STARTUP
PROJECTED REVINUF KEUUIREXE'ITS - EXAMPLE UTILITY* Ll'lESTIINE* NEH CCIIIIQMIC PRfMSLJ
DISPLAY SHEFT FUR YEAR* 1 .
ANIUAL UPCRATIlHI Kb-IIR/K<4 > 4711
60.19 TOilS PE' il'NIH DRV
T(II»L CAPITAL INVESTMENT 1S7I94O1IO
ANNUAL QUANTITY UNIT CUST**
CASF 90'
SLl'OGE
TilTAL
A: 'iUAi.
C'IST.*
DIRECT COSTS
RAW MATERIAL
LIHESTOUE II*. 0 K TON1 *.OU/TUll
SUdTUTAL RAW MATERIAL
17*1730
174)700
CIIHVERSIPH COSTS
OPERATING LABOR AND
SUPERVISION 18910.0 MAN-HR It.lO/HAN-HR
UTILITIES
SUAK 118720.0 K IB IiOO/K LI
PROCESS WATER 116160.0 K GAL 0.12/IC GAL
fLECTRUlTV 807*8*10.0 KrfH olor^KWH
MAINTEMAIICE
LABOR AND MATERIAL
AHALVSES 6110.0 MR (T.OU/HR
486330
1697*00
10009
21*2900
9*27800
10)900
SUBTUTAL COIIvFHSIOII CllSTS IOu9&lnO
SUBTOTAL DIRECT COSTS
nanaooo
INDIRECT COSTS
"OVCRHFADS
PLANT AND ADMINISTRATIVE 1 60.0* OF CONVERSION COSTS LESS UTILITIES)
FIRST YEAR OPERATING AND HAINTErlA.ICE COSTS
LFVELIZEO CAPITAL CHAKGESI 14.71UF TOTAL CAPITAL INVESTMENT!
36M101
15411800
FIRST VEAK AIIUUAL REVENUE RECUlREHENTS laoiaiin
EuuivALinr FIRST VFAP UMIT REVENUE REQUIREMENTS* NILLS/MMM
LEVEUZEP UPfRATIIlG AHO HAIMTE'UNCE I 1.886 TINES FIRST YEAR UPER. ( IIAIN.I
Lk'VELIItn CAPITAL CHARGES! ll.6*« OF TOTAL CAPITAL INVESTMENT)
llVHIZEP ANNUAL REVEUUE REQIIIHEHEHTS
EQUIVALENT LEVEL IZEU UNIT NEVEKUE HtQUIREHEIITS* MILLS/KWH
HEAT KATE 9500. BTD/Krill - MEAT VALUE OF C'lAL 11100 liTU/LB
8.29
29064800
23817970
52882770
11.18
COAL H4TE 1920700 IHNS/VR
-------
APPENDIX B
INDUSTRIAL BOILER LIMESTONE FGD SYSTEM PREMISES
MATERIAL BALANCES
EQUIPMENT LIST
B-l
-------
"*" Clean flue gas
N)
Raw flue gas
Makeup water *•
CaCO- additive
i reft**
tOTM. /»OW lATC
(bo*,)
JS,IIO
Voo
fa/*')
novf jtArf
mi to
riots * *rg
6/U
C/4J
JB.3JC.
/1
87H
tlOVK.
40/AMfJ
. J
4LITM.I
2V 1
b-o
•JIA*
0.1
JS&
¥0
Sludge
LIMESTONE FGD PROCESS
Boiler size.: 30 x 106 BTU/Hr.
Coal type: Eastern
S02 Removal: 90%
-------
W> *• Clean flue
gas
Cd
Raw flue gas *
Makeup water »
CaCO- additive v
trrfAia ttuutn / ffjCAifnov
lofM. /iohf **re
(GO*)
rftim A nut {•£)
<>*/*,)
(Jl MMU/l.)
(tcrn.^
L/OUO fHAif n out * A re
(it /*.)
i
C.AI
81*0
—
*f.o
ff*«
301/
Of IT
1f>t
—
/vr
1^
3* ft
3
uevet
,«,.»'
jstr
1 1 „/«»
^...
scxvttf*.
*»*•'
•IfV'f
'•»•"•'
,.,-
s
ALKALI
7.?
7"!
t
AHlfVf
VtTCf
reeo
11 to
JV
99?*-
11f
t
i
"'
t
?tf/3
""
M
/-
Sludge
LIMESTONE FGD PROCESS
Boiler size: 75 x 106 BTU/Hr,
Coal type: Eastern
S0» removal: 90%
-------
"*" Clean flue gas
w
I
Raw flue gas »-
Makeup water
CaCO- additive
IOTM. /I Oh/ 4*Tf~
rcMff* tnjxe (mf)
641 f\0\J tMlf
(IL MCM.ll/h.)
(AtfM)
L/OUO rune no** *Air
101/0
m***-
31HO
/S/13
30.1
*•*-
ftn?
Ao'-*
19/4,
Jl-/
Sludge
LIMESTONE FGD PROCESS
Boiler size: 150 x 10 BTU/Hr.
Coal type: Eastern
S09 removal: 90%
Reproduced from
best available copy.
-------
w
i '
Raw flue gas '
Makeup water
CaCO- additive
intAM Huutn t temufnou
term, /low t»Tf
(COM)
TfMrounutf (•?)
fa/**) .
(AtfM)
1*31*0 fHUC nOHf MTf
101/0 ffiAtc A«K/ mrr
4?
zr
tr
r
qrir
6*1
mvff
US'
s~orr*.
i A
X/
j
iitvat
Lfiff
~+
,«».
4.
XAtttllA
J Jtv-io1
-- '
M.
il
i
j
ALfM.1
1 Q*l /
1 ff Q/
>
L_
AHCfl/f
Ji'.f
""»
»
"™
"°*
2«3
i/ * clean tiue gas
j>
^ 1
k
4
nvotif
S.9
Mt
i**
t
T3
/^
. Vacuum >frv . _. .
' Filter ^
-------
EQUIPMENT LIST - PURCHASED PRICE (1978 Dollars)
LIMESTONE FGD - INDUSTRIAL BOILERS
W
Raw Material Handling
Pneumatic Conveyor
Silo - 2 wt capacity
Screw Feeder
Mix Tank
Mixer
Feed Pumps - 2
Fans
SO? Scrubbing
Absorber
Hold Tank
Mixer
Circulation Pumps
Solids Separation
Clarlfler
Clarlfler Pumps - 2
Vacuum Filter
Clarlfler Recycle Pumps
8.8
Description
94.4k Ibs
30 gal
6 gpm
12.900 acfm
12.900 acfm
5.220 gal
1,000 gpm
7 . 1 gpm
7.1 gpm
0.7 gpm
6 gpm
MUt
$
3.394
24.000
1.193
270
190
6.000
3JLQ5J
8.3.QO
21.000
6.500
3.400
17.000
4I.MQ
25.000
6.400
27.000
6.000
64^400.
22 MUt
Description
237.9k Ibs
76 gal
15.2 gpm
32.300 acfm
32.300 acfm
13.135 gal
i
2.596 gpm
18 gpm
18 gpm
1.8 gpm
15 gpm
$
3.394
46.000
1,193
390
300
7.200
5ft..471
i.T.iOO
40.000
12.000
6.500
20.000
is^ss
29.000
7.800
31.500
7.200
75.500
44 MUt
Description
480.0k Ibs
152 gdl
30.4 gpm
64.800 acfm
64.800 acfm
26.220 gal
5,134 gpm
36.2 gpm
36.2 gpm
3.6 gpm
30 gpm
$
3,394
73.000
1.193
600
430
8.400
81,012,
30.000
66.000
19.000
10.300
23.000
118.300
33,600
8,800
40.000
8.400
9JL.S-Qft
58.6 MUt
Description
637.0k Ibs
179 gal
35.8 gpm
74,800 acfm
74,800 acfm
30.270 gal
48 . I gpm
48.1 gpm
8.9 gpm
34.3 gpm
$
3.394
87.000
1,193
670
460
8.700
10L.430
U.flflO
72.000
21.500
11.500
24.000
129.000
•38,000
9.200
54.000
8,600
109.800
-------
APPENDIX C
UTILITY BOILER LIMESTONE FGD SYSTEM
PREMISES ON AN "INDUSTRIAL BASIS"
MATERIAL BALANCES
EQUIPMENT LISTS
CAPITAL INVESTMENT ESTIMATES
ANNUAL O&M COSTS
ANNUAL REVENUE REQUIREMENTS
C-l
-------
APPENDIX C
As discussed in Section 2.1.2.3, TVA estimated the costs of utility
boiler limestone FGD systems on an "industrial basis," i.e. with the following
design scope differences from the standard TVA design scope described in
Appendix A:
1. No stack gas reheat.
2. No spare absorber modules.
3. No on-site pond disposal. The waste solids are thickened
and filtered to form a sludge which is hauled to off-site
landfill disposal by an outside contractor.
This design is more typical of industrial boiler FGD system designs and is
similar to the FGD system design scope used by Radian to develop industrial
boiler FGD system costs.
The following information is included for each FGD system in this Appendix:
1. Plant heat rate
2. Flue gas characteristics
3. Coal analysis
4. Limestone analysis
5. Complete FGD system design scope
6. Material and energy balances
7. FGD system operating conditions
8. Sludge pond design criteria
9. FGD system process stream characterization
10. FGD system equipment list and costs
11. Equipment installation costs
12. Indirect investment costs
13. Annual O&M costs
14. Annual revenue requirements
C-2
-------
Reheat & Spare Scrubber Investment
do3 $,
Boiler Capacity, MWe
Reheat
Equipment
Installation Factor
Total Direct Investment
Indirect Investment Factor 1
Total Capital Investment
Spares
Equipment
Installation Factor
Total Direct Investment
Indirect Investment Factor 1
Total Capital Investment
// Scrubbing Towers - Operating/ Spares
"Utility Basis"
"Industrial Basis"
1980
100
735
2.25
1652
.979
3269
1988
2.25
4468
.979
8843
1/1
1/0
$)
250
1284
2.25
2884
1.978
5707
2292
2.25
5148
1.978
10183
2/1
2/0
500
2140
2.21
4729
1.975
9340
2423
2.21
5354
1.975
10575
4/1
4/0
1000
4279
2.16
9255
1.975
18279
4854
2.16
10499
1.975
20735
8/2
8/0
Pond - determined by difference:
Utility Case - (Industrial Case + Reheat + Spares)
C-3
-------
100 MW
EXAMPLE INDUSTRIAL* LIMtSTONBj MEW ECONOMIC PREMISES CASB 001
•*• INPUTS •••
BOILER CHARACTERISTICS
MPGAWATTS . 100, INDUSTRIAL BASIS
BOILER HEAT RATE • 9900. BTU/Kiin
EXCESS AIR •39. PERCENT/ INCIJDINB LEAKAGE
HOT GAS TEHPERATURE • 300. DEB P
COAL ANALYSIS* WT » AS PIKED
« H 0 N J CL ASH^ H20
66.70 3.60 9.60 1.30 3.»6 0.10 13.10 ».OQ
SULFUR OVERHEAD • 92.0 PERCENT
ASH OVERHEAD • 80.0 PERCENT
HEATING VALUE OF COAL • 11700. 9TU/LB
EFFICIENCY, EMISSION,
FLYASH REMOVAL»LBI/H BTU
UPSTREAM OF SCRUBBER 99.T 8.03
WITHIN SCRUBBER 80.0 0.01
CUST OF UPSTREAM FLYASH REMOVAL EXCLUOeO
ALKALI
LIHESTUNE I
EAC03 « 97.18 XT » ORY BASIS
SOLUBLE NCO •070
INERTS • 2,»9
MOISTURE CHNTENT •IiOO LB 120/100 IBJ DRT UIMESTONE
LIMESTONE HARONgSS rfORK 1MOEX FACTOR • 10.00
LIMESTONE DECREE OF GRIND FACTOR •1.35
FLY ASH I
SOLUBLE CAU •U.a
SOLUBLE HCO « 0.0
INERTS • 100,00
RAW MATERIAL HANDLING AHEA
NUMBER OF REDUNDANT ALKALI PREPARATION UNITS •
C-4
-------
100 MW
SCRUBBER SYSTEM VARIABLES
NUMBER OP OPERATING SCRUBBING TRAINS •
NUMBER OF REDUNDANT SCRUBBING TRAINS •
NUMBER OF BEOS •
NUMBER OF GRIDS •
HEIGHT OF SPHERES PER BED •3,0 INCHES
1.1 QUID-TO-GAS RATIO • S3. GAL/1000 ACF(SATD)
SCRUBBER CAS VELOCITY • 12.S PT/SEC
INDUCED DRAFT SCRUBBER FAN OPTION
SCRUBBER PRESSURE • 14|7 P5IA
STOICHIUMETRY •1.29 HOLE CAC03 ADDED AS LIMESTONE
PER HOLE CS01»aHCLl ABSORBED
S02 REMOVAL • 90, PERCENT
6NTRA1NHENT LEVEL • 0.10 WT I
gHT RESIOENCE TIME • 18.0 H1N
S02 OXIDIZED IN SYSTEM • »O.Q PERCINT
SOL10S IN REC1RCULATEO SLURRY • 13.0 WT »
SOLIDS DISPOSAL SYSTEM
COST OF LANO • 5000.00 DOLLARS/ACRE
SOLIDS IN SYSTEM SLUDGE DISCHARGE • 80.0 XT «
SOLIDS IN CLARIFIES DISCHARGE • 3».Q XT »
CLARIFIES SOLIDS SETTLING RATE • 8.20 PT/HR
SOLIDS IN PILTER CAKE • 5O.O WT «
FILTRATION RATF • 1.20 TONS ORY SQL1DS/FT2 PAY
NO REHEATERS
C-5
-------
100 MW
EXAMPLE 1NOUSTRUL* LlHESTONEi 1EM iCONOMIC PREMISES CASE OOi
••» OUTPUTS •••
HOT CAS TO SCRUBBER
HOLE PERCENT LB-MOLE/HR
C02 1Z.J3B
HCl 0.006
Stli 0.214
02 9.360
NI 73.227
HID 6.65*
S02 CONCENTRATION
0<*509E*0*
0.2290E*01
0.7B29E*02
0.20326*0*
0.27*96*09
0.2*326*0*
IN SCRUBBER MLBT CAS
LB/HR
0.19896*06
0.83916*02
Qi9019E+0*
0.6902E*09
0.770*E*06
0,*381E*OS
• 2142. PPM
• 9.28 IBS / MILLION BTU
FLYASH EMISSION • 0,03 LBS/HILLION BTU
• 0.019 CRAINS/SCF IH6T1 OR 27. LI/HR
SOLUBLE CAP IN PLY ASH • 0. LB/HR
SOLUBLE MGD IN PLY ASH •Ot
HOT GAS FLOW RATE • .230«E*06 SCPH (60 010 ft I*.7 PSIAI
• .337*8*06 ACFM <300. DEO ft 1*.T PI1A)
CORR6SPQNQ1N6 COAL FIRING RATB • .B120E*09 LB/HR
HOT CAS HUM101TV • 0.0*2 LB H23/LB ORV OAS
MET BULB TEMPERATURE • 12*. OB6 F
WET CAS FKOH SCRUBBER
MOLE PERCENT LB-MQLE/HR LB/HR
C02
HCL
S02
Ul
N2
H20
11.T16
0.000
0.020
5.U9
70.300
12.793
0,*9B2E*0*
0,ll*9E*00
0.78296*01
0.2021E*0*
0.27*9E*09
0,500*6*0*
0.2017E*06
Oi*lT9E*Ol
0.9019E*OJ
0.6*69E*09
§.770*E*06
i90l9E*OB
S02 CQNCtNTK4TIUM IN SCHUBBER OUTLET OA9 •ZOO. FPH
FLYASH EMISSION •0,02 UBS/MILLION BTU
• 0.007 CRAINS/SCF (HET) OR 19. LB/HR
TOTAL WATER PICKUP • 99. 6PH
INCLUDING 2.3 GPH ENTRAINHENT
WET CAS FLOW RATE • .2*706*06 SCFM (60 DEO ft 1*.T PSIA)
• .27796*06 ACPH (12*. PEG P» I*.7 PSIA)
MET CAS SATURATION HUMIDITY • 3.3H7 LB H20/IB URY CAS
C-6
-------
FLUE GAS TO STACK
100 MW
HOLE PERCENT
LB-HOLB/HR
LB/HR
CD2
HCL
S02
dz
N2
H20
11.697
0>000
0.020
3.160
70.188
12.934
0.43826*04
0.1143E+00
0.7829t*01
0.20Z1E+J4
0.27496*03
0.3067E*04
0.2017E*06
Oi4173E*01
§•30136*03
i6469E*03
0.7704E+06
Oi9128E*03
SPECIFIEDS02 REMOVAL EFFICIENCY • 90.0 *
CALCULATED 502 EMISSION • 0,31 POUNDS PH HILLIUN BTU
CALCULATED S02 CONCENTRATION IN STACK CAS •
200. PPM
FLYASH EMISSION • 0.02 IBS/MILLION BTU
• 0.007 GRAl'IS/SCF (NET) OR
13. LB/HR
STACK GAS PLOW RATE •,2474E*06 SCP1 160 DEC fi 1*77
• .2»19E+0> ACPH 1131. PEG ft 14.T P81AI
C-7
-------
100 MW
HATER BALANCE INPUTS
RAINFALL! IN/YEAR) SO.
POND SEEPAGE(CM/SEC)«1O«»8 90,
POND EVAPQRATIQN( IN/YEAR) 92.
WATER BALANCE OUTPUTS
MATER AVAILABLE
RAINFALL
ALKALI
TOTAL
Ot 6PM
1. 6PM
l! 6PM
109 i LB/HH
461. L8/HR
S69. LB/HR
HATER REQUIRED
HUMIDIMCATION 93. GPM 4A939, LB/HR
j, gPj} - i»6, MBS
24. DPM 11*11. LB/HR
ISPOSAL WATER
HYOBATION MATER _ 2. 0PM _ 1201. LB/HR
_ _ 1201. LB
CLARIFIfcR EVAPORATION 4. OPN Z09T. LB/HR
POND EVAPORATION _ a. QPM _ 0. LB/HR
SEEPAGE A. OPH o, LB/HH
TOTAL MATER REQUIRED 123. 6PN »267*( LB/HR
NtT MATER RBQU1R60 _ II*. BPM _ 6210*. IB/HR
C-8
-------
100 MW
SCRUBBER SYSTEM
TOTAL NUMBER OF SCRUBBING TRAINS (OPERATING+KEDUNOANO • 1
$02 REMOVAL •90.0 PERCENT
PARTICIPATE REMOVAL IN SCRUBBER SYSTEM •30,0 PERCENT
TCA PRESSURE DROP ACROSS3 BEOS •8,6 IN. H20
TOTAL SYSTEM PRESSURE DROP • I3t» INt H20
OVERRIDE TOTAL SYSTfcM PRESSURE OK(1P • 20.0 IN. H2Q
SPECIFIEDLIOUID-TQ-GAS-RATIO•99. GAL/1000 ACF(SATO)
LIMESTONE ADDITION • 0,9Z14E*0* LB/HR DRV LIMESTONE
SPECIFIEDLIMESTONE STOICHlQMETKr • I,IS HOLE CAC03 ADDED AS LIMESTONE
PER HOLE (S02+2HCLI ABSORBED
SOLUBLE CAP FROM FLY ASH • 0.0 HOLE PER HOLE IS02**HCL) ABSORBED
TOTAL SOLUBLE HCO • 0.0 HOLE PER HOLE (S02+2HCLI ABSORBED
TOTAL STOICH10HETRV • 1.23 10LE SOLUBLE (CA*HC|
10LE SOLUBLE
PER HOLE (SOI
2«2HCL) ABSORBED
SCRUBBER INLET LIQUUR PH *5iAA
HAKE UP WATtH •
CROSS-SECTIONAL AREA PER SCRUBBER •170. SQ FT
C-9
-------
100 MW
SOLIOS DISPOSAL SYSTEM
TOTAL CLARIFIER(S) CROSS-SECTIOHAL AREA •
366*( SO PT
SYSTEM SLUDGE DISCHARGE
SOLID
LIQUID
SPECIES
CAS03 .1/2 HZU
CASO* .2H20
tACOJ
INSOLUBLES
H20
CA»*
MG**
SOS-
JO*—
CL-
LB-MOLE/HR
0.49J2E«02
O.Z101E*OZ
0!l7a8E»
-------
100 MW
](RUB.BE,R SLURRV
BLEED
_._-.- ...... .....
SPECIE!
CAS03 .1/2 H20
CAS04 .ZH20
CACQ3
INSOLUBLES
H20
CA**
MC»*
$03—
sof-
fit''
A0«
fOTAL FLOH RATE
LB-HOLE/HR
0.4932E*02
0.2101E*02
0.1788E+02
0.37«6E*04
0.70*7E*01
0.0
0.107SE+00
0.7444E»00
0.1233E*02
0.0
• 0.8034E+03
• 146.
LS/MR
0.6367E+04
0.361ftE*04
o!2773E»03
0.6749^*03
0.28236*03
0.0
0.86096*01
0.71316*02
§.41716*03
LB/HR
OPH
TOTAL SUPERNATE
JPECIES
H20
CA+*
MC+*
$03—
$04—
EC-
Ml*
TOTAL FLOW RATE
8UP6RHATE TO MET
RETURN
LB-HOLE/HR
0.2976E*04
0.5^916*01
0.0
0.8943E*Ol
0.5914E*00
0.0
• 0.9429E*09
• 109,
BALL MILL
LB/HR
0.9362E»Q9
0.0
o|j68lE*02
0.0
LB/HR
OPH
___..-_.. .. ... -..- — —
SPECIES
H20
CA**
MC»*
S_0}—
$04—
Cli-
AD«
TOTAL FLOH RATE
LB-HQLE/HR
0.3370E+03
a!o
0.9673E-02
0.6696E-01
0.1109E«01
0.0
• 0.6143E+04
• 12.
LB/HR
0,6071^*04
§.2S41E*O2
.0
0.7744E*00
0.64326*01
§.3932E*02
.0
LB/HR
CP1
C-ll
-------
100 MW
LIMESTONE SLURRY
••••••"•• — ••— •
SPECIES
CAC03
SOLUBLE MCO
INSOLUBLES
H20
CA#»
MC+*
503—
SO*—
CL-
AD*
TOTAL PLOW RATE •
•
SUPERNATE RETURN
SPECIES
HID
CA+*
HC**
SOS—
Sd*—
CL-
AO*
TOTAL PLOW HATE •
•
RECYCLE SLURRY TO
SPECIES
CAS03 .1/2 H20
CJSO* .7H2H
CACJl
INSULUBLES
H20
CAV*
MG++
SOS-
JO*—
ZL-
AO*
TOTAL FLOW RATE •
•
PESO
••M«
LB-MOLE/HR
0,89*3E*02
0.0
0.33706*03
0.63396*00
0.0
O.9673E-OZ
0.6696E-01
0.1109E*01
0.0
0.1J36E*OJ
19.
TO SCRUBBER
LB-HOL6/HR
o!*965E*01
0.0
0.79766-01
0.92**E*00
0.86866*01
0.0
0.*811E*09
96.
SCRUBBER
LB-HULE/HR
0.3139E*0*
o!l871E*0*
0739196706
O.7372E*O3
0.0
0.11Z9E*OZ
0.77«7E*02
O.1Z10E*O*
0.0
0.8*0*6*07
19Z6*.
L9/HR
0.8992^*04
0.0
0.2626^*63
§,607^6*04
.2s*iE*o2
0.0
o. f 7**E~*86
0,6432E»01
0.3932E*02
0.0
LB/HR
OP<4
OR EHT
••• ••••••
LB/HR
0,*T93b'«AS
0.1990E*03
0.0
0,60696*01
0.903TE*02
0.30796*03
0.0
LB/HR
OP1
LJ/HR
0.66616*06
0.17336*06
0,18736*06
0.29U1E*09
0.70606*07
0.2999E*09
0,0
0,*U06E*03
0,7*80E*04
0,»S72f*flS'
0.0
LB/HR
GP1
C-12
-------
100 MW
FLUE GAS COOLING SLUR'V
SPECIES
LB-HOLE/HR LB/HR
§AS(J3
Aid*
CAC03
.1/2 H20
• 2H2D
INSOLUBLES
H20
CA*»
MG»+
S03--
S04--
CL-
AD*
0.3732E+03
0,15996*03
0.1361E»03
O.Z830E«03
0.3961E+OZ
0.0
0.81B1E+00
0.3663E+OJ
0.93S1E+02
0.0
0,*8*»E*OS
O.Z7S16+03
0.13626*03
OtZHOE^O*
0.»U3e*06
0.214«E*04
0.0
0.63JOE*02
§.S*40E*0»
.9>2SE»04
0.0
TOTAL FLOW RATE
• 0.6112E+06
• 1110.
LB/HR
OP1
CLARIFIER UNDERFLOW SLURRY
SPECIES
CAS03 .1/2 HZO
CASO* .2H20
CAWl
INSOLUBLES
H20
CA++
MC+*
S03—
Sd4—
CL-
AD>
TOTAL FLOW RATE
LB-HOLE/HR
0.4932E*OZ
0.2101E02
o.i7aat*o2
0.122SE*0«
0.2310E+01
0.0
0.3324E-01
0.2440E*00
0.»0
LB-HOLE/HR
0.0
0.0
0.0
0.2*09E»0*
O.OJ3E+O1
0.0
0.6916E-O1
0.4788E+00
0.7930E*01
0.0
LB/HR
0.0
0.0
0.0
O.fl
0.*3*1E»03
0.1B17fe»O3
§.0
,3337E*01
0.4S99E+02
O.ZB11E«03
0.0
TOTAL FLOW RATE • o.*J92E»o» LB/HR
C-13
-------
100 MW
38.
FILTER CAKE SIUHRV
SPECIES
LB-HOLE/HR LB/HR
CAS03 .1/2 H20
CASU4 . 2H2O
CAC03
INSOLUHLE5
H20
CA**
MC**
$03—
SO*—
CL-
AD.
TOTAL FLOW RATE
0.4932E*02
0.2101E*O2
0.17«BE«02
0.6611E*03
o!o
O.IB98E-O1
0.13146*00
O.2176E*01
0.0
. 0.2410E*03
0.6367E»0*
o!l790E»0*
O.Z773E»OJ
0.119l£»03
o.'o
0.1919E*01
0.1262E»02
0.771*6*02
0.0
Lfl/MR
33,
FILTRATE FRUH FILTER
SPECIES
L8"HULE/HR LB/HR
5*}°3 .1
2AS04 .2
/2 H20 0.0
.0
•w
03
H2D
0.0
0.0
.0
.0
INSOLUBLES
H20
0.3667E*03 0.1021E*03
CA»*
MC+*
0.1066E+01
0.0
it
0,*272E»02
0.0
S03--
s*—
CL-
A0>
giilWi+og—PitQ9»*Ot
0.1863E+010.6612E«02
0.0
0.0
TOTAL FLOM RATE » 0.10336*03
•
-------
100 MW
EXAMPLE INDUSTRIAL* LIMESTONE* NEW ECONOMIC PREMISES
CASE 001
WPSUL CONTENT (XII
ASH CONTENT IX) 1
BTU RAT I NCI
BOILER TVPEl
NO. OF SCRUBBEKSI
SCRUBBER VELOCITY (FT/HII
PLANT SIZE (NH)I
OPERATING HRS/VRI
PUMP IMG RATE (GAL/1000 ACFII
SCA RATlOl
PARTICULATI REMOVAL
3.36
19.10
11 TOO
DRV PULVERIIED COAL
790.0
100
9296
Ifl .06
1.300
INVESTMENT AND OPERATING COST
PARTICULATE EMISSION REGULATION (LB ASH/MILLION BTU) I
FLUE GAS TEMPERATURE ICOLD) |F)|
FLUE GAS TEMPERATURE (HOT) IFII
CHIT OF ELECTRICITY |6/KWHR)|
COST OF STEAM ( I/THOUSAND LBll
FIRST YEAR CAPITAL CHARGE FACTOR!
8AGHOUSE RATIO JOPIR. SO. FT. /ACTUAL 1Q.PT.H
BA6 COST (t/SQiFT.)l
BAG LIFEIVEARSII
FLUE GAS REHEAT TEMPERATURE (FII
CHEMICAL ENGINEERING PLANT INDEXI
0.01
100.0
700.0
0.01
2.00
o.iio
O.BO
0,70
l.JP
111.
263.0
(ACTUAL SQ.FTi/CALC. SO. FT.)
n
ELECTROSTATIC PRECIPITATORt
REQUIRED REMOVAL EFFICIENCY (XII
DRIFT VELOCITY IFT/MII
SPECIFIC COLLECTION AREA (SQ,FT./ACFM) I
COLLECTION AREA ISO. FT. II
TOTAL CORONA PUWER (KWII
AUXILIARY POWER (KMII
FAN POWER IKWII
PUMP POWER IKWII
TOTAL POWER (Kwll
OPERATING AIR/CLOTH RATIOI
INSTALLED AIR/CLOTH RATIQl
REQUIRED PRESSURE DROP ( INCHES) 1
DIAMETER (FEET)I
REQUIRED REHEAT (ATU/HR)!
STEAM SUPPLY/YR (THOUSAND LBll
INSTALLED COST 11979 DOLLARS)! f
FIRST YEAR CAPITALIZED COSTI 9
ANNUAL POWER COSTl »
ANNUAL OPERATING AND
MAINTENANCE COST (1479 DOLLARS)! B
REPLACEMENT COST (1979 DOLLARS)!
ANNUAL REHEAT COSTI
COLD
99.70
27?!f4
91719.4
112.T
6B.4
Si.l
291.9
1.0
1982491
189169
moi
46137
HOT
99.70
20.00
194462.1
202. B
191.6
•0.4
416.8
1.0
B 2921881
B 9269||
B 66977
B 69211
BAOHOUSE FABRIC FILTERS
•
t
B
»
I
99,70
171226'. 8
168. 9
164.0
432.9
2.4
1.9
9.0
4277191
771120
69982
49187
93026
SCRUBBERS
99,70
3208,0
till. I
60.1
27
1X04911.0
B 9917090
B 1067041
B 988392
t 110499
B 14071
TOTAL ANNUAL COST I
AMIUALUEO COST OF POWERU1ILL5/KWNR) I
370207
0.70
662721
1.26
939719
1.79
1960209
1.77
-------
100 MW
RAH MATERIAL HANDLING AND PREPARATION
ITEM
DESCRIPTION
NUi
MATERIAL
LABOR
MOBILE EQUIPMENT
RECLAIM HOPPER
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYUR
RECLAIM INCLINE BELT CONVEYOR
RECLAIM PIT DUST COLLECT!!*
RECLAIM PIT SUMP PUMP
RECLAIM BUCKET ELEVATOR
FEED BIN
BIN NEIGH FEEDER
GYRATORY CRUSHERS
BALL MILL OUST COLLECTORS
BALL MILL
HILLS PRODUCT TANK
MILLS PRODUCT TANK AGITATOR
MILLS PRODUCT TANK ILURRY
PUMP
SLURRY PEED TANK
SLURRY FEED TANK AGITATUR
SLURRY FEED TANK PUMPS
TOTAL EQUIPMENT COST
BUCKET TRACTOR
TFT WIDE/ 4.29FT HT« 2FT
WIDE BOTTOM, CS
3.3HP
100FT* 1HP
193PT, »OHP
POLYPROPYLENE BAG TYPE
60GPM, TOFT HEAD. IMP
90FT HIGHi TSHP
13FT OIAj 21PT STRAIGHT
Slot HT« COVERED, CS
14FT PULLEY CENTERS* IMP
T9HP
POLYPROPYLENE BAG TYPE
2200 CFM« 7.3HP
4.6TPH* 100. HP
9900 GAL IOPT 0|A* 10PT
HT/ FLAKEOLASS LINED CS
10HP
17.GPM/ 09FT HEAD,
I. HP* 1 OPERATING
AND I SPARES
10Z37.GAL, 1Z.OFT DIA*
12. OFT HT, PLAKEGLASS-
LINED CS
13.HP
19.GPM, »0 ft HEAD,
I. HP, 1 OPERATING AND
1 SPARE
I
1
\
1
\
\
\
n
1
1
1
1
I
1
1
2
1
1
z
— '
69176.
1039.
46BT.
19618.
S1661.
66*8.
*BT1.
«*9«1.
121TO.
14169.
B490*.
664 BI
1B70TJ.
1924.
6939,
»9JO.
3B70,
10BZ5.
4930.
491369.
Oi
679.
412.
11BB.
1024.
2160.
64B.
9509,
6641.
64B,
ITBSi
Z160.
16J96, X
1024 «
IPlIi *-
191Z.
»ZB7« *
B9B. >
1S1Z. 4
33972.
C-16
-------
100 MW
• »
SCRUBS INO
ITEM
DESCRIPTION
NO, MATERIAL
LABOR
1.0. FANS
SMELL
RUBBER LINING
5 1ST ELIMINATOR
LURRY HEADER AMD NUZZLES
GRIDS
SPHERES
TOTAL TCA SCRUBBER COSTS
SOOTBLOWERS
EFFLUENT HOLD TANK
EFFLUENT HOLD TANK AGITATOR
COOLING SPRAY PUHPS
ABSORBER RECYCLE PUHPS
20.0IN H20, WITH UBS,
HP MOTOR AND DRIVE
201489. OAL* 32.9PT D1A«
32.9FT HT« FLAKEGLASS*
LINED CS
97. HP
moiGpH IOOPT HEAD*
SI. HP* 1 OPERATINO
AND 1 SPARE
7632«GPN< IOOPT HEAD*
»34. HPf 2 OPERATING
1 746391.
217*80.
221274,
42946.
J23l*!
91010.
129939.
1 7601B2,
B 19182,
1 44847,
1 9947B.
z ia»TO,
> 219649,
10449.
990B7,
17282,
19016.
4716,
4B*Oi
16899,
AND 1 SPARE
HAKEUP HATER PUHPS
TOTAL EQUIPMENT COST
999..GPHJ 200, FT HEAD*
47. HPf 1 OPERATING
AND 1 SPARE
2 10909,
*18767S8.
1189,
149478.
C-17
-------
100 MW
HASTE DISPOSAL
ITEM
DESCRIPTION
ND. MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATOR
THICKENER FEED PUMP
THICKENER
THICKENER UNDERFLOW SLURRY
PUMPS
THICKENER OVERFLOW PUMPS
90320. GAL, 16.2PT DIA,
32.3FT HT, PLAKOLASS.
LINED CS
33. HP
1*6, GPM, 60FT HEAD,
».HP, 1 OPERATING
AND I SPARE
3664. SO. FT., 68. FT 01 A,
6.0TANK FT HT
34.GPH, 5.SFT HEAD,
O.HP , 1 OPERATING
AND 1 SPARE
88, GPM, TS.OFT HEAD,
I 1T8S6,
1 20219.
2 6113.
1 102389.
2 4187.
2 7913.
14266.
1601,
1991.
101313.
1312.
I19i
3. HP, 1 OPERATING
AND 1 SPARE
THICKENER OVERFLOW TANK
FILTER FEED TANK
FILTER FEED TANK
AGITATOR
FILTER FEED SLURRV PUMP
1430. GAL* 6.4PT OIA,
6.0FT HT
892. GAL, S.3FT 01 A,
3.3FT HT, PLAKEGLASS*
LINED cS
2. HP
27. GPM, SOFT HEAD*
1 843.
1 1036.
1 863.
I 6767.
931.
84Ii
69.
2261,
UUP, 2 OPERATINC
AND 1 SPARE
FILTER
60. SO FT FILTRATION
2 94890.
26491.
AREA
FILTRATE PUMP (PER FILTER)
FILTRATE SURGE TANK
FILTRATE SURGE TANK PUHP
10.GPH, ZOiOFT HEAD,
O.HP, Z OPERATING
AND 2 SPAMS
3*1. GAL, S.9FT DIA,
3.9fT HT
Zl.GPM, 85. OFT HEAD,
4 13978.
1 124.
2 7142.
1924.
214,
779,
l.MP, 2 OPERATING
AND ZSPARE
_-_-..-._ .........
TOTAL EQUIPMENT COST
289046.194461,
C-18
-------
100 MW
o
I-1
VXD
•LIMESTONE SLURRV PROCESS — BASISl 100 1H
PROJECTED CAPITAL INVESTMENT REQUIPEMEMTS -
EQUIPMENT
MATERIAL
LABOR
MPlNG
MATERIAL
LABOR
DUCTWORK
MATERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
PONO CONSTRUCTION
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
BUILDINGS,
MATERIAL
LABOR
SERVICES AND MISCELLANEOUS
SUBTOTAL DIRECT INVESTMENT
ENGINEERING DESIGN AND SUPERVISION
CONSTRUCTION EXPENSES
CONTRACTOR FEES
CONTINGENCY
SUBTOTAL FIXED INVESTMENT
ALLOWANCE FOR STARTUP AND MODIFICATIONS
INTEREST DURING CONSTRUCTION
SUBTOTAL CAPITAL INVESTMENT
LAND
WORKING CAPITAL
TOTAL CAPITAL INVESTMENT
UNIT, 1981 STARTUP
> EXAMPLE INDUSTRIAL,
INVESTMENT,
RAW MATERIAL
HANDLING AND
PREPARATION
94!
199.
79.
0.
0.
110.
161.
0.
H.
:
94.
176.
41.
6.
14.
19.
106.
1791.
198. ,
281.
88.
456.
2736.
210.
410.
3356.
9.
110.
3475.
LIMESTONE, NIW ECONOMIC PREMISES
THOUSANDS OP
SCRUBBING
1877.
149.
904.
71.
191 f
287.
26.
ii.
0.
H.
.
138.
249,
121.
26.
Oi
0.
260,
4281.
189.
689.
214.
1114.
6681.
914.
1002.
8197.
1.
269.
8467.
1980 DOLLARS
HASTE
DISPOSAL
289.
194.
199.
86.
0.
0.
B.
.
0.
«.
.
200 1
978,
40.
J4,
\\
107.
1767,
199.
281,
88,
459.
2756.
212.
411,
3381.
9.
111.
3497,
CASE 001
DISTRIBUTION
TOTAL
2691.
194.
892.
217.
391.
267.
m.
.
0.
H.
.
412.
1001.
202.
79.
19.
20.
474.
7801.
702.
1249.
390.
2029.
12173.
916.
1626.
14936.
IS.
491.
15441.
PERCEI
HT
OF DIRECT
INVESTMENT
14.0
4.9
11.4
1.0
9.0
1.7
2.0
o!o
1.1
1.6
9.9
12.9
2.6
1.0
0.2
0.1
6,1
100.0
9.0
16.0
9.0
26,0
156.0
12.0
21.4
191.4
0.2
6.1
197.9
(8/11
-------
100 MW
o
I
10
O
tin's STONE SLURRY PROCESS — BASISI 100
PROJECTED REVENUE REQUIREMENTS " EXAHPL
SW UNIT, 1981 STARTUP
E INDUSTRIAL* LIMESTONE. NEW ECONOMIC PREMISES
DISPLAY SHEET FOR YEARS 1
CASE 001
ANNUAL OPERATION KU-HR/KU • 3216 - 0.6 cap factor
6.01 TOMS PER HOUR DRY
TOTAL CAPITAL INVESTMENT 14*72000
ANNUAL QUANTITY UNIT COST,*
SLUDGE
TOTAL
ANNUAL
COST,*
D|RECT fOSTS
RAW MATERIAL
LIMESTONE
SUBTOTAL RAW MATERIAL
24.2 K TONS B.OO/TDN
19?7
-------
250 MW
EXAMPLE INDUSTRIAL, LIHiSTOHEj «48* ECONOMIC PREMISES CASE 001
••• INPUT! •••
BOILER CHARACTERISTICS
MEGAWATTS •2907
INDUSTRIAL BASIS
BOILER HEAT RATE • 9900. BTU/Krfn
EXCESS AIM • 39. PERCENT* INCLUDING LEAKAGE
HOT GAS TEMPERATURE • 300. DEO r
COAL ANALYSIS* UT X AS FIRED
C M 0 N S CL ASH H20
66.70 3.80 3.6Q 1.30 3.16 0.10 13.IQ *.OQ
SULFUR OVERHEAD « 92.0 PERCENT
ASH OVERHEAD • ao.o PERCENT
HEATING VALUE OP COAL • 11700. BTU/LB
EFFICIENCY,
FLVASH REMOVAL
UPSTREAM OF SCRURBER 99.T 0.03
MITHIN SCRUBBER 30.0 0.02
COST OF UPSTREAM FLVASH REMOVAL EXCLUDED
ALKALI
LIMESTONE
CAC03 « 97.18 WT I DRY BASIS
SOLUBLE HCO • 0,0
INBRTS • 2.88
MOISTURE CONTENT • S.OO LB HZO/100 IBS DRY LIHE5TONE
LIMESTONE HARDNESS WORK INDEX FACTOR • 10.00
LIMESTONE DEGREE OF GRIND FACTOR
FLV ASH I
SOLUBLE CAO • O.O
SOLUBLE MCO • 0.0
RAW MATERIAL HANDLING AREA
NUMBER OF REDUNDANT ALKALI PREPARATION UNITS •
C-21
-------
250 MW
SCRUBBER SYSTEM VARIABLES
NUMBER Or DPFHATING SCRUBBING TRAINS • I
NUHBER Of REDUNDANT SCRUBBING TRAINS • 0
NUMBER (IF BEOS • 3
NUMBER Of GRIDS • ?
HEICHT Of SPHERES PER BED •9tO INCHES
LIOUIO-TD-CA5 RATIO •55. GAL/1000 ACF(SATD)
SCRUBBER GAS VELOCITY • 12,3 PT/5EC
INDUCED DRAFT SCRUBBER FAN OPTION
SCRUBBER PRESSURE • 1*«7 PSIA
STOICHIOMETRY • 1.29 HOLE CACOJ ADDED AS LIMESTONE
PER MOLE (S02*»HCL1 ABSORBED
S02 REMOVAL • 90. PERCENT
EMTRAINMENT LEVEL • 0.10 WT «
EHT RESIDCNCE TIME • 12.0 HIM
S02 OXIDIZED IN SYSTEM • 30.0 PERCENT
SOL 105 IN RECIRCULATED SLURRY • 19.0 MT 1
SOLIDS OISPUSAL SYSTEM
COST OF LAND • 8000.00 DOLLARS/ACRE
SOUPS IN SYSTEM SLUOliE DISCHARGE • 90.0 HT «
SOLIDS IN CUARIFIER DISCHARGE • 38.0 WT »
CLARIF1ER SOLIDS SFTTLlNC RATE • 0.20 FT/MR
SOLIDS IN FILTER CAKE • 50.0 HT «
FILTRATION R*Tt • 1.20 TONS DRY SOL101/FTI DAY
NO REHEATERS
C-22
-------
250 MW
EXAMPLE INDUSTRIAL* LIMESTONE* SEM ECONOMIC PREMISES CASE 002
••• OUTPUTS »•*
HOT CAS TO SCRUBBER
MOLE PERCENT LB-HULE/HR
C02 lZi338
HCL 0.006
S02 0.214
02 5.560
N? 75.227
H20 6. 614
S02 CONCENTRATION
0.1127E+09
0.5726E+01
0.1997E+09
O.JOBOE+04
0.6874E+OS
0.6080E+04
IN SCRUBBER INLET
LB/HR
0.4961E+06
S.2088E+01
.UblK+oU
0.1626E+06
0.1926E+OT
0.109SE+06
GAS • 2142. PPM
IBS / MILLION BTU
FTVASM EMISSION • 0.03 LRS/NILLION BTU
• 0.015 CRAIflS/SCP (WET) OH 74. LB/HR
SOLUBLE CAP IN FLY ASH •
SOLUBLE MCO IN FLY ASH •
0. LI/HR
HOT GAS FLOW RATE •,S77ZE*06 SCPH 160 BED ft 14.7 PIIAI
. .84356*06 ACFM (100. DEC f, 14.T PSIAI
CORRESPONDING CdAL PIRING RATl • .2030E+06 LB/HR
HOT GAS HUHIOITY • 0.042 LB H2Q/LB DRY OAS
MiT 8UIB TEMPERATURE • 124. DEC F
THflSAS THOH SCRUBBER
MOUE PERCENT IB-MOLE/HR LB/HR
C02
HCL
S02
02
N2
HZO
11.716
0.000
0.020
3.169
70.300
12.799
0.1146E+05
0.286JE*00
0.19576+02
0.305*6+04
0.6874E+OS
0.1291E+05
O.S042E+06
0.10446+02
0.1254E+04
0.1617E+06
0.1926E+07
0.2234E+06
S02 CONCENTHATIDN IN SCRUBBER QUIlfeT CAS •ZOO. PPM
FLYASH EMISSION •0.02 LBS/MlLLION BTU
• 0.007 GRA1NS/SCF IXET1 OR 37. LB/HR
TOTAL MATE* PICKUP • 237. CPH
INtLUOINO9.6 CFM tNTR«INMtNT
WET CAS PLOW RATE •.61766+06 SCFM (60 DEC ft 14.7 PSIA)
• .6938E+06 ACFM 1124. PEG F, 14.7 PSIA)
MET CAS SATURATION HUMIDITY . 0.087 LB H20/LB DRY GAS
C-23
-------
250 T1W
FLUE GAS TO STACK
HOLE PERCENT
C02
HCL
$02
02
NZ
H20
SPECIFIED
11.697
0.000
0.020
S.160
70.180
12(934
502 REMOVAL
LB-MOLE/HR
0.1146E+OS
0.2B63E+00
§. 19S7E+02
.5054E+0*
0.6874E+OJ
U.1267E*03
EFFICIENCY •
LB/HR
0.30*2E»06
Otl044E*02
0.1234E«04
O.UlT'i+Ob
0.192bE*07
O.J282£*06
90.0 X
CALCULATED 502 EMISSION • 0<33 POUNDS PER MILLION BTU
CALCULATED SU2 CONCENTR4TIOH IN STACK CAS •200. PPM
FL'YASH EMISSION • 0.02 LBS/MllHON
8TU
(NET)
•0(007 GRAINS/SCF (NET)OR3T. LB/HR
S7ACK CAS FLOW RATE • ,6186E*06 SCFM (60 DEC ft 14,7 PSIA)
• .7047E+06 ACFH (HI. DEO Ft 14.T PilA)
C-24
-------
250 flW
WATER BALANCE INPUTS
RAINFALL! IN/YEAR)
POND SEEPAGE(CH/SEC)»10«»B JO.
POND E VAPOR ATI DM (IN/YEAR) 32.
HATER BALANCE OUTPUTS
HATER AVAILABLE
RAINFALL
ALKALI
TOTAL
1. OPN
2. GPN
). GPN
271. LB/HR
1192. LB/HR
1421, [i/HR
HATER REQUIRED
HUNIDIMCATION 2>2. GPN 1198*8. LB/HR
'jfHH!ii"3I« Iti SM .i"i»- I-;/H"
DISPOSAL HATER60. GPNZVTT6. LB/HR
HYORATION HATER 6. GPN 100*. LB/HR
10.
CLARIFIER EVAPORATION10. OPN92*1. LB/HR
POND EVAPORATION 0. GPN 0. LB/HR
SEEPAGE0. GPH0. LB/HR
TOTAL HATER REQUIRED111. GPH 196684. LB/HR
NET HATER REQUIRED 311. OPN 199261. LB/HR
C-25
-------
250 MW
SCRUBBER SYSTEM
TOTAL NUHBEK OF SCRUBBING TRAINS IDPERATINGtREDUNDANTI • 2
SQ2 REMOVAL •90tO PERCENT
PARTICIPATE REMOVAL IN SCRUBBER SYSTEM • 90,0 PERCENT
TCA PRESSURE DROP ACROSS9 BEOS •8.6 IN. H20
TOTAL SYSTEM PRESSURE DROP • lit* IN. HZO
OVERRIDE TOTAL SYSTEM PRESSURE DROP • 20iO INi HZO
SPECIFIED LIOUIO-TO-GAS-RATIO •tit GAL/1000 ACMSATD)
LIMESTONE ADDITION • 0«2304E+03 LB/HR ORY LIMESTONE
SPECIFIEDLIMESTONE STQICHIUMETKY•UZ9 HOLE CACQ3 ADDED A3 LIMESTONE
PER MOLE (3tU4»HCLl ABSORBED
SOLUBLE CAP FROM HY ASH • 0.0 HOLE PER HOLE (S01»»HCL> ABSORBED
TOTAL SOLUBLE HCO • 0.0 MOLE PER HOLE ISOZ+ZHCL) ABSQRBEO
• I.2S HOLB SOLUBLE
-------
250 MW
SOLIDS DISPOSAL
SYSTEM
— ••"• ~ ....—•. ......
TOTAL CLARIFIER(S) CROSS-SECTIONAL AREA « 9139. SO PT
SYSTEM SLUDGE DISCHARGE
— -_- ...... ......... SOLID LIQUID
COMP, CDHP.
SPECIES
CASD3 .1/2 H2O
CASIM .2H20
CAC03
INSOLUBLES
H20
CA**
MG*»
JOS-
SIM-.
CL-
LR-HOLE/HR LB/HR HT X PPM
O.1233E+03 0.1592E*09 IZ.84
O.S233E+02 0.90»l£*0» 30.01
0.**71E*02 0.*47bE*04 l*>86
...... 0.6933E*03 2.30
0.16J3E+0* 0.297BE*05
0.3109E+01 0.12*6E*03
0.0 0.0
0.4744E-01 0.17988*01
0.12B4E*00 fl.313Jt»oi
O.J440E+01 0.19288*03
*136.
0.
116.
10*7.
6*01.
TOTAL DISCHARGE
FLOW RATE • 0.6026E*OS LB/HR
• 83. GPH
TOTAL DISSOLVED
SOLIDS IN DISCHARGE LIQUID I 11697.
PPH
DISCHARGE LIQUID PH •7.28
C-27
-------
250 NW
SCRUBBER SLURRY BLEED
ECIES
LB-MOLE/HR
*»
• 1/2 MZU
.2H20
0.1233E*03
0.52S3E+02
. 904 IE to*
•m
INSOLUBLE:
H20
HG+*
S03—
50*—
CL-
A0«
-__—-_.-
o! 17626*02
0.0
0.2688E*00
o!30B3E*02
0.0
0.69336*03
0.1667E*06
0.7061E+03
0.0
0.2152E*02
6.l7R«E*ol
0.1093E*0»
0.0
OTAL PLUM KATE
O.Z009E*06 LB/HR
368. 0PM
TOTAL SUPERNATE RETURN
SPECIES
H20
HC**
503—
SO*—
CC-
A0>
TOTAL FLOW RATE
LB-HOLE/HR
0.7**OE»0*
0.1*OOE*OZ
0.0
0.2136E*00
0.1*7BE*01
o!o
• 0.1336E*06
• 271.
LB/HR
0,13*OE»06
0.96106*03
0.0
0.1710E*02
O.U20£*03
0.0ft81G*01
0.0
LB/HR
CPX
SUPERNATE TO WET BALL HILL
SPECIES
H20
CA**
HC**
503—
SO*—
AO.
TOTAL FLOW RATE
LB-HOLE/HR
0.78766*03
0.1*82E*01
0.0
0.2261E-01
O.IS6IE*00
0.2592E*01
0.0
• 0.1*36E*OS
LB/HR
o!»938E*02
0.0
0.1810E*01
0.i503E*02
§.9190E*02
.0
LB/HR
29.
C-28
-------
250 MW
LIMESTONE SLURRY
SPE£IES
CACdS
SOLUBLE HCO
INSOLUBLES
H20
CA++
HC**
SOS-
JO*—
CL-
AD*
TOTAL FLOH RATE •
•
SUPERNATE RETURN
SPECIES
H20
CA*+
MC++
S03—
Jo*—
CL-
AD.
TOTAL FLOW RATE •
•
R'ECVCLE SLURRY TO
SPECIES
CAS03 .1/2 H20
CASO* .2H20
CAC03
INSOLUBLES
H20
CA»+
MC*+
SOS-
JO*—
AD.
TOTAL FLOW RATE •
FEED
LB-HULE/HR
0.2236E+03
0.0
O.B424E*03
0.1*B2E+01
0.0
0.2261E-01
0.1S69E+00
0.2992E*>01
0.0
i 0.3839E*OJ
48.
TO SCRUBBER
LB-MOLE/HR
0.6693E»04
0.1251E+02
0.0
0.1910E+00
0.1322E»Oi
0.2190E+02
0.0
0.1213E«06
243.
SCRUBBER
LB-HOLE/HR
0.1290E+03
o!*677E+0*
o79797E+06
o!o
0.2B12E+02
0.1947E+03
O.S229E*04
0.0
0.2101E+08
LB/HR
0<223BE»09
0.0
0.0969E»0}
0.191BE»09
0.393BE*02
0.0
0.1B10E»Ol
0.1J03E+02
0,»190E»02
0.0
LB/HR
CPU
OR EHT
•• •••
LB/HR
o.uvvc*oo>
0.5016E»0>
0.0
0.1I29E«02
0(1270E»03
0.7762E«0>
0.0
LB/HR
CPU
LB/HR
O.U69E«OT
fl.9*57E*06
0.46«2E*06
0.7252E*09
0.176SE+08
o!o
o!l870E»OJ
0.0
LB/HR
38161.
C-29
-------
250 HW
FVUE GAS CODLING SLURRY
SPECIES LB-HOLE/HR
CAS03 .1/2 H20 0.43816*03
CASO* .2H20 0.39976*03
CAC03 0.3*026*03
INSOLUBLES -_.—>_
H2Q 0.71256*08
CA** o.ii*oe*oi
MC+* 0.0
303— 0.20*5E*Ol
SO*— 0.1*16E*02
CL- 0,23*36+03
AD- 0.0
TOTAL FLOW RATE • 0.15286*07
• 2775,
LB/HR
0.12116*06
0,68786*09
0.34056*09
0.12B*E«O7
o!o
0.1637E'»oi
§. 1360E*0*
.83136*0*
0.0
LB/HR
GP1
CLARIPIER UNDERFLOW SLURRY
•— — -• — — — — —
SPECI6S LB-HOLE/HR
(AS03 ,1/2 H20 0.1233E*03
CASO* .2H20 O.J2336*02
CACQ3 O.U71E+01
INSOLUBLES -...———
H2C1 0.30696*0*
CA*« 0.377*6*01
MC*+ 0.0
S03— O.SB11E-01
SO*— 0.60996*00
CL- 0.10106*02
AD> 0.0
TOTAL FLOW RAT6 • 0,860BE<*05
• 139.
LB/HR
0,1992E*05
0.90*16*04
8.*t76E+0*
0.6933E*03
0,93306*09
0,231*6*03
0.0
0.35816*03
0.0
LB/HR
GP1
SUPERNATE FROM CLARIFIER
SPECIES LB-HOLE/HR
JA503 .1/2 H20 0.0
CASO* .2H20 0.0
CAC03 0.0
INSRLUBLES .._—..—
H20 0.602*6*0*
CA** 0.11336+02
Or.** o.o
SII3— 0.17296*00
SO*— 0.1197E+01
CL- 0.19B3E*O2
A0> 0.0
LB/HR
0.0
0.0
0.0
0.0
0.10856*06
0.0
0.13^*6*02
0.11JUE+03
0. 70266+03
0.0
TOTAL FLOW RATE • n.io986*o6 LB/HR
C-30
-------
250 MW
.220
GPM
FILTER CAKE SLURRY
SPECIES
I. B-MOLE/MR IB/HR
CASOJ .1/2 H20
CASO* .ZHZO
CAC03
INSOLUBLE5
H20
CA**
MG**
SOS—
SO*—
CL-
AD>
0. 12336+03
0.3Z33E*OZ
O.**716*02
0.16536*0*
0.3109E+01
0.0
0.4744E-01
0.32846*00
O.3440E*Ol
0.0
0.1S92E+01
0.9041E»04
0,**76E»0»
O.O933E»03
§.Z97BE*03
.12*66*03
0.0
0.379BE*01
0,31S3E»02
o.i9zae*o9
0.0
TOTAL FLOW RATE • O.AQ26E*Oi LB/HR
FILTRATE FROM FILTER
SPECIES
LB-HOLe/HR LB/HR
CAS03 .1/1 H»0 0.0
CASU* .ZHZO0.0
•w-
0.0
CASU*
EAC03
0.0
INSOLUBLES
H20
0.1*176*0*
^STO
0.2332E*03
0.106BE*0>
0.0
CA++
MC**
0.2663E+01
0.0
503—
SO*—
0,*067E-U1
0.2B13E»00
0.3Z56E*01
CL-
ADP
0,*t
0.0
0.0
TOTAL FLOW RATE • 0.23B2E*03 LB/HR
32,
GPH
C-31
-------
250 MW
EXAMPLE INDUSTRIAL. LMESTONEj NCW ECONOMIC PREMISES
CASE DPI
MPSUL CONTENT IV) 1
ASH CONTENT (XII
BTU RATINGl
BOILER TYPE!
NO. OF SCRUEBERSI
SCRUBBER VELOCITY IFT/MH
PI Ant sliE IHNH
OPERATING HRS/VRI
PUMPING RATC (GAL/1000 ACFII
HA RAT 101
(ACTUAL SO.FT./CALC. SO.FT.I
PARTICIPATE REMOVAL
3.36
19.10
11700
DRV PULVERIZED COAL
2
7iO,0
290
9296
20.00
1.300
1
INVESTMENT UNO DPEMTIN6 COST
PARTICIPATE EMISSION REGULATION ILB ASH/MILLION BTUII
FLUE GAS TEMPERATURE ICOLO) (F)|
FLUE GAl TEMPERATURE (HOT) (fll
COST OF HECTRICITV (I/KHHRH
CUST OF STEAM (1/THDUSAND LBlt
F1KST YEAR CAPITAL CHARGE FAcTORl
BACHOUSE RATIO (OPER. SQ.FT. /ACTUAL SQ.FT.) I
BAG COST (I/SQ,FT.II
BAG LIFEIVEARSH
FLUE OAS REHEAT TEMPERATURE |F)|
CHEMICAL ENGINEERING PLANT IHDEXI
0,03
300.0
700.0
6.03
2.00
0,160
o.eo
0,70
1.00
132.
261.0
ELECTROSTATIC PRICIPITATORI
u>
COLO
HOT
BAOHOUSE FABRIC FILTIRS
SCRUBBERS
REQUIRED REMOVAL EFFICIENCY (*>i
DRIFT VELOCITY (FT/MII
SPECIFIC COLLECTION AREA |SQ.FT,/ACFM} |
COLLECTION AREA (SO. FT.) I
TOTAL CdRdNi puifER (kwJl
AUKILIARV POWER (KM)I
FAN POWER (KU)|
PUHP PUHER (Kf)l
TOTAL POWE> (few II
OPERATING AIR/CLOTH RATIO!
INSTALLED AIR/CLOTH RATIO!
REQUIRED PRESSURE DROP (INCHES II
DIAMETER (TEETH
REQUIRED REHEAT (RTU/HRH
STEAM SUPPLY/YR (THOUSAND LBII
INSTALLED COST (1979 OOLIARSII 1
FIRST VEAR CAPITALIZED CDSTl t
ANNUAL POWER COST! 1
ANNUAL BPCHAVIhfi AND
MAINTENANCE COST 11979 DOLLARS )l 1
REPLACEMENT COST (1979 DOLLARS)!
ANNUAL KEHSAT COST!
99.70
27.19
277.74
111,1
lta.9
132,0
6*2, T
1.0
3996969
641367
994B4
76790
99.70
8«'P.o
I7V.99
416199,2
906,4
424.1
101,1
till.!
1.0
A 6989009
» 1187499
» 172980
t 119231
99,10
43 3067*. 2
309.8
iiA.6
969'. It
2.4
s!o
1 9162336
1 1692274
1 97631
1 132564
99,70
B020,0
«S3,*
60.8
u
3012260.0
17591.T
6 I273Z169
t 2296033
1 1471479
t 66B123
TOTAL AMNUAL COiT,
ANNUAL I IEO CUST OF POWiR(HILLS/KHHR» I
Q.62
B 14»306
I 1990314
-------
250 MW
RAH MATERIAL HANDLING AND PREPARATION
.
ITEM
DESCRIPTION
NUi
MATERIAL
LABOR
HUB Hi EQUIPMENT
RECLAIM HOPPER
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOR
RECLAIM INCLINE BELT CONVEYOR
RECLAIM PIT DUST COLLECTOR
RECLAIM PIT SUMP PUMP
RECLAIM BUCKET ELEVATOR
FEED BIN
BIN WEIGH FEEDER
GYRATORY CRUSHERS
BALL MILL OUST COLLECTORS
BALL HILL
HILLS PRODUCT TANK
HILLS PRODUCT TANK AGITATOR
HILLS PRODUCT TANK SLURRY
PUMP
SLURRY FEED TANK
SLURRY FEED TANK AGITATOR
SLURRY FEED TANK PUMPS
TOTAL EQUIPMENT COST
BUCKET TRACTOR
TFT WIDE* 4.29FT MT« 2FT
WIDE BOTTOM. CS
3.SHP
IDOFTf 2HP
193FTJ »OHP
POLYPROPYLENE BAG TYPE
60GPM* TOFT HEAD* IMP
90FT HIGH* T9HP
HFT 01A* Z1FT STRAIGHT
DE Hti COVERED* CS
UFT PULLEY CENTERS* 2HP
T5HP
POLYPROPYLENE BAG TYPE
2200 CFM* T.SHP
11.9TPH* 199. HP
9500 GAL IOFT OIA. 10FT
HT» FLAKEGLASS LINED CS
10HP
4B.GPH* 60FT HEAD*
2. HP* 1 OPERATING
AND I SPARES
29392. GAL« 16,3FT DIAj
16.3FT HT. FLAKEGLASS-
LINED CS
28. HP
24.GPH. 60 ft HEAD.
I. HP* Z OPERATING AND
I SPARE
1
1
I
n
I
1
1
\
I
1
I
1
1
1
i
2
1
1
9
•
63176.
1039,
46BT.
19618.
91661.
6648.
2071.
49991.
12170.
14169.
14904.
6648,
162689.
1924.
6999.
4830,
9891,
20T01.
6892,
933994.
0,
679.
432.
1188.
3024.
2160.
648.
9909,
6643.
648.
1782,
2160,
18649,
1024,
1912,
1912,
7896.
1641,
2268,
61368,
C-33
-------
SCRUBBHO
250 HW
ITEM
DESCRIPTION
NO. MATERIAL LABOR
I.Ot FANS
20.0IN HZO» KITH 1*62.
HP MOTOR ANQ DRIVE
1698993.
23709.
SHELL
RUBBER LINING
MIST ELIMINATOR
SLURRY HEADER AND NOZILES
GRIDS
SPHERES
925363.
517890.
107209.
130762.
212*42.
316993,
TOTAL TCA SCRUBBER COSTS
1830636,
128125t
SOOTBLOHERS
16
38365,
34964,
EFFLUENT HOLD TANK
291861.GAL' 39.OFT DIA* 2
35.0FT HT« FLAKECLASS-
104060,
81262,
LINED CJ
EFFLUENT HOLD TANK AGITATOR
66, HP
1)9102,
22088i
COOLING SPRAT PUMPS
1388,GPH IOOFT HEAD*
64,HP< 2 OPERAT1MO
19919V
10696,
ABSORBER RECYCLE PUMPS
9940.CPMf lOOrT HEAD«
44Z.HP« 4 OPERATING
346500,
AND 2 SPARE
MAKEUP WATER PUMPS
1368.GPH< 200,FT HEAD*
117.HPi 1 OPERATING
AND I SPARE
15981,
1742,
TOTAL EQUIPMENT COST
4809373. 339432.
C-34
-------
250 HW
WASTE DISPOSAL
ITEM
DESCRIPTION
NO.
MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATOR
THICKENER FEED PUMP
THICKENER
THICKENER UNDERFLOW SLURRY
PUN'S
THlCKENiR OVERFLOW PUMPS
62B9B.GAL* 17.5FT OIA*
33. OFT HT* FLAKGLASS.
LINED CS
J8.HP
365. GPN* 60FT HEAD*
10. HP* 1 OPERATING
AND 1 SPARE
9159.SQ.FT.jlOa.FT DIA*
T.2TANK FT HT
139. GPN* T.2FT HEAD*
l.HP i I OPERATING
AND 1 SPARE
220. GPM, TS.OFT HEAD*
1
1
2
I
2
2
207ZO.
23676.
7870.
195262.
60B7.
7»97.
1659*.
IB77.
2982.
196729 •
1912.
867,
7, HP* I OPERATING
AND 1 SPARE
THICKENER OVERFLOW TANK
FILTER PEED TANK
FILTER FEED TANK
AGITATOR
FILTER FEED SLURRY PUHP
3629. GALf 9.1FT DIA*
7.2FT Ht
2230. GAL< T.2FT OlAj
7.2FT HT» FLAKEfiLASS-
LINED CS
*.HP
68. CPM, SOFT HEAD*
1
1
1
3
1919.
m*.
21*1.
Tt07.
1004.
1991.
170.
2266.
2.HP* Z UPEKATINB
AND 1 SPARE
FILTER
191. SO FT FILTRATION
2
1*3*67.
31670.
AREA
FILTRATE PUHP (PER FILTER)
26.GPI1* 20. OFT HEAD*
O.HP, 2 OPERATING
4
1*2B1.
1557.
AMD 2 SPARE
FILTRATE SURGE TANK
FILTRATE SURGE TANK PUHP
093. UAL/ 9t3FT OIA*
5.3FT HT
52.GPM« 1».OFT HEAD/
1
2
598.
7369.
395.
803.
?..HP» 2 OPERATING
AND ZSPARt
.____..._ .........
TOTAL EQUIPMENT 105T
440IW6. 260397.
C-35
-------
250 MW
o
I
U)
1 LIHESTI1NB SLURRY PROCESS — • bASISl 290 *t
PROJECTED CAPITAL INVESTMENT REQUIREMENTS
EQUIPMENT
MATERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTWORK
MATERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
POND CONSTRUCTION
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
ABOR
BUILDING^
MATERIAL
LABOR
SERVICES. AND. MISCELLANEOUS
SUBTOTAL DIRECT INVESTMENT
ENGINEERING DESIGN AND SUPERVISION
CONSTRUCTION EXPENSES
CONTRACTOR FEES
CONTlNGENCV
SUBTOTAL FIXED INVESTMENT
' ALLOWANCE FOR STARTUP AND MODIFICATIONS
INTEREST. DURING CONSTRUCTION
SUBTOTAL CAPITAL INVESTMENT
LAND
WORKING CAPITAL
TOTAL CAPITAL INVESTMENT
' UNIT* 1981 STARTUP
- EXAMPLE INDUSTRIAL!
INVESTMENT!
RAH MATERIAL
HANDLING AN5
PREPARATION
914.
61.
Ill-
lot,
0.
0.
ill.
lot,
0.
IT.
ii,
96.
1ST.
*!•
T,
lit
19.
"• . ...
1866.
166.
199.
91.
485.
2911.
224.
41T.
3572.
9.
116.
3697.
LIMESTONE
THOUSANDS
SCRUBBING
4209.
119.
11TO.
160.
914.
T19.
99.
Ult
0.
111.
194,
294,
BIT.
240.
Jo.
0,
0.
. 46T,
9616.
B6T,
1942.
4B2.
2505.
15032.
1196.
2299.
18443.
2.
999.
19044,
, NEW ECONOMIC PREI
OF 19BO DOLLARS
WASTE
DISPOSAL
440.
160.
2B6.
116,
0.
0.
H.
,
0.
0.
0.
209.
602.
40.
14.
IS:
10T,
2199.
198,
1S2.
110,
572.
3431.
264.
919.
4210.
8.
137.
4355.
IISES
TOTAL
9181.
661.
1666.
17T.
994.
T19.
191.
472.
P.
192.
229.
997.
1149.
129.
101,
11.
It.
664,
11700.
1211.
2192,
689.
9562.
21372.
1644.
1206,
Z62ZZ.
19.
892.
27093.
CASE 002
DISTRIBUTION
PERCENT
OF OlRKf
INVESTMENT
IT, 6
4,8
12.2
2.T
7,0
9.2
1.4
• !«
0,0
1.1
1.7
4.4
9.8
2,4
0.7
0.2
0.2
4,8
100.0
9.0
16,0
J'°
26.o
156.0
12.0
»»«.
A* I. 4
0.1
6.2
197.8
-------
250 MW
n
i
"ft"'
.' LIMESTONE SLURRY PROCESS — BASISI 25
PROJECTED REVENUE REOUIREHENTS - EXAHP
13,06 TONS
TOT
DIRECT COSTS
RAH MATERIAL
LIMESTONE
SUBTOTAL RAH MATERIAL
CONVERSION COSTS
OPERATING LABOR AND
SUPERVISION
UTILITIES
PROCESS HATER
ELECTRICITY
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
Sludge Disposal
SUBTOTAL CONVERSION CO
SUBTOTAL DIRECT COSTS
INDIRECT COSTS
OVERHEADS
PLANT AND ADMINISTRATIVE
FIRST YEAR OPERATING AND HA
LEVELIIED CAPITAL CHARGES I
FIRST YEAR ANNUAL COSTS
HEAT RATE 9500, BTU/KWH
0 HW UNIT. 1981 STARTUP
LE INDUSTRIAL* LIMESTONE* NEM ECONOMIC PREMISES
DISPLAY SHEET FOR YEAR* 1
ANNUAL OPERATION KH-HR/KW • 5296
PER HOUR DRV
AL CAPITAL INVESTMENT 26270000
ANNUAL QUANTITY UNIT COSTjt
60.5 K TONS B.OO/TON
14020.0 MAN.HR Ui90/HAN«HR
VTVTOiO K GAL Oill/K OAL
22501120.0 KNH 0.029/KMH
SiZOtO HR ITiOO/HR
158.3 !' tons 15.00/HR
5TS
1 60.0* OP CONVERSION COSTS LESS UTILITIES)
INTENANCE COSTI
14.71 DP TOTAL CAPITAL INVESTMENT)
HEAT VALUE OP COAL UTOO BTU/LB
CASE 002
SLUDGE
TOTAL
ANNUAL
COST.»
4BOOO
4BOOD
•
435200
11 BOO
B52600
1096000
54BOO
^-f«W6l
&238£l
5 109 16 I
2376397
7485768
S98261
11468439
COAL RATE 531500 TONS/VR
-------
500 MW
EXAMPLE iNPUSTRIALj LIMESTONE, MEM gCONOHIC PREMISES CASE 001
*•• INPUTS ••«
BOILER CHARACTERISTICS
MEGAWATTS • SOTT INDUSTRIAL BASIS
BOILER HEAT RATE «9500. BTU/KrfH
EXCESS AIR •39, PERCENT* INCLUDING LEAKAGE
HOT CAS TEMPERATURE • 100. DEC f
CQAL ANALYSIS* HT « AS HIRED I
C H o M S sl IM HJO
66.70 3'.BO 5.60 1.30 ».16 0.1Q 13.IB 4.0O
SULFUR IIVEHHEAO • n.o PERCENT
ASH OVERHEAD • 80.0 PERCENT
HEATING VALUE OP COAL m 11700. ITU/19
EFPICIBICY/
•Wfflfr
FTYASHSfTOVAl
UPSTREAM OF SCRUBBER 99. T 0.01
WITHIN SCRUBBER 50.8 0.02
COST OF UPSTREAM FLYASH REMOVAL EXCLUDED
ALKALI
LIMESTONE
CAC03 « 97.13 NT » ORY BASIS
SOLUBLE hCU •070
INERTS • ».B»
DT
HOTSTURETBNTENT • S.OD It H20/100 LBS DRV LIMESTONE
LIMESTONE HARDNESS WORK INDEX FACTOR » 10.00
• 1<3!
LIHESTUNE DECREE OF GRIND FACTOR
PLY ASH
SOLUILC^AU • 0,0 \fr I
SOLUBLE M60 » 0.0
RAN HATEHIAL HAMDLIN'i AREA
NUMBER OF REDUNDANT ALKALI PREPARATIUN UNITS •
C-38
-------
500 MW
SCRUBBER SYSTEM VARIABLES
NUMBER UF OPERATING SCRUBBING TRAINS • *
NUMBER nf REDUNDANT SCRUBBING TRAINS •5
NUMBER UF BEDS •3
NUMBER OF GRIDS •*
HEIGHT OF SPHERES PER BED •3,0 INCHES
LIOUIO-TO-GAS RATIO •53. GAL/1000 ACP(SATD)
SCRUBBER CAS VELOCITY • 12.J PT/5JC
INDUCED DRAFT SCRUBBER FAN OPTION
SCRUBBER PRESSURE • l».T PSIA
STOICH10HETRY •1.23 HOLE CAC03 ADDED AS LIMESTONE
PER MOLB (S02»»HCLI ABSORBED
S02 REMOVAL • 90, PERCENT
ENTRA1NMEMT LEVEL « 0.10 MT «
EHT RESIDENCE TIME • 12.0 BIN
SO* OXIDIZED IN SYSTEM • 30.0 PERCENT
SOLIDS IN REC1RCULATED SLURRY • U.O HT g
SOLIDS DISPOSAL SYSTEM
COST OF LAND • 5000.00 DOLLARS/ACRE
SOLIDS IN SYSTEM SLUDGE DISCHARGE • 30.0 HT »
SOLIDS IN CLARIFFER DISCHARGE • 38.0 lit «
EL'ABtPlER SOL10S SETTLING RATE • 8.20 PT/HR
SOLIDS IN FILTER CAKE • 50.0 MT »
FILTRATION RATE • 1.20 TONS PRY SQLl'uS/fT2 DAY
NO REHEATERS
C-39
-------
500 MW
EXAMPLE INDUSTRIAL* L I ME STONE J ME* ECONOMIC PREMISES CASE 003
**• OUTPUTS ••*
HOT CAS TO SCRUBBER
MOLE PERCENT L8-M(1LE/HR
C02 12.33*
HCL 0.006
Stiz 0.214
02 3.360
N2 73.227
H2tl 6.63*
S02 CONCENTRATION
0.2233E*05
0.1l»SE*Ol
0(39146*03
0.1()16E*03
0,1J75E«06
0.1216E«OS
IN SCRUBBER MLET CAS
LB/HR
0,9923E»06
O.M7SE.03
O.ZSaaEtOS
0.3231E*06
0,»8i2E*07
0.2191E*06
• 1142. PPM
IBS / HILLION BTU
FLYASH EMISSION • 0.03 LBS/HULION BTU
_ • 0.013 6RAINS/SCF (MET) OH 1*7. LB/HR
SOLUBLE CAP IN FLY ASH »
SOLUBLE MGO IN FLY ASH •
o. LB/HR
0.
HOT CAS FLDrf RATE •iTT5*E*0' SCFH (60 DEC fi l*TT PSIA)
• ,1687E*Q7 ACFM (100. OBO f, 14.7 PSUI
CORRESPONDING COAL FIRING RATE • .6060E«06 LB/HR
HOT CAS HUMIDITY • 0.0*2 LB H20/LB DRV CAS
WET BULB TEMPERATURE • 12*. QBC t
MET CAS FROH SCRUBBER
HOLE PERCENT LB-MOLE/HR LI/HR
C02
HCL
J02
02
N2
H20
11.716
0.000
0.020
3.109
70.300
12.793
0.22«1E*03
0.97266*00
0.39UE+02
0.1011E*09
0.137SE*06
0.2302E*03
0.10066*07
OiZOB8E»OZ
0.23088*0*
0.)Z94E*06
0.>852E*07
0.4308E*06
SD2 CONCENTRATION IN SCHUHBER OUTLET 6»5 •ZOO. PPH
FLYASH EMISSION •0.02 IBS/MILLION BTU
. 0.007 CRAINS/SCP (WET> OR 74. LB/HR
TOTAL HATER PJCKUP • *73. CPH '
INCLUDING 11.9 CPU ENTKAINnENT
WET CAS FLOW RATE •.123SE*07 5EFM (60 DEB ft 14.7 PSIA)
- .13686*07 ACFH (126. DEC Pi 16.7 PSIA)
MET GAS SATURATION HUMIDITY » 0.067 LB H20/LB DRY CAS
C-40
-------
FLUE GAS TO STACK
500 MW
HOLE PERCENT
LB-HI1LE/HR
LB/HR
C02
HCL
S02
02
N2
Hzn
11.697
0.000
0.020
3.160
70.188
12.934
O.ZZ91B+OJ
0.5726E+OO
0.391*6+02
0.1011E+OJ
0.137SE+06
0.2933E+09
0. 1008E+OT
0.20B8E+02
§.2S08E+0*
.3234E+06
0.383ZE+07
0.456*6+06
SPECIFIEDS02 REMOVAL EFFICIENCY •90.0 I
CALCULATED soz EMISSION •0.93 POUNDS PER MILLION BTU
CALCULATED S02 CONCENTRATION IN STACK CAS •
200. PPH
FL'YASH EHISSION . 0.02 LBS/KILLION ar
LLION BTU
S/SCF (WET)
•0.007 GRAINS/SCF (W
7». LI/HR
STACK CAS FLOW KATE • . 1237E*07 SCFN (60 DEC f, 14.7 PSU)
• .1*096*07 tCPM (HI. OES ti 14'.7 PllA)
C-41
-------
500 MW
WATER BALANCE INPUTS
RAINPftLLlIN/YEAR) JO.
PQND 5EEPAGE(CH/5EC)*10**8 SO,
POND EVAPURATION( IN/YEAR) 12.
HATER BALANCE OUTPUTS
HATER AVAILABLE
RAINFALL
ALKALI
TOTAL
1. OPH
3. 0PM
6. SPh
5*1. LB/HR
Z304. LB/HR
Zfl*6. LB/HR
HATER REOUtREO
HUHIDIFICATION»6«i 6PNI1169J, LB/HR
ENI5A|ll!PejI»l! .ill H" 3630. LB/HR
DISPOSAL WATER119. GPH9V95I. LB/HR
HYQRATION MATER 12. GPH ftOOTt LB/HR
CLARIFIER EVAPORATIONlit OPHi04B>« LB/HR
PsON0tEVAPORAT,ON gj.OPH ^^R.
TOTAL HATER REQUIRED627. CPN 113368. LB/HR
NET MATER REQUIRED 6tl. OPH 1103Z1. LB/HR
C-42
-------
500 MW
SCRUBBER SYSTEM
tRUBBINb TRAINS lOPERATlNB+REDUNDANTI •
SD2 REMOVAL • 90tO PERCENT
PARTICULATE REMOVAL IN SCRUBBER SYSTEM • 90>0 PERCENT
TCA PRESSURE DROP ACROSS 1 BEDS • a,6 INi H20
TOTAL SYSTEH PRESSURE DROP • 13,9 IN. H20
OVERRIDE TOTAL SYSTEM PRESSURE DROP • ZOiO INi H2U
SPECIFIED liauiO»TU-GAS-RATIO • 99i OAL/iOOO ACF(SATD)
LIMESTONE ADDITION • 0<4607E*09 LB/HR DRY LIMESTONE
SPECIFIEDLIMESTONE STOICHIOMETRV•1.29 MOLE CAC03 ADDED AS LIMESTONE
PtR MOLE ISO»«2HCLI ABSORBED
SOLUBLE CAP FROM FLY ASH • 0.0 HOLE PER MOLE (S02«2HCL) ABSORBED
TOTAL SOLUBLE HCO • 0.0 HOLE PER MOLE tS02«2MCLI ABSORBED
TOTAL STOICHIOHETRY • 1.19 MOLE SOLUBLE (CA*MC1
PER NOLI (S02*2HCLI ABSORBED
SCRUBBER INLET LIQUOR PH • 3(66
MAKE UP WATtR.* B2l< 6PM
CROSS-SECTIONAL AREA PER SCRUBBER •461. SO FT
C-43
-------
500 MW
SOLIDS DISPOSAL
SYSTEM
— — — •— — —
TOTAL CLARIFIERCS) CROSS-SECTIONAL AREA • 18318, SQ FT
SVSTEH SLUDGE DISCHARGE
____.» ___--- -.
SPECIES
CAS03 .1/2 H2O
§ASO* .2H20
AC03
INSOLUBLES
H20
CA*+
MG++
CL-
m—~mmm—m
LB-MOLE/HR
0.2466E*Q3
0.1091E+03
0.89*26+02
0. J306E+04
0.6218E+01
0.0
0.94B9E-01
0.6568E«00
0.1088E*02
SOLID
COMP.
LB/HR MT X
0.91B4E*fl9 92.84
0.1B08E»09 30.01
O.B9JlE*0* 14.66
0.1387E+04 2.30
0.9999E»09
0.0
0.759TE*01
0,63096*02
0.3«9TE*03
LIQUID
CMP*
PPM
4136.
0.
126.
10*7.
6401.
TOTAL DISCHARGE
TOTAL DISSOLVED
FLOW RATE •
•
0.120SE+06 LB/HR
147. 5AH
SOLIDS IN DISCHARGE LIQUID • 1169T
. PPM
DISCHARGE LIQUID rH • 7,28
C-44
-------
500 MW
SCRUBBER SLURRY BLEEP
SPECIES
CAS03 .1/2 HZO
§AS04 .2H20
AC03
INSQLUBLES
H2Q
CA»*
MG+*
S03--
in*—
CL-
AD-
TOTAL FLDU RATE
LB-HOLS/HR
0.2466E«03
0.1031E+03
dltt^fl+oi
0.18736*03
0.35246*02
0.0
0.5377E+00
0.37226*01
0.61656*02
0.0
• 0.40176*06
• 730.
LB/HR
0.318*6*03
0.18086*03
0
-------
500 MW
LIMESTONE SLURRY FEED
SPECIES
CAC03
SOLUBLE HCO
INSQLUBLE5
H20
CA*#
MG+*
S03—
S04--
CL-
AD*
TOTAL FLOW RATE
L8-HQLE/HR
0,4471E*03
0.0
0.16896*04
0.29636*01
0.0
0. 49226-01
0.3130E+00
0.3184E+01
0.0
• 0.7678E+OS
• 97,
LB/HR
0,4476E*03
§.0
. 1313E«04
0.30356*01
0,H88E*03
0.0
Oi3620E*01
0.30076*02
0.1838E*03
0.0
LB/HR
OP-*
SUPgRNATE RETURN TO SCRUBBER HR EHT
SPECIES
H2Q
CA*+
MC+*
S03—
504—
CL-
AOi
L8-MQLE/HR
0.1331E+05
0.2303E+02
0.0
0.3819E+00
0,26*4E+OX
9. 43796+02
A.o
LI/HR
0.239TE*0»
o.iooae«o*
0.0
«.30J8E*02
i2940E«0>
0.11526*04
OiO
TOTAL PLOW RATE • 0.24236*06 LB/HR
485. CPU
RECYCLE SLURRY TO SCRUBOER
SPECIES
LB-HOLE/HR LB/HR
CAS03 .1/1 H20
CASO* .2(120
CAC03
INSOLUBLES
H20
CA++
HG**
S03--
S04—
CL-
AD*
TOTAL FLOW RATE
0.2SBOE+OS
0.1099E4OS
0.9354E+0*
0.19996*07
0.36866*04
0.0
0.3629E*OZ
0.3893E+03
0.&44I>E+04
0.0
• 0.4202E+08
• 76321.
0.33306*07
0»1891E*07
Oi 93646*06
O.U50E*06
0.33106*01
0.14776*06
0.0
0.4903E*04
0.37*06*09
0.22866*06
0.0
LB/HR
flFI
C-46
-------
500 MW
FLUE GAS COOLING SLURRY
SPECIES LB-MOLE/HR
CAS03 .1/2 H20 0.1B76E+0*
CASO* (2H20 0.7993E+03
CAC03 0.6803E+03
INSOLUBLES .._—_.—
H20 0.1*29E+O6
CA++ 0.2681E+03
MG+* 0.0
S03— 0.*091E+01
SO*— 0.2832E+02
A0> o!o
TOTAL FLOW RATE • 0.3096E*07
• 9991.
LB/HR
0.2*22E«06
0.1376^*06
0.6810E*OS
0.1099E«09
0.2967E»07
5.iot*e*oJ
0.0
0.2720E*0»
0.1663E«05
0.0
LB/HR
0PM
CLARIFIER UNDERFLOW SLURRY
•»— — • — •— »— •— ••—
SPECIES LB.MQLE/HR
CAS03 ,1/2 H20 0.2*666*03
CASO* .2H20 0.1091E+03
CAtdi O.S94ZE+OZ
INSOLUBLES — — —
H20 0.6139E*0*
CA** 0.113SE*02
MG** 0.0
S03— 0.1762E+00
CL- o!2021E+02
AO. 0.0
THTAL FLOW RATE • 0.1722E*06
• 270.
LB/HR
o!lBOBE«09
O.B9SiE*6*
0.1387E»0*
0.1106E«06
0,*629E«0»
0.0
0.1*11E*O2
0.7163E»03
0.0
LB/HR
OP1
SUFERNATE FRUH CLARIFIER
SPECIES Lft-HQLE/HR
CASD3 .1/2 H20 0.0
CASH* ,2H20 0.0
CAC03 0.0
INSOLUBLES — — —
H20 0.120SE+OS
CA+* 0.2264E+O2
MC++ O.i)
S03— • 0.3*9BE*00
SO*— 0.239*E»01
CL- 0.3969E+O2
A0< 0.0
LB/HR
0.0
0.0
0.0
0.0
0.2170E*06
0.9ofi3E»oS
0.0
0.2769E«02
0.2JflOE*03
o!o
TOTAL FLOW RATE • 0.2196E*06 LB/HR
C-47
-------
500 MW
439.
6P1
FILTER CAKE SLURRY
SPECIES
LB-MOL8/HR LB/HR
CAS03 .1/2 H20
CASO* .2H20
CAC03
INSOLUBLE3
H2Q
CA**
MC+*
S03~
SO*—
CL-
AD*
0.2*66E*03
0.1031E*03
0.89*2E*12
0.33066*0*
0,621BE*01
0.0
0,9*S9E-01
0.6368E+00
o,ioaaE*oi
0.0
0,318*6*03
0.1808E*03
p.«9sie*o»
6.1387E»0*
0.39936*09
0.2*926*03
0.0
0.7597E»Ol
0.6309E*02
Oi 48976*01
0.0
TOTAL FlOM RATE • 0
^2091*0.^
HR
FILTRATE FROM FILTER
SPECIES "~
CAS03 .1/2 H20
CASU* .2H20
CAC03
INSOLUBLES
H20
CA**
MC**
Sd3—
sq*—
CL-
AD'
TOTAL FLOW RATE
L8-MOLE/HR
0.0
0.0
0.0
0.2833E*0*
0,9330E*Ol
0.0
a(8139E>01
0.3630E400
0.9329E*01
0.0
• 0.91696*09
LB/HR
0.0
5.a
0.0
0.0
0.91096*09
0.2136C*0>
0.0
Ot09iie«oi
0.3*086*02
0.33066*03
0.0
kS.
-------
500 MW
EXAMPLE INDUSTRIAL. LIMESTONE* HEM ECONOMIC PREMISES
CASE 003
I
-p-
MPSUL CONTENT (Sll
ASH CONTENT («ll
BTU RAT ING 1
BOILER TVPEl
NO. OF SCRUBBERS!
SCRUBBER VELOCITY (FT/MM
PLANT SUE (HWll
UPEHATINC HRS/VRI
PUMPING RATE ICAL/1000 ACFII
SCA P.ATIOI
(ACTUAL SQ.FT./CALC. SQ.FT.)
PARTICIPATE REMOVAL
3,16
15 10
11 TOO
DRV PULVERIIEO COAL
4
TJO.O
500
1216
20.00
1. 100
INVESTMENT AND OPERATING COST
PARTICIPATE EMISSION RfcGULATjON ILB ASH/MILLION BTUII
FLUE CAS TEMPERATURE (COLO) |F||
FLUE CAS TEMPERATURE (HOT! IFII
COST OF ELECTRICITY li/KhHRtl
COST OP STEAH 1 I/THOUSAND IBM
FIRST YEAR CAPITAL CHARGE FACTORl
BAGHOUSE RATIO (OPER. SO. FT. /ACTUAL SO. FT. II
BAG COST (»/SQ,FT.II
BAG LIFRIVEARSII
FLUE CAS REHEAT TEMPERATURE (F||
CHEMICAL ENGINEERING PLANT INOEXI
0.01
100.0
TOO.O
0.01
2.00
0.1BO
0,60
0,70
1.00
IK.
263.0
ELECTROSTATIC PRECIPITATORI
COLO
HOT
BAGHOUSE FABRIC PILTIRS
SCRUBBERS
REQUIRED REMOVAL EFFICIENCY 1*11
DRIFT VELOCITY |FT/M)I
SPECIFIC COLLECTION AREA (SQ'.PTi/ACFHI I
COLLECTION AREA (SQ.FT.Ii
TOTAL CORONA PUHER |KW||
AUXILIARY POWER (KHM
PAN POWER IKWII
PUMP POWER IKMII
TOTAL PflwiH IKHII
OPERATING AIR/CLOTH RATIQl
INSTALLED AIR/CLOTH RATIO!
REQUIRED PRESSURE DROP 1 INCHES II
DIAMETER IFEETII
REQUIRED REHEAT CBTU/HRII
STEAM SUPPLY/VR (THOUSAND LBII
INSTALLED COST (1979 DOLLARS)! A
FIRST YEAR CAPITALIZED COSTl 1
ANNUAL POWER COST! 1
ANNUAL OPERATING AND
MAINTENANCE COST 11979 DOLLARS)! t
REPLACEMENT COST 1(979 DOLLARS II
ANNUAL REHEAT COSTl
99.70
27.19
468576.7
661,6
407.4
ii*,o
1111,0
1.0
6362679
1111469
101479
112891
99.70
20.00
m.54
971109,6
1012,1
913.2
4BI.O
I"l. 0
1.0
» 12I76I1J
• 2193762
» 133291
» 169411
99.70
866113.3
490:2
1120.1
1810.1
2.4
1.9
S'.O
t 16103390
t 29400T3
t 27}9aS
» 717ZB
* 265128
99.70
16039,9
3267. {
19107, T
60.8
JO
6024348.0
Illti.4
• 22712816
» 4099484
» 2942936
* 1192909
• 70167
TOTAL ANNUAL COST I
ANNUAL HEP COST OP PQWER1HILLS/KWHR> I
1499841
0.37
2720466
1.04
1334864
1.33
8103716
1.16
-------
500 MW
. RAH MATERIAL HANDLING AND PREPARATION
ITEN
DESCRIPTION
NUi
MATERIAL
LABOR
CAR SHAKER AND HOIST
CAR PULLER
UNLOADING HOPPER
UNLOADING VIBRATING FEEDER
UNLOADING BELT CONVEYOR
UNLOADING INCLINE BELT
CONVEVOR
UNLOADING PIT OUST COLLECTOR
UNLOADING PIT SUMP PUMP
STORAGE BELT CONVEYOR
STORAGE CONVEYOR TRIPPER
MOBILE EQUIPHENT
RECLAIM HHPPER
RECLAIM VIBRATING FEEDER
RECLAIM BELT CDNVETUK
RECLAIM INCLINE BELT CONVEYOR
RECLAIM PIT DUST COLLECTOR
RECLAIM PIT SUMP PUMP
RECLAIM BUCKET ELEVATOR
FEED BIN
BIN WEIGH FEEDER
GYRATORY CRUSHERS
BALL HILL DUST COLLECTORS
ZOHP SHAKER 7.SMP HOIST
Z9HP PULLER* SMP RETURN
16FT DM* IOFT STRAIGHT
INCLUDES 6 IN 39 GRATE ING
3.JHP
20FT HORIZONTAL* SHP
310FTi SOHP
POLYPROPYLENE BAGTVPE*
INCLUDES OUST HOOD
60GPM. TOFT HEAD* SHP
200FTJ SHP
30FPN. 1HP
SCRAPPER TRACTOR
TFT WIDE* 4.29FT HTt ZFT
WIDE BOTT3M, C5
3. SHP
too f ft »Hf
193FT* 40HP
PULYPROPYLENE BAG TYPE
600PM* 70PT HEAD* SHP
90FT HJOH» TIHP
13FT D1A* 21FT STRAIGHT
SIDE HTj COVERED* CS
14FT PULLEY CENTERS* 2HP
TSHP
POLYPROPYLENE BAG TYPE
1
1
1
I
\
\
I
\
\
I
1
2
t
1
1
1
1
1
2
2
2
2
61661,
S4099,
L3I9T.
4687.
9809.
T3133.
9S91.
2071.
62670.
2832*.
121633.
2071.
9171,
23099.
H661,
664B,
Z071,
lTQ02t
2*T*1.
28138.
169807.
13297.
10801.
16Z02,
*9l9t
432 •
UB8i
3996 •
»»20.
668.
1240.
7961,
&•
HSOi
864.
2176 11
3024.
Zl60i
648«
990«i
13289, -
1296.
3964.
4320.
ZZOO CFH» l,3Hf
BALL MILL
MILLS PRODUCT TANK
ll.JTPH, 133. HP
530O GAL IOPT DIA« IOFT
HT. FLAKECLASS LINED CS
2
1
329Z7B.
TB«7,
37290.
6049.
MILLS PRODUCT TANK AGITATOR IOHP
13079.
3024.
C-50
-------
500 MW
MIILS PRODUCT TANK SLURRY *B.CPH/ 60FT HEAP, 3 71»9. 2268
PUMP
SLURRY PEED TANK
SLURRY FEED TANK ACITATUR
SLURRY FEED TANK PUMPS
2. HP/ Z OPERATING
AND 1 SPARES
9118}. GALj Z0.6FT OIA< 1 19700.
20.6FT HT» FLAKECLAS5«
LINED CS
43. IIP 1 13BOS.
24.CPHI ftO FT HEADj 6 13783.
12331.
2680.
4936.
l.HP* 4 OPERATING AND
2 SPARE
.-..___.. .——.._
TOTAL EBUIPMENT COST129277*,160082,
C-51
-------
500 MW
SCRUBBINO
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
1.0. FANS
tHELL
UB8ER LINING
5 1ST ELIMINATOR
Lu*Rv HEADER AND NUZZLES
GRIDS
SPHERES
TOTAL TCA SCRUBBER COSTS
SOOTBLOUERS
EFFLUENT HOLD TANK
EFFLUENT HOLD TANK AGITATOR
COOLING SPRAY PUMPS
ABSORBER RECYCLE PUMPS
ZO.OIN HZOi WITH 1482.
HP MOTOR AND DRIVE
1911)60. GAL' 19,OFT OIA<
33. OFT HT/ FLAKEGLASS-
LINED CS
66. HP
13BB.GPN 100FT HEAD*
6*.HP{ 4 OPERATING
AND * SPARE
9940fGPMt IOOPT HEAD*
442. HP* 8 OPERATING
4 9397163.
109QT6S.
1035699,
21*417.
261329.
46*884.
633986.
4 366 1279 f
32 76729.
4 208139.
* 278604.
B 71838,
12 691000,
47*10.
296Z91,
69127,
162329.
88392,
21988,
74909,
AND * SPARE
MAKEUP MATER PUMPS
TOTAL EQUIPMENT COST
Zr79,GPH« ZOO. FT HEAD*
234. HP* 1 OPERATING
AND 1 SPARS
Z 24900,
m~~»mmmmm *
8411090.
Z649,
•«.••«•«••
722206.
C-52
-------
500 MW
•
WASTE OISPUSAI
ITEM
DESCRIPTION NO. MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATOR
THICKENIR FEED PUMP
THICKENER -
THICKENER UNDERFLOW SLURRY
PUMPS
THICKENER OVERFLOW PUMPS
62898. GAL* 17.5FT OIA« 1 10TZO.
33. OFT HT, FLAKGLASS-
LiNfio cS
38, HP 1 11676.
730.GPH, 60FT HEAD/ 2 13252.
20. HP, 1 OPERATING
AND 1 SPARE
183lB.SQ.FT.jl33.FT OIAj I 323299.
B.6TANK FT HT
270. GPM. 9.1FT HEAD* 2 6683.
l.HP * 1 OPERATING
AND 1 SPARE
09. GPM, TS.OFT HEAD, 2 8339.
16336,
1877,
4037,
337388i
2616.
933.
14.HP* 1 OPERATING
AND 1 SPARE
THICKENER OVERFLOW TANK
FILTER FEED TANK
FILTER FEED TANK
AGITATOR
FILTER FEED SLURRY PUMP
FILTER
7230. GAL* 12. OFT DIA« 1 2188.
8|6FT HT
4460. GAL* 9.1FT OIAt 1 1086,
9.1FT HT* FLAKEGLASS.
LINED CS
7. HP I 4237.
13S.GPM, SOFT HEAD, 1 10117.
».HP, 2 OPERATING
AND 1 SPARE
301. SO FT FILTRATION 2 196139.
13TB.
2*64,
337,
289B.
36249.
AREA
FILTRATE PUMP (PER FILTER)
FILTRATE SURGE TANK
FILTRATE SURGE TANK PUHP
32.GPH, 20. OFT HEAD* 4 1*331,
O.riP, 2 OPERATING
AND 2 SPARE
1703. GAL/ 6.6FT OIA, 1 949.
6.6FT HT
103. GPM, dS.OFT HEAD, 2 7606.
4, HP, 2 OPERATING
AND 2SPARE
13B4.
627.
829.
TOTAL EQUIPMENT CIJST
6372T7, 4099TZ.
C-53
-------
500 MW
o
I
Ul
LIMESTONE SLURRV PROCESS — BASIS! 900 HI
PROJECTED CAPITAL INVESTHENT REQUIREMENTS
»•
EQUIPMENT
MATERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTWORK
MATERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
POND CONSTRUCTION
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
BUILDINGS
MATERIAL
LABOR
SERVICES AND MISCELLANEOUS
SUBTOTAL DIRECT INVESTHENT
ENGINEERING DESIGN AND SUPERVISION
CONSTRUCTION EXPENSES
CONTRACTOR FEES
CONTINGENCY
SUBTOTAL FIXED INVESTHENT
ALLOWANCE FOR STARTUP AND MODIFICATIONS
INTEREST DURING CONSTRUCTION
SUBTOTAL CAPITAL INVESTHENT
LAND
WORKING CAPITAL
TOTAL CAPITAL INVESTMENT
1 UNIT, 1911 STARTUP
<• EXAMPLE INDUSTRIAL!
INVESTMENT*
RAW MATERIAL
HANDLING AND
PREPARATION
12S3.
160.
m.
.
0.
0.
241.
ilTl
0.
1)7.
ii.
161.
410.
»1.
11.
11.
16.
11*.
1849.
146.
61),
1*2.
1000,
5998.
461.
900.
7359.
10.
232.
7601.
LIMESTONE/
THOUSANDS
SCRUBBING
B411,
722.
2341.
11*.
1991,
1*10.
iia.
147.
0.
lie*
1ST.
191,
1090.
468.
M,
0,
0,
618,
1*013,
1711.
1045,
992.
4949.
2962.
2284.
4494.
36430.
1.
1149.
37582.
NEW ECONOMIC PREI
OF I960 DOLLARS
WASTE
DISPOSAL
617.
410.
186.
14i.
0.
0.
H.
,
0.
I*
5.
219,
674,
40.
94.
26,
16.
91,
2780,
2)0,
441.
119.
723.
4337.
114,
691,
5322.
11.
168.
5503.
HISBS
TOTAL
••*.•«
10301.
1292.
1028.
£84.
1951,
1480.
IB A.
9 Jo,
0.
177.
(71.
971.
2114,
602.
146.
99.
62.
860.
25699.
2309,
4105.
1283.
6671.
60027.
1079.
6004.
49110.
27.
1149.
50686.
CASE 001
DISTRIBUTION
PERCENT "
OF DIRECT
INVESTHENT
,...—._,
40.1
9.0
11. a
2.4
7.6
9.8
!•>
1.6
0.0
1.9
I.I
l.B
B.I
2.1
0.6
0.2
0.2
1.4
100.0
v.o
16.0
9.0
26.0
156.0
12.0
21.4
191.4
4.1
6.0
197.5
-------
500 MW
o
I
Ol
LlHESTUNk SLURRY PROCESS — BASISl 500
V
PROJECTED REVENUE REOUIRtMENTS - EXAMPLE
MM UHlTj 1911 STARTUP
INDUSTRIAL. LIMESTONE, NEW ECONOMIC PREMISES
DISPLAY SHEET FOR YEAR* 1
CASE 003
ANNUAL OPERATION KW-HR/KW • 9236
30.13 TONS PER HOUR DRV
TOTAL CAPITAL INVESTMENT 49147000
ANNUAL QUANTITY UNIT COST* I
SLUDGE
TOTAL
ANNUAL
COST,!
DIRECT COSTS
RAH MATERIAL
LIMESTONE
SUBTOTAL RAH MATERIAL
IZl.i K TONS 8. GO/TON
968600
96B600
CONVERSION COSTS
OPERATING LABOR AND
SUPERVISION
UTlLimS
PROCESS WATER
ELECTRICITY
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
Sludge Disposal
ttaao.O HANaHft 12,90/MAN.HR
199930.0 K CAL 0,11/K CAL
44629970.0 KWH 0.029/KUH
4830iO HR 17,00/HR
316.7 K tons 1S.OO/HB
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
936000
13900
12941BO
20*2700
Izlo6
473089S
873939B "
9707998 '
INDIRECT COSTS
OVERHEADS
PLANT AND ADMINISTRATIVE i
60.0* OP CONVERSION COSTS LBSS UTILITIES!
FIRST YEAR OPERATING AND MAINTENANCE COSTS
LEVELIIED CAPITAL CHARCES( 14
FIRST YEAR ANNUAL REVENUE
.17. OF TOTAL CAPITAL INVESTMENT)
REQUIREMENTS
4453079
14161077
7450842
21611919
HEAT RATE 9SOO. BTH/KWH
HEAT VALUE OP COAL
11700 BTU/LB
COAL HATE 1066900 TONS/YR
-------
1000 MW
EXAMPLE iNOUSTRIALj LIMESTONE* NEX ECONOMIC PREMISES CASE 00*
*•• INPUTS *•*
BOILER CHARACTERISTICS
MEGAWATTS • 1000. 1MDUSTMAL BASIS
BOILER HEAT RATE • 9500. BTU/MH
EXCESS AIR •39. PfcRCENT/ INCLUDING LEAKAGE
HOT CAS TEMPERATURE • 300V DEC F
COAL ANALYSIS* WT I AS FIRED 1
C
66.70
SULFUR
H Q
3.80 J.60
OVERHEAD • 92
N
1,
1?
30
S
1.16
CL
0.10
ASH
IS. 10
H20
4.00
PERCENT
ASH OVERHEAD » BO.O PERCENT
HEATING VALUE OP COAL • 11700. STU/LB
EFFICIENCY/
FLYASH REMOVALILB3/H ITU
UPSTREAM OF SCRUBBER 9<.T 0.01
WITHIN SCRUBBER 50.3 0.02
COST OF UPSTREAM FLYASH REMOVAL EXCLUBEO
ALKALI
LIMESTONE
CACD3 • 97.13 WT I DRY BASH
SOLURLE MGU • 0,0
INERT* » 2.83
MOISTURE CONTENT • S'.OO LB H20/100 LBS ORY LIMESTONE
LIMESTONE HARDNESS WORK INDEX FACTOR • 10.00
LIMESTONE UEGREE OF GRIND FACTOR •[715
FLY ASH
SOLUBLE CAD • 0,0 WT I
SOLUBLE HCO • 0.0
INERTS• 100,00
RAH MATERIAL HANDL(rtG AREA
NUMBER UF RtDUMOAMT ALKALI PRCPARATIUN UNITS •
C-56
-------
1000 MW
SCRUBBER SYSTEM VARIABLES
NUMBER Or OPERATING SCRUBBING TRAINS •
NUMBER OP REDUNDANT SCRUBBING TRAINS •
NUMBER Or BEDS •
NUMBER OF GRIDS •
HE IGHT OF SPHERES PER BEIT* ).0 INCHES
LIOUID-TO-GA5 RATIO » 99t GAL/1000 ACF(SATD)
SCRUBBER GAS VELOCITY • 12.3 PT/SEC
INDUCED DRAFT SCRUBBER FAN OPTION
SCRUBBER PRESSURE • I*t7 PSIA
STOICHIONETRV •1.29 MOLE CAC01 AOOEO AS LIMESTONE
PER HOLE (S02+2HCU ABSORBED
S0» REMOVAL • 90. PERCENT
ENTRAPMENT LEVEL « 0.10 WT «
EHT RESIDENCE TIME . 12.0 HIN
S02 OXIDIZED IN SYSTEM • 30.0 PERCENT
SOLIDS IN RECIRCULATEO SLURRY • 15.0 MT «
SOLIDS DISPOSAL SYSTEM
COST OF LAND • 1000.00 DntLARS/ACRB
SOLIDS IN SYSTEM SLUDGE DISCHARGE • 80.0 WT I
SOLIDS IN CLARIFIES DISCHARGE • 33.0 WT «
CLARIFIER soi.IDS SETTLING RATH • a.20 FT/HP.
SOLIDS IN FILTER CAKE • SO.O XT »
FILTRATION RATE • 1.20 TONS DRY 50HDS/FT2 BAY
NO REHEATERS
C-57
-------
1000 MW
EXAMPLE INDUSTRIAL. LIMESTONE* SEW ECONOMIC PREMISES CASE oo*
••• OUTPUTS **•
HOT CAS TO SCRUBBER
HOLE PERCENT
C02 12.338
HCL 0.006
S02 0.21*
02 3.36U
NZ 79.227
H20 6.63*
S02 CONCENTRATION IN
L8-MULE/HR
0.4509E+09
0.22906+02
0.78296+03
0.20326403
0.27*96+06
0.2432E+03
SCRUBBER INLBT GAS
LB/HR
0.1985E+07
0.8331E+03
O.JOHE+03
0.6302E+06
0.770*8+07
0.43816*06
• 11*2. PPM
MILLION BTU
FLYASH EMISSION •0.03 IBS/MILLION BTU
• 0.015 CRAINS/SCF tMETI OR 29*. Li/MR
SOLUBLE CAP IN FLY ASH .
SOLUBLE MOD IN FLY ASH •
I. LB/HR
HOT GAS FLOW RATE* .2309E+07 SCPH (60 010 Fi 1»,7 PSIA)
• .337*E*07 »CPH OOP. 080 f, I*.7 PilAI
CORRESPONOtNC COAL FIRING RATE • .81206+86 LB/HR
HOT CAS HUH1P1TV • 8.0*2 Lfl H20/L9 PRY SA1
WET BULB TEMPERATURE « 12*. DEC F
WET CAS FROM SCRUBBER
MOLE PERCENT LB-MOLE/HR LB/HR
£02
HCL
S02
02
N2
H20
11.716
6. 000
§.020
.169
70.JOO
12.793
0.*J82E»03
5.ii*se*o!
0.7BZ9E+02
0.2021E+OS
0.27*96*06
0.500*E+03
?-?917S*2I
o.*I?sl+3i
0.3013E»0*
o!6*6«E+06
0.770*E+07
0.901SE+06
S02 COMCEHTRATlriM IN SCRUBBER OUTLET GAS • 200. PPN
FLVASH EMISSION • 0.02 IBS/MILLION BTU
• 0.007 CRAINS/SCF (WET! OR 147. LB/HR
TOTAL WATER PICKUP • 930. CPM
INCLUDING22.3 GPM ENTRAINHENT
WET GAS FLOW RATE •,2*7UE*07 5CFM (60 DEC ft 14.7 PSIA)
. .27796*07 ACFH (124. PEG F. 14.7 PSIAI
WET CAS SATURATION HUMllllTV « 3.097 LB H2Q/LB DRY CAS
C-58
-------
1000 MW
FLUE CAS TO STACK
HOLE PERCENT
LB-.HOLE/HR
LB/HR
C02
HCL
SD2 '
U2
N2
H20
11.697
0.000
0.020
3.160
70.18(1
12. 93*
0.4S8ZE+09
0.11
-------
1000 MW
HATER BALANCE INPUTS
RAINFALL! IN/YEAR) »0.
PONO SEEPAGE(CM/SEC)»10»»8 10 •
POND EVAPORATION! IN/YEAH1 M.
WATER BALANCE OUTPUTS
WATER AVAILABLE
RAINFALL 2< 0PM 1066, LB/HR
ALKALI 9. 6PM *60T. LB/HR
TOTAL:11. 6PH9691i IB/HR
WATER REQUIRFO
HUHIOIFICATION»27. 6PM463391, LB/HR
ENTRAPMENT 23. 6PM 11260. LB/HR
DISPOSAL ufATER Z36> CPM 119l05i LB/HR
HVORATION NATFR t». CPM 120i». LB/HR
CLARIFIER EVAPORATION42• CPM20969i LB/HR
POND EVAPORATION 0. CPM 0. LB/HR
SEEPAGE Oi CPM 0< LB/HR
TOTAL MATER REQUIRED1294. GPM 6Z6736, LB/HR
NET WATER REQUIRED jlQ. 0PM 6*100. LB/HR
C-60
-------
1000 MW
SCRUBBER SYSTEM
TOTAL NUMBER OF SCRUBBING TRAINS (OPERAT]NG*REDUNDANT) • 8
502 REHOVAL •90,0 PERCENT
PARTICULATE REMOVAL IN SCRUBBER SYSTEM • 30,0 PERCENT
TCA PRESSURE DROP ACROSS3 REDS •l|6 INi HZO
TOTAL SYSTEM PRESSURE DROP • 13,9 IN* MZO
OVERRIDE TOTAL SYSTEM PRESSURE DROP • 20.0 IN, HZO
SPECIFIED UQUID-TO-GA5-RATIO •Sit GAL/1000 ACF(SATD)
LIMESTONE ADDITION • n.9Z14E«OJ LB/HR DRV LIMESTONE
SPECIFIED LIMESTONE STOItMIQMETRY i 1,29 HOLE CACOB ADDED AS LIMESTONE
PER HOLE ISO»»»HCL1 ABSORBED
SOLUBLE CAP FROM Ply ASH • 0.0 MOLE PER MOLE (S02+2HCLI ABSORBED
TOTAL SOLUBLE HCO • 0.0 MOLE PER HOLE (S02*2HCL1 ABSORB60
TOTAL STOICHIOHETRY • i.»» note SOLUBLE ICA+MOI
PER HOLE (S02*2HCL) ABSORBED
SCRUBBER INLET LIQUOR PH •3.66
MAKE UP MATER • 1243. GPM
CROSS-SECTIONAL AREA PER SCRUBBER •«61, SQ FT
C-61
-------
1000 MW
SntlOS DISPOSAL SYSTEM
TOTAL CLARIFIERIS) CROSS-SECTIONAL AREA •36636. SO FT
SYSTEM SLUDGE D1SCHARKE
SPECIES
CAS03 ,1/2 H20
CAS04 .2HZO
CAC03
INSOLUBLES
H20
CA**
MG**
S03--
$04—
CL-
LB-MQLE/HR
0.4932E+03
0.2101E+03
6.i?oaE*o3
0.6611E*04
0.12446*02
0.0
0.1698E4.00
0.1114E+01
0.2176E*02
LB/HR
0.636TE»03
0.3616E+OJ
o.i^oe+os
§.27736*04
,1191E*06
§•49898*03
.0
0.1S19E*02
6.l262E*Ol
O.T714E*03
SOLID
COMP.
MT »
52.84
30.01
li.U
2.30
LIQUID
CQMPj
PPH
4186.
0.
126.
1047,
&4O1.
TOTAL DISCHARGE FLOW RATE • 0.24108*06 LB/HK
CPN
• Q.2410J
• 334.
TOTAL DISSOLVED SOLIDS IN DISCHARGE LIQUID • 11697. PPH
DISCHARGE LIQUID PH •7,28
C-62
-------
SCRUBBER SLURRY BLEED
1000 MW
SPECIES
LR-MOLE/HRLB/HR
CAS03 .1/2 H20
CASO* .2H2Q
INSOLUBL'ES
H20
CA**
HC**
S03—
SO*—
CL-
AD-
0,*932E*03
0.2101E*03
0.i788E+oJ
0,37*6E*09
0.70*7E«02
0.0
0.10736*01
0.7***E*01
0.1233E+03
0.0
0.6367E*03
0.36166*03
0.l79oE»oS
0.2773E»0*
0.6749E«06
0.2B23E«0*
0.0
O.B609E*fl2
0.7191E*03
0.*371E*0*
0.0
TOTAL FLOW RATE • O.B03*E«06 LB/HR
CPU
TOTAL SUPERNATE RETURN
SPECIES
LB-MOLE/HR LB/HR
H20
0.2976E*OS 0.3362E«06
CA*+
MC**
0.53996*02
0.0
S03—
SO*—
0.6I!«OE*02
CL-
AB»
o.a
0.0
TOTAL FLOW RATE • 0.5»23E*06 LB/HR
1083.
SUPERNATE TO WET BALL MILL
SPECIES
H20
CA**
HC**
SOS—
SO*—
CL-
AD*
LB-MOLE/HR
0.31Z3E+0*
0.3875E*01
U.O
O.B963E-01
0.6206E*00
0.102BE*02
0.0
LB/HR
0.9626E*09
0.23S9E*03
0.0
0.7J77E»Ol
0.9961E«02
0.36**E*03
0.0
TOTAL FLOW KATE • 0.3693E*09 LB/HR
11*. GP1
C-63
-------
LIMESTONE SLURRY HEED
1000 MW
SPECIES
CAC03
SOLUBLE HGO
INSOLUBLES
H20
CA**
HG*«
S03—
sn«—
CL-
AD>
TOTAL FLOW RATE
LB-MULE/MR
o!o
0.33706*04
0.58736*01
0.0
O.8965E.O1
§.62066*00
.10286*02
0.0
• 0.13366*06
LB/HR
0.09926*09
0,0
0,262aE*04
0.60716*03
0,23356*03
0,0
0,71776*01
§.59616*02
,3644E*OJ
0.0
LB/HR
GP1
SUPERMATE RETURN TO SCRUBBER on EHT
SPECIES
H20
C4+*
MG++
S03--
S04--
CL-
AO*
LS-HOLE/HR
0.2664E*OS
0.50116*02
0.0
0.76A7E+00
0.!iZ93E*Ol
0.8768E+02
0.0
LB/HR
0<*799E*06
0.20086*04
0.0
0.61226*02
0.30B5E*01
§.31086*0*
.0
TOTAL FLOW RATE •
0.4d36E*06 LB/HR
972. 6P1
RECYCLE SLUHRY TO SCRUBBER
SPECIES
LB-MOLE/HR L8/HR
CAS03 .1/2
CAS04 .2H20
H20 0.5159E*08
SQ*
CACD3
0.2198E*03
0.18716*08
0.18716*08 0.1873E
. .... 0.2 90 IE
873E*OT
INSOLUBLES
H20
0.3919E+07
9016*06
.70606*08
CA*»
MC*«
0,7372E*04
0.0
0,29556*06
Q.O
S03—
SD4—
0.11256*03 0.40066*04
CL-
A0»
0.0
0.0
TOTAL FLOW KATE
• 0*
rrt
2643.
Lfl/
CM
HR
C-64
-------
1000 MW
FLUE GAS COOLING SLURRY
SPECIES LB-mjLE/HR
CAS03 .1/2 H20 0.3732E*O4
CAS04 .2H20 0.1J99E+O4
CAC03 0.1361E*04
INSOLUBLES .__.___—
H20 0.28SOE+O6
CA*» 0.9361E*OI
M6++ 0.0
S03— O.B101E*01
S04— 0.5663E+02
CL- 0.93B1E+03
AD> 0.0
TOTAL FLOM RATE • 0.&112E*07
LB/HR
0.*B44E*06
0.2731E*06
0.13626*06
0.21106*09
O.S13SE*OJ
5.2l49E*oS
0.0
0.43506*03
0 • 3%^OE tQ4
0 • 33256 t09
0.0
LR/HR
• 11101. OP1
CLARIFIER UNDERFLOW SLURRY
— — ••- -•— — — — —
SPECIES LB-MOLE/HR
CAS03 .1/2 M20 0.4932E*03
§ASD4 .2H20 0.2101E+03
AC03 a:l7B8E*flS
INSOLUBLE! .__———
H20 0.1228E*09
CA»» 0.2310E»02
MG*» 0.0
$03— 0.3324E*00
$04— 0.2440E*Ol
CL- 0.4041E*02
A0> 0.0
TOTAL FLOW RATE • 0.3443E*06
• 541.
LB/HR
0.63676*05
0.36166*03
6.1T4oE*oS
0.2773E«04
0.2212E*06
0.92376*03
0.0
0.28226*02
0.23446*01
§.1433E«04
.0
LB/HR
GP1
SUPERNATE FROM CLARIFIER
SPECIES LB-HOLE/HR
CASQ3 .1/2 M20 0.0
CAS04 ,2H20 0.0
CAC03 0.0
INSQLUBLES — — — —
H20 0.24H9E*03
CA** O.493}E*U2
MC*+ 0.0
S03— 0.6916E*00
CL- O, 7V JO t +O2
AO* 0.0
LB/HR
0.0
0.0
0.0
0.0
0.43416*06
O.ID17E*04
0.0
0.9537E*02
0.15996*03
oio
TOTAL FLOM RATE • 0.43»2E*06 LB/HR
C-65
-------
1000 MW
379 GPM
FILTER CAKE SLURRY
SPECIES
Ifl-HOlE/HR L8/KR
CAS03
CASQ4
CACQ3
INSOLI
H2O
CA++
MC+*
SOS--
SIM--
CL-
AD*
TOTAL
.1/2 H20
, 2H2D
J9LES
FLOW RATE
0.4932E+03
0.2L01E+O3
0.17B8E+03
0.6611E*O4
0.0
0.1898E*00
0.1314E*Ol
0.2176E+O2
0.0
• 0.2MOE*06
0.6367E*05
§!l790E*03
,Z^3E'*0*
0.119lE»O6
0,»985E*03
0.0
O.Ul»E»02
0.1262E>03
0,77l»E*03
0.0
LB/HR
33*,
CPK
FILTRATE FROM FILTER
SPECIES
LB-HULE/HR LB/HR
CA
m^&
H20 0.0
4*£-
0.0
0.0
CA
CACU1
o.o
0.0
INSOLUBLE]
HZO
0.56676*04 o!lQ2lE*06
«*272E»Oi
CA*-»
KG*-*
OilOA6E+OZ
0.0
0,0
. 1126E+01
0,1302B*OZ
1082E*03
CL-
AD.
.1B65E»02
0.0
0.0
TOTAL FLOW RATE • 0.1033E*06
033E*Oft LB/H
207, CP1
C-66
-------
1000 MW
EXAMPLE INDUSTRIAL* LIMESTONE* NEW ECONOMIC PREMISES
CASE 00*
UPSUL CONTENT IX) 1
ASH CONTENT l»l
BTU RATING!
BOILER TVPEl
NO. OF SCRUBBERS!
SCRUBBER VELOCITY (FT/HII
PLANT SIZE (HW)I
OPERATING HRS/YRI
PUMPING RATE (GAL/1000 ACFII
SCA RATlOl
PART ICUL ATI REMOVAL
3.36
11.10
11700
DRY PULVERIZED COAL
6
790.0
1000
9296
20.00
1.100
INVESTMENT AND OPERATING COST
PARTICIPATE EMISSION REGULATION ILB ASH/NRLION BTUII
FLUE GAS TEMPERATURE (COLD) (Fl|
FLUE GAS TEMPERATURE (HOT! (£11
COST OF ELECTRICITY (l/KbHRII
COST OF STEAM I/THOUSAND LBll
FIRST YEAR CAPITAL CHARGE FACTORI
BAGHOUSE RATIO (OPER. SQ.FT. /ACTUAL Sfl.FT.)!
BAG COST (t/SQ.FT.)l
BAG LIFEIYEARSJI
FLUE GAS REHEAT TEMPERATURE (F)l
CHEMICAL ENGINEERING PLANT INDEXI
0.03
300.0
700.0
0.01
2.00
o.ieo
0.80
0.70
1,00
132.
169.0
(ACTUAL SQ.FT./CALC. SQ.FT.)
o
I
ELECTROSTATIC PRBCIPITATORJ
REQUIRED REMOVAL EFFICIENCY (III
DRIFT VELOCITY II-T/MII
SPECIFIC COLLECTION AREA (SQ.FT./ACFM) I
COLLECTION AREA (SO.FT.)I
TOTAL CORONA POWER (KNII
AUXILIARY POWER (KMll
FAN POWER (KW)I
PUMP POHER (KHJI
TOTAL POWER (KMII
OPERATING AIR/CLOTH RATIOl
INSTALLED AIR/CLOTH RATIUI
REQUIRED PRESSURE ORUP I INCHES II
DIAMETER (FEETtl
REQUIRED REHEAT (RTU/HRM
STEAM SUPPLY/YR (THOUSAND LBll
INSTALLED COST (1979 OOLLARSII •
FIRST YEAR CAPITALIZED COSTI »
ANNUAL POWER COST! »
ANNUAL OPERATING AND
MAINTENANCE COST (197* DOLLARS) I *
REPLACEMENT COST (1979 DOLLARS)!
ANNUAL REHEAT COSTl
COLD
99.70
J7.19
277.7*
917133.9
1327. 1
678.1
S2B.6
2713.7
1.0
12109691
2183771
416669
161977
HOT
99.70
20.00
J7T.H
194*619.0
20Z1,6
1971.7
101. «
4BOI.I
1.0
» 2291*496
1 4060111
1 732*36
t 2*9066
BAOHOUSE FABRIC FILTERS
99.70
1732267:0
771". 8
26*0:2
1*19.9
*r»
l'*
s.o
t 2901070*
» 92)1996
t 920673
t 110662
S 930297
SCRUBBERS
99.70
12079.9
6939.1
3B619.*
60.1
3D
120*9106.0
70366.7
» *09BB6BI
» T31«*VZ
» 968991!
1 2129900
» 1*071*
TOTAL ANHOALTOSTl
ANNUALIZED COST OF POHERdlLlS/KHHR11
2766433
0.93
90*1617
0.96
f 6391188
1.22
19476041
2.94
-------
1000 MW
RAW MATERIAL HANDLING AND PREPARATION
'
ITEM
DESCRIPTION
Nil.
MATERIAL
LABOR
CAR SHAKER AND HOIST
CAR PULLER
UNLOADING HOPPER
UNLOADING VIBRATING FEEDER
UNLOADING BELT CONVEYOR
UNLOADING INCLINE BELT
ZOHP SHAKER 7. SHP HOIST
25HP PULLER* SMF RETURN
16FT DIA« 10FT STRAIGHT
INCLUDES 6 IN SO ORATE ING
3. SHP
20FT HORIZONTAL* SHP
310FT. SOHP
1
1
1
1
I
1
61661.
S40S9.
13297.
*68T.
9809.
T31J3.
10801.
16202.
4919.
412.
11SI.
1996.
CUNVEVI1R
UNLOADING PIT DUST COLLECTOR
UNLOADING PIT SUMP PUMP
STORAGE BELT CONVEYOR
STORAGE CONVEYOR TRIPPER
MOBILE EQUIPMENT
RECLAIM HflPPER
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOR
RECLAIM INCLINE BELT CONVEYOR
RECLAIM PIT DUST COLLECTHR
RECLAIM PIT SUMP PUMP
RECLAIM BUCKET ELEVATOR
FEED BIN
BIN WEIGH FEEDER
GYRATORY CRUSHERS
BALL MILL DUST COLLECTORS
BALL MILL
MILLS PRODUCT TANK
POLYPROPYLENE BAGTVPCj
INCLUDES DUST HOOD
60GPNj TOFT MEAD. 9HP
SOOFTf THP
30FPN, IMP
SCRAPPER TRACTOR
TFT UIDEj 4.29FT HTi 2PT
MIDE BOTTOM, CS
3.3HP
300FT* THP
193FT* 40MP
POLYPROPYLENE BAG TVPE
60GPH* TOFT HEAD/ SHP
90FT HIGH. T5HP
13FT OIA« 21FT STRAIGHT
SIDE HT, COVERED, CS
14FT PULLEY CENTERSi 2HP
TSHP
POLYPROPYLENE BAG TYPE
2200 CFM» 7, IMP
23.8TPH* III. HP
5500 GAL 10FT DIA* IOFT
HT/ FLAKEtlLASS LINED CS
I
1
I
1
1
}
1
1
1
1
1
1
2
2
2
2
2
2
9591.
20T1.
•7469.
2332*.
111613.
1106.
1*060,
S09T2.
91661.
664S.
2071.
97002.
24741.
2B33S.
169807.
13297.
437624.
7847.
4320i
648.
4861,
7961,
0,
2029.
1296.
3964,
3024,
2160.
648,
5909,
13285.
1296.
3564.
4320,
45802,
6049.
MILLS PRODUCT TANK AGITATOR 10HP
13079,
3024.
068
-------
1000 MW
HILLS PRODUCT TANK SLURRY
97.GPH, 60FT HEAOi
10166.
2307.
PUMP
SLURRY FEED TANK
»,HP» 2 OPERATING
AND 1 SPARES
102170. CALj 2J.9FT DIAj 1 24921.
19894.
2S.9FT HT« FLAKEGLASS-
LINEO CS
SLURRV PEED TANK AGITATOR
SLURRY PEED TANK PUMPS
72. HP 1 59206.
24.GPH> 60 FT HEAD* 12 IT966.
l.HP, B OPERATING AND
* SPARE
4377.
90T1.
TOTAL EQUIPMENTCDST^
1491*99.
116141.
C-69
-------
1000 MW
SCRUBS INO
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
1.0. FANS
SHELL
RUBBER LIMING
HIST ELIMINATOR
SLURRY HEADER AND NOZZLES
§RIOS
PHERES
TOTAL TCA SCRUBBER COSTS
SOOTBLOWERS
EFFLUENT HOLD TANK
EFFLUENT HOLD TANK ACITATUR
COOLING SPRAV PUMPS
ABSORBER RECYCLE PUMPS
MAKEUP WATER PUMPS
TOTAL EQUIPMENT COST
Z0.01N HZOt WITH 1402.
HP MOTOR AND DRIVE
291861. OAL' 33, OPT DIA«
39. OFT HT* PLAKEGLASS*
LINED CS
66. HP
13BB,GPM 100FT HEAD*
64.HPi B OPERATIND
ANO 8 SPARE
99*0. GPNi IOOFT HEAOj
**2. HPj 16 OPERATING
AND 8 SPARE
9991. GPMj 200|FT HEAD*
468. HP i 1 OPERATING
ANO 1 SPARK
8 679*377,
2101332.
2071400.
428831.
323031.
929769.
12679T2.
a 7322339.
64 133439.
a 416318.
B 397109.
16 143677.
24 1386001.
Z 97333.
16830896.
9*820.
912301.
138233i
329030<
193410.
4Z77*.
149007.
6292 1
1622069.
C-70
-------
1000 MW
WASTE DISPOSAL
ITEM
DESCRIPTIUN NO. MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
ABSORBER BLEED TANK AGITATOR
THICKENER FEED PUMP
THICKENER
THICKENER UNDERFLOW SLURRY
PUMPS
THICKENER OVERFLOW PUMPS
THICKENER OVERFLOW TANK
FILTER FEED TANK
62898. OAL* 17.9FT DIA* 1 20720.
39. OFT HT* PLAKGLASS-
LINED CS
3B.HP 1 23676.
1499. GPM« 60FT HEAD* 2 19863,
41.HP< 1 OPERATING
AND 1 SPARE
36636.SO.FT.*216.FT DIA* I 962891.
10.9TANK FT HT
941.GPHJ 11.9FT HEAD* 2 7049.
3. HP * 1 OPERATING
AND 1 SPARB
879. CPM. 73. OFT HEAD* 2 9690.
28, HP* 1 OPERATING
AND 1 SPARE
14900. GAL* 13.JFT DIA* 1 1779.
IO.SFT HT
8921. GAL* 11.3FT DIA* 1 4899,
ll.JFT HT* PLAKEGLASSf
16934.
1877.
9466.
602732.
3941.
1091.
2*9*.
191 1 1
LINED CS
FILTER FEED TANK
AGITATOR
FILTER FEED SLURRY PUMP
FILTER
10. HP I 8072.
270. GPH. 90FT HEAD* 1 11199.
7. HP* Z UPCRATIN6
AND 1 SPARE
603. SO FT FILTRATION Z 268148.
6*0.
392*.
41*89.
AREA
FILTRATE PUMP (PER FILTER)
FILTRATE SURGE TANK
FILTRATE SURGE TANK PUMP
103. GPM* ZO.OPT HEAD* 4 14816.
l.HPt Z OPERATING
AND 2 SPAKE
J41Q.DAL* B.9FT DIA* 1 19O6.
8.3FT HT
207. GPM. 89. OFT HEAD* 2 7979.
7,HP» Z OPERATING
AND 2SPARE
1619.
113.
870.
TOTAL EOUIPMENT COST
9602*4.097160.
C-71
-------
1000 MW
o
-~J
ro
• ' . — — •
"LIMESTONE SLURRY PROCESS — BASISl 1000 *H UNIT* 19B1 STARTUP
PROJECTED CAPITAL INVESTMENT REQUIREMENTS
. EXAHPLR INDUSTRIAL.
INVESTMENT*
RAH MATERIAL
HANDLING AND
PREPARATION
LIMESTONE,
THOUSANDS
SCRUBBING
NEK ECONOMIC PREMISES
OF 1980 DOLLARS
HASTE
DISPOSAL
TOTAL
CASE 004
DISTRIBUTION
PERCENT.
OF DIRECT
INVESTMENT
CQUIPHENT
MATERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTWORK
MATERIAL
LABOR
FOUNDATIONS
MATERIAL
LABOR
POND CONSTRUCTION
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
BUILDINGS
MATERIAL
LABOR
SERVICES AND MISCELLANEOUS
SUBTOTAL DIRECT INVESTMENT
ENGINEERING DESIGN AND SUPERVISION
CONSTRUCTION EXPENSES
CONTRACTOR FEES
CONTINGENCY
SUBTOTAL FIXED INVESTMENT
ALLOWANCE FOR STARTUP AMD MODIFICATIONS
INTEREST DURING COIISTRUCTKIM
SUBTOTAL CAPITAL INVESTMENT
LAND
HORKING CAPITAL
TOTAL CAPITAL INVESTMENT
1498.
1B6.
441.
19* ,
0.
0.
(90.
771,
0.
17T.
VI.
160.
162.
»?!•
14.
so.
11.
109.
4492.
404.
719.
229.
1168.
7008.
519.
1091.
8S98.
11.
269.
8878.
16BJI.
1622.
4681.
618.
>99T.
1016.
216.
494.
0.
460.
TT4.
1040.
lais,
?{*•
1ST.
0.
0.
916.
97643.
(368.
6023.
1832.
9787.
58723.
4917,
B809.
72049.
6.
2296.
74311.
960,
687.
929.
isil
0.
0.
14.
31.
0.
0.
0.
141.
782.
H.
.
92.
9).
91.
3746.
137.
999.
187.
974.
5861.
490.
877.
7170.
24.
224.
74 18.
19290.
2496.
9647.
1016.
1997.
1096.
991.
1119.
0.
616.
867.
1444.
2962.
1092.
IK.
101.
106.
1116.
49882.
4129.
7341.
2294.
11929.
71575.
9906.
10736.
•7117.
42.
2749.
90608.
42.0
9.4
12.1
2.2
8,7
6.7
1.2
2.9
0.0
1.4
1.9
1.1
6.9
2.4
0.9
0.2
0.2
»•«.
100.0
9.0
16.0
9.0
260.0
156.0
12.0
21.4
191.4
0.1
6.0
197.9
-------
1000 MW
o
I
^LIMESTONi SLURRY PROCESS — BASISl 1000
PROJECTED REVENUE REQUIREMENTS - EXAMPLE
«N UNIT. 1961 STARTUP
INDUSTRIAL* LIMESTONE. NEH ECONOMIC PREMISES
DISPLAY SHEET FDR VEARp 1
CASE 004
ANSUAL OPERATION KW-HR/KX • 9296
60.26 TONS PER HOUR DRY
TOTAL CAPITAL INVESTMENT BTBSJOOO
ANNUAL QUANTITY UNIT COST.*
SLUDGE
TOTAL
ANNUAL
COST.*
DIRECT COSTS
RAH MATERIAL
LIMESTONE
SUBTOTAL HAM MATERIAL
242.1 K TONS B. DO/TON
1917200
191T200
CONVERSION COSTS
OPERATING LABOR AND
SUPERVISION
UTILITIES
PROCESS WATER
ELECTRICITY
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
Sollda Disposal
91*00.0 MAN-HR U.90/MAN.HR
If I860. 0 K GAL OilS/K OAL
B66I6170.0 KWH 0.019/KMH
6440.0 HR 1T.OO/HR
633.5 K tone 15.00/TON
SUBTOTAL CONVERSION COSTS
SUBTOTAL DIRECT COSTS
673700
47000
2919700
16TOSOO
109600
9S01797
16522297 ' '
18459497
INDIRECT COSTS
OVERHEADS
PLANT AND ADMINISTRATIVE 1
60.0* OF CONVERSION COSTS LESS UTILITIES)
FIRST YEAR OPERATING AND MAINTENANCE COSTS
LEVELIZED CAPITAL CHARGES) 14.71 OF TOTAL CAPITAL INVESTMENT)
FIRST YEAR ANNUAL COSTS
8373358
26832855
13319376
•»•••••••»•
40152231
HEAT RATE 9400. BTU/KMH
HEAT VALUE UF COAL UTOO BTU/LB
COAL RATE 2133600 TONS/VR
-------
APPENDIX D
UTILITY BOILER LIME DRY SCRUBBING FGD SYSTEM PREMISES
MATERIAL BALANCE FOR 0.7% SULFUR COAL - 70% SULFUR REMOVAL
1982 BARE EQUIPMENT COSTS
EQUIPMENT INSTALLATION FACTORS
SCALE FACTORS
1982 CAPITAL INVESTMENT
OPERATING LABOR & SUPERVISION ASSUMPTIONS
ANNUAL O&M COSTS
1984 ANNUAL REVENUE REQUIREMENT
D-l
-------
O
to
Generic lime spray dryer process. Flow diagram.
-------
500 MWe
0.7%S - 70% Removal
GENERIC LIME SPRAY DRYER PROCESS
MATERIAL BALANCE
1
.'
•.
-I
1
A
1
L°
Screan to
Description
TaeaL acrean. Lh/hr
scfm at 60° F
Pressure, osla
in
DH
tjfldlssolved solids, t
Ash we Z (wee)
Ciilftir ut T l"uet)
I
Coal co boiler
489 . 700
9.71
0.59
2
Combusclon air
co air heacer
5.119 .000
1.131.000
1
CoHbusclon air
co boiler
4.419.000
976, 400
4
Cu co
economizer
4.897.000
1.045.000
J
Gas co
air heacer
4.397.000
1.045.000
1 'OS 1
1
I
1
J
h
1
1
u
11
Stream No.
Descrlpcion
SCfo ac 60° F
Tenoeracure . °F
BDm
Specific aravlcv
EH
UndllloLved solids. !
6
Gas co
J.S97.000
1.200.000
WO
7
Gas co
4.547.000
975.000
100
8
Gas from
spray dryer
4.743.000
1.020.000
160
9
Gas co
scack*
5.7IS.OOO
1.290.000
171
10
Wasce co
landfill
44.650
1
i
t>
\
h
1
1
1
10
Scream *lo
Dvscrlpclon
TocaL screaa, Ib/hr
scfm ac 60' F
Pressure, pslg
»<•
Specific gravlcy
PH
Undlssolvcd solldsr *
11
Uasce co
recycle
parclculace silo
55.450
12
lakeup uacer
co recycle
slurry cank
33,150
166
13
Recycle slurry
co spray dryer
1 18.600
~G
14
Makeup lime
co slaker
3.661
IS
Makeup wacer
co slaker
11.150
23
i
.
1
•*
'1
If)
Screan -4o
Descclpclon
scfm ac 60*F
aom
M
Undl
-------
LIME DRY SCRUBBING FGD CAPITAL INVESTMENT1
Capital Investment. 103$
0.7% S -
Direct Investment
Material Handling
Feed Prep
Gas Handling
SO 2 Absorption
Particulate Removal (Baghouse)
Particulate Handling & Recycle
Solids Disposal
Total Process Capital
Services, Utilities, Misc.
(6% TPC)
Land Fill Construction
Total Direct Investment
Indirect Investment
Engr. Design & Supv.
A & E
Construction Expense
Contractor Fees
Contingency
Total Fixed Investment
Other Capital Requirements
Startup & Modification
Interest During Const.
Royalties
Land
Working Capital
Total Capital Investment
&/kwe
70% Removal
1,634
615
9,471
7,088
11,133
1,392
444
31,777
1,907
2,345
36,029
2,522
721
5,765
1,801
9,367
56,205
5,621
8,768
180
720
1,927
73,421
146.8
3.5% S - 90% Removal
4,639
1,378
10,481
8,713
10,855
636
674
37,376
2,243
4,199
43,818
3,067
876
7,011
2,191
11,393
68,355
6,836
10,663
2,019
1,320
2,795
90,188
180.4
Source: Tom Burnett, Economic Evaluation Section, TVA, Muscle Shoals,
Ala., July 1980. These results are preliminary and are not approved
by TVA or EPA.
Bases
T982 $
500 MWe Boiler
D-A
-------
LIME DRY SCRUBBING FGD ANNUAL REVENUE REQUIREMENT
Direct Costs
Unit Cost, $
0.7% S - 70% Removal 3.5% S - 90% Removal
Annual Annual
Annual Quantity Cost 103$ Annual Quantity Cost 103$
Direct Costs
Raw Materials
Lime
$i02/ton-0.7% S
$ 75/ton-3.5% S
10,100 tons 1,030.2
86,100 tons 6,457.5
Conversion Costs
Operating Labor & Supv
FGD
Solids Disposal
Utilities
Process Water
Electricity
Steam
Maintenance
Labor & Material
Analyses
Waste Disposal Operation
Total Conv. Costs
Total Direct Costs
Indirect Costs
Overheads
Plant & Admin.
First Year - 0 & M
Levelized Capital Charges
(14.7% of TCI)
Total First Year Annual Revenue Requirement
Levelized First Year 0 & M
(1.886 x First Year 0 & M)
Levelized Annual Revenue Requirement
$15/m-h
$21 /m-h
$0.14/kgal
$0.037 /kwh
$2.70/MBtu
$21/m-h
$0.15/ton
25,400 m-h
14,560 m-h
78,600 kgal
39,405,000 kwh
4,160 m-h
122,800 tons
381.0
305.8
11.0
1,458.0
2,091.7
87.4
18.4
4,353.0
5,383.5
29,120 m-h
20,800 m-h
134,600 kgal
41,603,000 kwh
4,160 m-h
280,800 tons
436.8
436.8
18.8
1,539.3
371.0
2,503.1
87.4
42.1
5,435.3
11,892.8
1.730.6
7,114.1
10.792.8
17,906.9
13.417.1
24,209.9
2.103.7
13,996.5
13.257.7
27,254.2
26.397.4
39,655.1
First Year Annual Revenue Requirement, mills/Kwh
Levelized Annual Revenue Requirement, mills/Kwh
6.51
8.80
9.91
14.42
^Source: Tom Burnett, Economic Evaluation Section, TVA, Muscle Shoals, Ala., July, 1980.
These results are preliminary and are not approved by TVA or EPA.
Bases
1984 $
500 MWe Boiler
0.63 Capacity Utilization Factor
D-5
-------
LIME DRY SCRUBBING FGD
BARE EQUIPMENT COSTS & INSTALLATION FACTORS
0.7% S - 70% Removal
3.5% S - 90% Removal
Material Cost
103$. 1982
Material Handling
Feed Preparation
Gas Handling
SC>2 Absorption
(3 operator, 1 spare)
Particulate Removal
(Baghouse)
Particulate Handling
and Recycle
8262.0
556.9
Installation Material Cost
Factor 103$, 1982
Installation
Factor
333.3
195.7
2260.0
4324.0
4.90 i
3.14 i 4'25
4.19
1.64
825.0
399.4
2260.8
5405.5
5.62 >
4.06 '
4.64
1.61
5.17
1.35
2.49
8032.0 1.35
266.7 2.38
(no Recycle)
Bases
1982 $
500 MWe Boiler
To obtain 1980$ cost multiply 1982$ costs by:
1980 286.1
Material CECI
1982 333.7
0.857
D-6
-------
LIME DRY SCRUBBING FGD
250 & 1000 MWe Assumptions
'Investment Scale Factors Scale Factor
Material Handling 0.89
Feed Preparation 0.57
Gas Handling 0.68
S02 Absorption 0.65
Particulate Removal 1.0
Particulate Handling 0.71
Solids Disposal 1.0
Land Fill Construction 1.0
Operating Labor & Supv
250,500 & 1000 MWe dry scrubbing in same proportions
as operating labor & supv. for the limestone cases.
Man-hours/year
MWe Wet Scrubbing Dry Scrubbing
250 20810 18580
500 28450 25400
1000 38910 34740
D-7
-------
APPENDIX E
INDUSTRIAL BOILER LIME DRY SCRUBBING FGD SYSTEM PREMISES
MATERIAL BALANCES
EQUIPMENT LISTS AND COSTS
E-l
-------
ALKALI
f
MAKE-UP WATER
RAW
FLOt
6A.S
Tl >
%
SPRAY DRXER
CLEAN FLUE GAS
BA6HOUSE
SPRAY DRYER FGD
,6
Boiler size: 150 x 10 BTU/Hr.
Coal type: Western
SC>2 removal: 75%
Type alkali: Lime
Percent ash*: 5.4% (wt)
Percent sulfur*: 0.6% (wt)
*Wet Basis
w
i
ISi
»Jb».li«« f
TOTAL FLOW
IBS.btO
EviV
ns
A
SOLIDS
Solid*
GAS now flATt
40.311.
SI.IST
SOLID
RMt
(81
181
-------
ALKALI
MAKE-UP WATER
CW6M4 FLUE GAS
RAW
FLUE.
V
SPRAY
\,
DRYER
^
BAG HOUSE
SPRAY DRYER FGD
Boiler size: 400 x 106 BTU/Hr,
Coal type: Western
S02 removal: 70%
Type alkali: Lime
Percent ash*: 5.4%(wt)
Percent sulfur*: 0.6%(wt)
*Wet basis
w
SOLIDS
1
Inlet &*%
Exit
SU«ry lo Diyir
Solid*
ToTfct. FLOW fTATC
/7S"
&A4 TLOW
IW/Hr
SCFM
LiQOlD FlOWRMt
IOLID
RMt
/BOD
-------
ALKALI
f
MAKE-UP WATER
n >
<*
CLEAN FLUE GAS
RAW
FLUE.
6A.S
V
SPRAY DRYER
HT
&A6HOUS6
-• SOLIDS
SPRAY DRYER FGD
Boiler size: 75 x 106 BTU/Hr.
Coal type: Medium Sulfur
S02 removal: 70%
Type alkali: Lime
Percent ash*: 13.2%(wt)
Percent sulfur*: 2.3%(wt)
*Wet basis
U D'^ftr
fLowt KATC
IWtw
9,7
PLOW flATC
3/JTS"
31,000
SOLID rtovJ RMt
-------
PI
ALKALI
CLEAN FLUE GAS
MAKE-UP WATER
ftf W/ - - . /^ •
FLUfc ^
GAS :
V
SPRAY
^
DRYER
^
BAG HOUSE
- SOLIDS
10TAU riovJ VATC
Ib/txr
T«.v.p f'F")
FLOW RAT6
iCFM
LIQUID FlOWRME
SOLID MOVAJ
Exit
It,
VS.?
&lurry i» Uiytr
b
Solid*
SPRAY DRYER FGD
Boiler size: 400 x 10 BTU/Hr.
Coal type: Medium Sulfur
S02 removal: 70%
Type alkali: Lime
Percent ash*: 13.2%(wt)
Percent sulfur*: 2.3%(wt)
*Wet basis
-------
td
EQUIPMENT LIST - PURCHASED I'RICF
LIME DRY SCRUBBING FfiD - TNIUISTKI Al. BOILERS
Raw Material Handling
Pneumatic Conveyor
Silo - 2 wk Capacity
Screw feeder
Mix Tank - 5 raw
Mixer
Lime Sinker
Feed Pumps - 2
44 MUt -
0.6% S - 70% Removal
Description $
3,394
63 k Ibs 18.500
1.193
330
270
16.000
7 . 200
46.900
118 MUt -
0.6% S - 70% Removal
Description $
3,394
167.7 k Ibs 36.000
1.193
760
S20
17,300
44 gpm _9,200
68.380
22 MWt -
2.3% S - 70% Removal
Description $
3.394
87.7 k Ibs 23.200
1.193
280
260
16.500
10 gpm 6,800
51.640
118 MUt -
2.3% S - 70Z Removal
Description $
3,394
466.7 k Ibs 72.000
1.193
760
520
18.800
45 gpm 9,200
105.930
Fans
62.800 acfm 29.000 146.000 acfm 54,000 33.000 acfra 18.000 151.200 acfm 55.000
SO? Scrubbing1
Absorber, Circulator
Tank (5 mln)
Mixer. Circulation Pumps
230.000
337.200
170,800
349.200
Solids Collection2
Baghouse
Equip.
Installation Costs
812.700
497,540
1,310.240
193.200
246.918
440.138
840,650
503,438
1,344,088
1b02 Scrubbing « Installed cost
Installation costs = - 1506523 + 168531 In ['acfin)
A/C «= air/cloth = 2.0 fpm
A/CJ
Equipment cost = 8.34 (dcfm)°-966/_2_\
U/C/
-------
APPENDIX F
DESCRIPTION OF TVA AND PEDCO ENVIRONMENTAL, INC.
INVESTMENT/COST COMPONENTS
F-l
-------
APPENDIX F
1.0 TVA INVESTMENT/COST COMPONENTS
1.1 Capital Investment
Capital investment estimates are based on an East Central location
(Kentucky, Illinois, Indiana, Ohio, Michigan, and Wisconsin) and represent
projects beginning in 1981 and ending in 1983. Capital cash flows for a
standard project are assumed to be 25% the first year, 50% the second year,
and 25% the third year of the project life. Capital costs for fixed assets
are projected to mid-1982, which represents approximately the midpoint of
the construction expenditure schedule.
Typically, capital estimates made by Emission Control Development
Projects are either preliminary or definitive level estimates. Preliminary
estimates are based on a process description, flow sheet, material balance,
and equipment list. Piping, ductwork, and instrumentation are normally
factored. The preliminary capital cost estimate is normally considered to
have a -20% to +40% range of accuracy. Definitive estimates are based on
the same items as a preliminary estimate plus a layout, instrument control
diagram, and piping diagram. The definitive estimate is considered to
have a -5% to +25% range of accuracy.
The total fixed capital investment includes direct capital costs for
equipment, building, utilities, service facilities, raw material and
byproduct storage, waste disposal facilities, engineering design and
supervision, construction expense, contractors' fees, and contingency.
The total capital investment includes the total fixed capital investment
plus allowances for startup and modifications, royalties, the cost of funds
used during construction, plus the cost of land and working caoital.
F-2
-------
(1) Direct Capital Costs - Process
Direct capital costs cover installed process equipment, piping, insula-
tion, transport lines, foundations, structural, electrical, instrumentation,
raw material and byproduct storage, site preparation and excavation, buildings,
roads and railroads, trucks, and earthmoving equipment.
Direct investments are prepared using standard estimation techniques
and the average annual Chemical Engineering cost indexes and projections
as shown in Table F-l.
The overtime premium for 7% overtime is included in the construction
labor. Appropriate amounts for sales tax and for freight are included in
the process capital costs.
(2) Direct Capital Costs - Utilities, Service and Miscellaneous Facilities
Necessary electrical substations, conduit, steam, process water, fire
and service water, instrument air, chilled water, inert gas, and compressed
air distribution facilities are included in the utilities investment.
These facilities are costed as increments to the facilities already
required by the power plant. For existing units, a package boiler is used
for all steam generation including reheat, since steam is assumed to be
unavailable from the power plant cycle. Flue gas from the package boiler is
added to the utility boiler flue gas before the scrubber.
Electrical switchyard locations are assumed to be approximately 200
yards from the control rooms. Control room location varies with each process,
depending upon equipment size and configuration. Generation facilities for
electricity are not included.
Service facilities such as maintenance shops, stores, communications,
security, offices, and road and railroad facilities are estimated or allocated
on the basis of process requirements.
F-3
-------
TABLE F-l
Cost Indexes
Year
Plant
Material
Labor
a. TVA
b. Same
1975
182.4
b 194.7
168.6
1976
192.1
205.8
174.2
1977
204.
220.
178.
projections
as index in Chemical
1
9
2
1978
218.8
240.6
185.9
Engineering
and Projections
1979a
240.2
262.5
209.7
(10) for
1980a
259.4
286.1
226.5
19813
278.9
309.0
244.6
1982
299.
333.
264.
"equipment, machinery,
3 19833
8 322.3
7 360.4
2 285.3
supports."
19843
344.9
385.6
305.3
c. Same as index in Chemical Engineering (10) for "construction labor."
-------
Services, nonpower plant utilities, and miscellaneous will normally
be in the range of 4% to 8% of the total process capital depending on the type
of process.
(3) Indirect Capital Costs
Indirect capital costs cover engineering design and supervision, architect
and engineering contractor costs, construction costs, contractor fees, and
contingency. Construction facilities, which include costs for mobile equip-
ment, temporary lighting, construction roads, raw water supply, construction
safety and sanitary facilities, and other similar expenses incurred during
construction are considered part of construction expenses and are charged
to indirect capital investment.
Listed below are the ranges of indirect costs to be used depending upon
the scope and complexity of design and construction involved in the process
being studied.
% of direct investment
Low Base High
Engineering design and supervision 678
Architect and engineering contractor 12 3
Construction expense 14 16 18
Contractor fees 4 5 6
Total 25 30 35
For comparative studies, a contingency of 20% is included since
projects normally have a higher likelihood of exceeding rather than under-
running the capital estimate. While actual projects could properly have both
project and process contingencies of varying amounts depending on the type
and developmental maturity of the process, comparability among processes
could be skewed by the use of different contingencies in the same study.
F-5
-------
(4) Other Capital Requirements
Startup and modification allowances are estimated as 8% to 12% of the
total fixed investment depending upon the complexities of the process being
studied.
For proprietary processes, either actual royalty fees or 0.5% of the
direct investment will be charged.
Cost of funds during construction is estimated fca be 15.6% of the total
fixed investment for each process. This factor is equivalent to the 10%
weighted cost of capital with 25% of the construction expenditures in the
first year, 50% the second year, and 25% the third year of the project con-
struction schedule. Expenditures in a given year are assumed to be uniform over
that year. Start-up costs are assumed to occur late enough in the project
schedule that there are no charges for the use of money used to pay startup
costs. For processes that have construction periods significantly different
than the 3-year premise period, the cost of funds during construction are
adjusted to the actual period required.
1.2 ANNUAL REVENUE REQUIREMENTS
Annual revenue requirements use 1984 costs and are based on 5500 hours of
operation per year at full load for pollution control processes that are
close-coupled with a utility boiler. Typical operating experiences are used
as a basis.
(1) Direct Operating and Maintenance Costs
Direct costs include raw materials, labor, utilities, maintenance, and
analytical costs. Unit costs for steam and electricity are based on the
assumption that the required energy is purchased from another source. Unit
costs ($/kW, mills/kWh) are calculated on the basis of net power output after
the addition of the pollution control systems. Acutally the electrical usage
F-6
-------
by the pollution control equipment after the ESP will result in a derating
of the utility plant for either a new or a retrofitted unit. To minimize
iterative calculations, instead of derating the utility plant, the pollution
control equipment (excluding ESP) will be charged with purchased electricity.
Maintenance costs are estimated to be 3% to 9% of the direct investment
based on unit size and process complexity.
(2) Indirect Operating and Maintenance Costs
Indirect costs cover levelized annual capital charges and overheads.
The levelized annual capital charges consist of sinking fund factor,
allowance for interim replacement, property taxes, insurance, weighted cost
of capital, income tax, credits for accelerated depreciation, and investment
credit. The levelized annual capital charge for a regulated utility is
14.7%.
Overheads consist of plant, administrative, and marketing expenses
assumed to be as follows:
Plant and administrative overhead = 60 % of conversion costs less
utilities
Marketing overhead is assigned as applicable for processes that
have byproduct sales
The plant and administrative overheads include plant services such as
safety, cafeteria, medical, plant protection, janitorial, purchasing personnel,
general engineering (excluding maintenance), interplant communications and
transportation, recreational facilities, and the expenses connected with top
management activities. Fringe benefits such as retirement, vacation, dental
and medical plans are included in the base wage rates.
F-7
-------
Credit is given for byproduct sales where appropriate. First-year
annual revenue requirements using levelized capital charges (14.7%) are
calculated. In addition, levelized annual revenue requirements are calculated
using a 10% discount factor, 6% inflation factor, and a 30-year economic life
giving a 1.886 leveling factor.
F-8
-------
2.0 PEDCo ENVIRONMENTAL, INC., INVESTMENT/COST COMPONENTS
Capital cost and annualized cost are estimated for each FGD system.
The capital cost represents the initial investment necessary to install and
commission the system. The annualized cost represents the cost of operating
and maintaining the system and the charges needed to recover the capital
investment, which are referred to as fixed costs or fixed charges.
2.1 Capital Costs
Capital costs consist of direct and indirect costs incurred up to the
successful commissioning of the facility. Direct costs include the costs of
various items of equipment and the labor and material required for installing
these items and interconnecting the system. Indirect costs are expenditures
for the overall facility that cannot be attributed to specific equipment;
they include such items as freight, spares, engineering, contingency, etc.
Direct Costs
The "bought-out" cost of the equipment and the cost of installing it
are considered direct costs. A bought-out cost of an equipment item is the
purchase price paid to the equipment supplier on a free-on-board (f.o.b.)
basis; this does not include the freight charges. Installation costs cover
the interconnection of the system, which involves piping, electrical, and
the other work needed to commission it. Also attributed to installation are
the costs of foundations, supporting structures, enclosures, ducting, control
panels, instrumentation, insulation, painting, and similar items. Costs
for interconnecting various items of FGD equipment include site development,
construction of access roads and walkways, and the establishment of rail,
barge, or truck facilities. Finally, the cost of administrative facilities
is considered a direct cost.
F-9
-------
Various procedures are available for estimating direct costs. The PEDCo
computer model uses the installation factor technique to estimate total
direct costs. The bought-out cost of each item of equipment is multiplied
by an individual installation factor to obtain the installed cost. This
installed cost includes a proportional cost for interconnecting the equipment
into the system. The installation factors are based on the complexity of
the equipment and the cost of the material and labor required. The installed
costs of all the equipment are added together to obtain the total direct
cost of the facility.
Indirect Costs
The indirect costs of an FGD system include the following:
Interest; covers interest accrued on borrowed capital during
construction.
Engineering costs; include administrative, process, project, and general
costs; design and related functions for specifications; bid analysis;
special studies; cost analysis; accounting; reports; purchasing ;
procurement; travel expenses; living expenses; expediting; inspection;
safety; communications, modeling; pilot plant studies; royalty payments
during construction; training of plant personnel; field engineering;
safety engineering; and consultant services.
Freight; includes delivery costs on FGD process and related equipment
shipped f.o.b. from point of origin.
Offsite expenditures: include expenditures for powerhouse modifications,
interruption to power generation, and service facilities added to the
existing plant facilities.
Taxes: include sales, franchise, property, and excise taxes.
F-10
-------
Spare parts; represent costs of items stocked to permit high
process availability; such items include pumps, valves, controls, special
piping and fittings, instruments, spray nozzles, and similar equipment.
Shakedown: includes costs associated with system startup.
Contractor's fee and expenses: include costs for field labor payroll,
supervision field office, administrative personnel, construction offices,
temporary roadways, railroad trackage, maintenance and welding shops,
parking lot, communications, temporary piping, electrical, sanitary
facilities, rental equipment, unloading and storage of materials, travel
expenses, permits, licenses, taxes, insurance, overhead, legal
liability, field testing of equipment, and labor relations.
Contingency costs; include costs resulting from malfunctions,
equipment design alterations, and similar unforeseen sources.
Land cost; includes only the cost of the land required for sludge
disposal. The cost of land for installing FGD equipment is accounted
for in the installation factors.
All indirect cost components, except land cost, are obtained by multi-
plying the direct costs by an indirect cost factor. The land cost is based
on land rate and the disposal area required.
2.2 Annual Revenue Requirements
The capital investment of a pollution control system is generally trans-
lated into annual fixed charges. These charges, along with the annual
operating costs, represent the total revenue requirement of a particulate
control system.
The annual fixed charges are classified under four cost components:
depreciation, taxes, insurance, and capital costs. The component costs
are summed to obtain the total fixed charges.
F-ll
-------
Depreciation: The value of the depreciation component is obtained
by using a straight-line depreciation over the life period of the
pollution control system. A 20-year life is assumed for depreciation
purposes. The annual cost is calculated by dividing the total capital
investment by the assumed years of life.
Annualized Costs
The annualized operating costs of an FGD system consist of the following:
Raw materials: include costs of lime for the FGD system and fixation
chemicals.
Utilities; include costs of water for slurries, cooling, and cleaning;
electricity for pumps, fans, valves, lighting controls, conveyors, and
mixers; fuel for reheating flue gases; and steam for processing.
Operating Labor: includes costs of supervision and skilled and unskilled
labor to operate, monitor, and control the FGD process.
Maintenance and repairs; include costs of manpower and materials to keep
the unit operating efficiently. The function of maintenance is both
preventative and corrective to keep outages to a minimum.
Overhead: represents business expenses that are not charged directly
to a particular part of a process, but are allocated to it. Overhead
costs include administrative, safety, engineering, legal, and medical
services; payroll; employee benefits; recreation; and public relations.
The capital investment in an FGD system is generally translated into
annual fixed charges. These charges, along with the annual operating cost,
represent the total revenue requirement or annualized cost of a system. The
annual fixed charges are calculated under four cost components: depreciation,
taxes, insurance, and capital costs. The values for these components are
obtained as follows:
F-12
-------
Depreciation: calculated by using a sinking-fund method over the life
period of the FGD system.
Taxes: calculated by multiplying the total capital cost by the input
tax rate. The tax rate varies for different plants.
Insurance: calculated by multiplying the total capital cost by the
insurance rate.
Capital charges: calculated by multiplying the total capital cost by
the input interest rate. Capital charges represent the interest paid
per year for the use of capital, and they vary according to interest
rates.
The total annual fixed charges are obtained by adding the values of the
above four components. The annualized cost or total annual revenue is the
sum of the annual operating costs and the total annual fixed charges.
F-13
-------
APPENDIX G
UTILITY BOILER LIME FGD SYSTEM COSTS
COMPARISON OF TVA'S OLD & NEW PREMISES
PEDCO ENVIRONMENTAL. INC.. COSTS
G-l
-------
APPENDIX G
In this Appendix, the TVA cost estimating procedures are described and
compared for their "old" and "new" premises (see Section 4 for discussion).
Costs are presented for a system based on the following:
500 MWe Boiler
Lime Wet Scrubbing
Approximately 90% SO- Removal
In addition, PEDCo Environmental, Inc., costs for a similar system
are also presented.
G-2
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
EKAMPLJ Cl
CAH oat
•*• INPUTS •••
CHARACTERISTICS
MEGAWATTS • 900,
BOILER HEAT RATE • 9000. 8TU/MH
EXCESS AIR • »». PEftCINT* INCLUDING LIAKAOl
HOT CAS TIMPERATUM • 100. 010 *
COAL ANALYSIS* NT « AS FIRED
NIClSIHNIB
i.M l.il a.ia IA.BB ift.T
ASH nuiaHgAD . no .a pmeent
MCATtur. \i«tu» ni gnu « in ia.B 0.09
l*nfT n» UHTBtAM Pl'»A*H KPMHWtl
ALKALI
LIMB j :—
SOLUBLE M60 • 0.0
HOISTURC CONTENT I S.OO LI HJO/100 LBS DRV LINE
FLY ASH I
SOLUBLE CAO •SToSf «
*nmai.E MCO .—a»a
INERT* • 100.00
RAM MATERIAL HANDLING AREA
of
ALKALI PREPARATION UNITS
G-3
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
1VSTEM
NUMBER Or OPERATING SCRUBBING TRAINS • »
NUMBER OF REDUNDANT SCRUBBING TRAINS •0
NUMBER OF BEDS «S
NUMBER OF GRIDS •*
HEIGHT OF SPHERES PIR BBO •S.O INCHES
LIOUID-TOxCAS RATIO •S3, OAL/1000 ACP(SATP)
SCRUBBER CAS VELOCITY • lZ,t P7/SEC
INDUCED ORAPT SCRUBBER FAN OPTION
SCRUBBER PRISSURE • !*•? PSIA
STOtCHIOHCTRY •1.10 MOLE CAO ADDED AS IIHE
. PiR HOLT
INLET i taunt »u . r.na
mission LIMIT • a. an LI im/x ITU
tMTRAINMENT LEVll" • O.lfl MT I
IMT tfiineMt TH4B . H-fl HIM
tn.ft »t»<*tMT
IBS tH «if I»f IILATgn >LU««V • 11-11 MT JL
SOLIDS DISPOSAL SYSTEM
af LAND • Hon.on nnLL*«»/*e»i
tBLIDS IN 8Y8TBM tl'llBCj DUeHARflg • IB.fl MT «
M*»IMIIM POMP tit* • 9t99. AfttH
MtUIMIIM gXCAUttinN • tS.OO
TO ponn • mo. CT
onun i infn tutu H.a fmcHt« CLAY
1TSAM tFHEATER IIN.LlNil
SATURATED STEAK TEHPERATURE • »70. OEG P
HEAT OF VAPORIZATION OP STEAM • 731. BTU/L8
OUTLET FLUE CAS TEMPERATURE • 173. DEC P
G-4
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
SUPERFICIAL GAS VELOCITY (FACE VELOCITY) • IS,0 FT/SEC
iniaa.oaon
G-5
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
EXAMPLE CASE OLB PRBHSis LIMI
CASE 001
•*• OUTPUTS •••
HOT BAJ TO
HOLE PERCENT
LB-MOll/HR
IB/HR
C02
uei
S02
O»
Nt
MZO
12.313
O.flOT
0.238
4.127
73.869
1.749
0.20S4E*03
o.i>o9C*a*
0.39621*03
0.«011R«04
0.12321*06
a.t*s«e*ai
0.9040B*06
a.44BIE*01
0.23381*03
0.21T6E*06
0.3432E«OT
a.2AiB**a*
8Q» CONCENTRATION IN SCRUBMR INLET CA3 • 2373. MM
• 3,6* IBS / MILLION 3TU
PLYASH EMISSION • 0,18 IBS/MILLION BTU
• a.091 CRA1MS/SCP (MiTI PR
811. LI/Ht
lOLUBLt ttO IN PLY ASM •
0. Li/HR
SOLUBLE MCO IN PLY ASH •
HOT CAS FLOW RATE • .10348*07 SCFH (60 016 ft 14.T PIU)
• .U40E»OT 4CPM 1300. BIO PJ J4.7 PilAi
COAL imtNfl RATB • .4H*t«at LB/HR
MOT BA« HUM 101 TV • B.BJ7 Li MO/LR D»V Ml
WFT HLJLB TtMPtRATUBI • H9. D«B F
NET CAS FROM SCRUBBER
MOLl PERttNT
LB-HOLI/HR
LB/HR
CO2
HCL
tn*
02
N2
HZO
11.540
0.000
a. nn
4.301
69.342
14.393
0.20308*0!
0.60436*00
O.i*liE*a»
O.T998E+04
0.1232E*06
0.2393E*03
.90241*06
.22041*01
.17001*114
.2339E«Ok
.34I2E*07
.46T1E«06
S02 CONCENTRATION IN SCRUBBER OUTLET CAS • 237. PPM
PLVASH EMISSION • 0.09 LBS/NILLION BTU
• a.041 GRAINS/SO IHtT> OR
611. LB/HR
TOTAL WATER PltKIIP • 419. 6PM
INCLUDING 10.2 CPM ENTRAPMENT
NET CAS FLOW RATE • .11226*07 SCFH (60 OEC F. 14.7 PSIA)
• .12Tlt*07 ACFH (129. 086 PJ 14.7 P11AI
MET CAS SATURATION HUMIDITY • 0.101 LB H20/LB DRV CAS
G-6
-------
FLUE GAS TO STACK
OLD PREMISES
500 MW
LIME WET SCRUBBING
HOLE PERCENT
Lg«MOLE/HR
LB/HR
en» 11.92t
HCL 0.000
in* 0.024
02 4.494
N> 69. Ml
H20 14.726
CALCULATED S02 REMOVAL
0.2O90R*OS
0.604SB*00
0.4213E*02
0.799BS*04
0.12128*06
0.16216*09
EFFICIENCY •
0.9B24E»0*
0.2204E«Ot
0.2700E+04
0.29991*06
O.14S2E*OT
0.4722E*06
99.4 |
SPECIFICO S02 EMISSION • 0.60 FOUNDS PER MILLION BTU
CALCULATED S02 CONCINTRAT10N IN STACK CAS •
217. MM
FLYASH EMISSION « a.09 LBS/MILLION BTU
• 0.041 CRAINl/SCF (HIT) OR All. LI/MM
STACK CAS FLOW RATE . ,U24E«07 1CFN (60 010 F» U,T MIA)
« .miB*nt *riM UTI. am i. IA.T
STEAM REHCATER
>UPBBFtelAL CA1
M.B ft/lie
«HIIAPC OIP» Pirru . i Tixm ACTUAL »IP» n.n.
«ATUBAT»0 STEAM TEMDEBATURi • 4TB. DIB 9
HIITI CT BLUB r.A« Tt MDCP ATII««
1 T< - MB I
»»OUI«BB HFAT INPUT TU BtHtATER • fl.8THt*fli BTU/MR
HUTSIPE PIPE PREIIURE DROP.
HIAT TRANSFER
COEFFICIENT
DIAMETER* IN. IN. H20
STU/HR FT! DEC F
REHEATER
PIPJ
NUMBER OF
P1PE1 PER
NUMBER OF
AREA« SO FT
Ota TBAIN
BANK FBR
TRAIN
BANKS I ROWS)
PER TRAIII
• T
CORTEN
THTAL
0.9977E*03
a.»1418«O4
B7
iT
G-7
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
UATEB BALANCE INPUT*
RAINFALL!1N/V«ARI SO.
POND SEEPAGE(CH/SEC)«10«M 90.
»nnn EVAPORATinNMM/vtARi 1*.
HATER BALANCE OUTPUTS
HATER AVAILABLE
RAINFALL 6*8. CPH KSlBTi LB/HR
ALKALI |. QPH ll>t. L«/H«
TOTAL647. 0PM»2>3t», IB/HR
HATER REQUIRED
HUHIOIFICATION »09. 6PM 10*391, (,1/HR
tMTBATNMfNT IB. C»M »OT4.
DISPOSAL HATER U*. 0PM BXI99. LB/HR
H YOU AT ION HAT6R _ 1». QPM _ 601T. Li/HR
CLARIFIER EVAPOKATION 0. 6PM 0. LB/HR
BOMB EVtPORATtnN _ **«. 6PM «t4OTt.
SEEPAGE I0i 6PM 40001. LI/HR
TOTAL HATER REQUIRED lit!. 6PM 9609(1. LB/HR
MBT UATBR RBCUtagn _ 4T8. CPU _ «1TS>1. L»/tl«
G-8
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
SCRUBBER SYSTEM
TOTAL NUMBER OF SCRUBBING TRAINS (OPERATING«REOUNOANT) • 4
S02 REMOVAL •89i* PERCENT
PARTICULATE REMOVAL IN SCRUBBER SYSTEM •30.0 PERCENT
TCA PRESSURE DROP ACROSS I BEOS • B.6 IN. HZO '.
TOTAL SYSTEM PRESSURE DROP • 14.6 IN. H20
OVERRIDE TOTAL SVSTIN PRESSURE DROP • 20.0 IN. H20
SPECIFIED110UIO.TO-OAS-RATIO•95. GAL/1000 ACFIIATDI
LIM6 ADDITION • 0.22691*01 IB/HR DRY LINE
SPECIFIED LIME STOICHIOHBTRV
1.10 HOLE CAO ADDED AS LIMB
BIB tint > >in«*»uf i i tain««iB
SOLUBLi CAP FROM FLV AIM • B.fl MOLE PBR MP.LE ISOIONCLI AilORBBB
THTAI «ni um > Mc.n • n.n MOLJ n» Mfiti
THTAI
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
SLURRY ULEBO
SPECIES
CAS03 .1/2 H20
CAS04 .2H20
CAC03
lucni 11*1 f
L8-MOLI/HR
0.2«78E*03
0.10538*03
0.339TE*02
0.17Q7E*09
0.2S7AE*02
0.0
0.3«96E*01
o.o
LB/HR
0.3199E»09
0.3601E»04
0.307SE*06
0.lB33E*a4
0.0
B.4a««E*at
0.333BE*OI
0.0
TOTAL FLOM RATE
0.36S2E«04 LB/HR
flPM
TOTAL SUPERNATE RETURN
L»-MOL£/H«
H>n
CA«*
HG»*
$03—
SD4—
CL-
An.
TOTAL Pl'OW
0.1174B«BS
0.23771*02
o.a
0,47196*00
0.12258*01
0.40026*02
a.n
RATI • a.2B64E*06
a.2HTE»A4
0.9I24E*03
0.377BE»02
0.3B«IE«al
0.14196*0*
a. a
LB/HR
171.
OPH
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
SOLUBLE MGO
INSOLUBLE!
H20
CA»*
HG**
sna—
SO*—
CL-
AD*
O.U
0.66696*0*
0.112*E»02
0.0
o.>o8«t*ao
0.13766*01
0.1772E«02
0.0
0.0
0.6312E»al _
0.12026*06
0.410SE*01
0.0
B.i***E«a2
0.11226*01
0.62106*01
0.0
TOTAL PLOH RATE • 0.19091*06 LB/HR
SUPERNATE RETURN TO SCRUBBER OR EHT
SPECIES
LJ/HJ
O.IT76t*0*
CA**
NC»«
S03—
tn^._
CL-
AH.
0.13256*02
0.0
0,26301*00
O.17«tB*ai
o,i23ie*oa
O.a
•5IIOE*0>
.0
.21066*02
. lT)7E*n*
.7*096*01
.0
TPTAL Bt'ou BAT»
in /Ha
m.
OPN
SLURRY TO
SPECIES
LB-HOLI/HR LB/HR
CAS03 .1/2 H20 0.26111*03 0.31TiB«07
CASD4 .fHJD
CAcoa
tMSHLUBLES
H20
rA»»
MC«*
«n»-_
SO*—
CL.
A0>
0.11106*09
0,1792i*0*
>••—•-•
0.17996*07
0.17161*04
0.0
0.ia«3E*OI
0.36868*01
0.497*8*04
0.0
0.19111*07
0.37966*06
S.1120EAO*
.92426*08
o.la««C»n«i
0.0
0.*11TC»A*
0.1I4lE*OS
0.1622E*B6
0.0
TOTAL PCOW RATI • 0.38SOE«Ot
_ . _ • 49931.
LB/HR
flPH
G-ll
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
FLUE GAS COOLING SLURRY
8PEC1E1
LB.MOlg/MI
CASOB .f/t H20
CAS04 .2H20
CAena
INSOLUBLE!
M3O
CA»«
Hr.^A
$OJ—
SD4—
Cl-
An.
THTAI il'OU RAT*
0.19001*04
0.8076i»OS
o.iTii««oa
0.1109E406
0,197S6*OJ
O.a
0.19228*01
0.26111*02
0.13271*01
0.0
• n.mnot+ni
a.24Sif»a6
0.1390E*06
0.2T«lE»al
0.81476*0*
0.21SftE»AT
0.791II*0«
o.o
0.3140E*0>
0.29711*04
0.11798*09
0.0
II /HI
soa*.
G-12
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
POND 06SIGN
in MINIMIZE TOTAL etur PLUS OVERHEAD
DEPTH OF POND
DEPTH OP EXCAVATION
LENGTH OF POND PERIMETER
LENGTH DP DIVIDE*
LENGTH PERIMETER FENCE
AREA OF BOTTOM
AREA OP INSIDE WALLS
AREA OF OUTSIDE MALLS
AREA OP RECLAIM STORABI
AREA OF POND
AREA OP POND SIT*
AREA OP POND SITE
VOLUME OF EXCAVATION
Ufll IIMC Of RECLAIM «TO8AGI
VOLUME OF SLUDGE TO BE
DISPOSED OVER LIPE OP PLANT
10. 49
1.9S
13269.
14O9.
1*219,
10T9.
114.
»».
9*.
120B.
1SB4.
>11.
13TS.
All.
TB16.
4891.
FT
PT
FT
PT
PT
THOUSAND YD!
THOUSAND YD*
THOUSAND YOJ
THOUSAND YD!
THOUSAND YDI
THOUSAND VB«
ACRES
THOUSAND YD!
THOUSAND VB«
THOUSAND YDI
ACRE PT
onum rncT« iTHniKAunS nc nni'iARll
LABOR MATERIAL TOTAL
CUjO iOa.
EXCAVATION
DIKE CONSTRUCTION
LINING! 12. IN. CLAY)
SODDING DIKE WALLS
ROAO CONSTRUCTION
PERIMETER COSTS* FENCE*
RECLAMATION EXPENSE
MONITOR NELLS
3919.
HIT.
1007.
at.
3B.
Tl.
BIO.
4.
•••••••«•••*««
93.
11.
142.
4.
3911.
191T.
100T.
US.
49.
• 14.
B30.
a.
••••••••
PONO CONSTRUCTION 8166. all. BBTT.
LAND COST 10BT.
PONO SITE9664.
OVERHEAD SB3I.
G-13
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
• »*MPLi CA1E PL0 »«JM1IS LIME
ooa
WPSUL CONTENT (SIT
ASU CONTENT IKII
BTU RATINGI
aniiER TVPEI
NO. OF SCRUB6ERSI
SCRUBBER VELOCITY IFT/MH
PLANT SUE (HWII
OPERATING HRS/VRI
PUMPING RATE (GAL/1000 ACFll
SCA RATIDl
P ARTICULATE REMOVAL
1.1!
14.00
10SOO
DRV PULVERIZED COAL
4
790.0
SOO
7000
SO. 00
1.100
INVESTMENT AND OPERATING COST
FARTICULATE EMISSION REGULATION (LB ASH/MILLION BTUII
FLUE OAS TEMPERATURE ICOLDI (Pll
FLUI qiS TEMPERATURE (uOTI till
COST OP ELECTRICITY (6/KWHR)|
COST OP STEAM 14/THDIlSANB Illl
FIRST YEAR CAPITAL CHARGE FACTOR I
BiiGHOUSE RATIO IOPRR. la.PT. /ACTUAL 10.BT.il
6AG COST IB/SO. FT.ll
RAO L|IIIV|lltll
FLUE GAS REHEAT TEMPERATURE (Pll
CHEMICAL ENGINEERING PLANT INOIII
0.1)
800.0
700.0
0.01
1.00
0.217
O.AO
0.70
• ,00
17).
aAi.a
(ACTUAL SQ.PT./CALC. SO.PT.I
I
I-1
-P-
ELECTROSTATIC PRICIPITATORS
COLO
HOT
BAOHOUSI FABRIC FILTERS
SCRUBBERS
REQUIRED REMOVAL EFFICIENCY nil
ORIFT VELOCITY (FT/HII
SPECIFIC COLLECTION AREA
COLLECTION AREA (50.FT.II
•a.so
(SQ.PT./ACPMII
fl.90
9B.IO
M.IO
178901.4
.
84IBBI.O
ITH1T.O
TOTAL CORONA POWER (KH)I
tllKILIARV POHBK tKUII
870,8
969.1
PAN POWER (KM)I
PUMP PflWER tKM11
11,0
lie
1611.I
ma.4
TOTAL POWER (KM)I
OPERATING AIR/tlOTH RATIBl
1411.9
1646.1
1.4
161).I
INSTALLED AIR/CLOTH RATJOl
REQUIRED PRESSURE PROP I INCHES 11
1.0
1.0
1.7
I.a
10.1
DIAMETER (FEET)I
BtOIIIBtP BEHEtT 1«TII/M»I1
1J44B4I4.0
STEAM SUPPLY W (THOUSAND L8IJ
INSTALLED COST 11979 DOLLARS II
FIRST YEAR CAPITALIZED COSTl
ANNUAL POWER COSTl
ANNUAL OPERATING AND
MAINTENANCE COST 11979 DOLIARSIl
6
6
B
A
4109471
891698
170091
•4097
,
6
B
A
7162069
1976114
116614
!•».»
11819196
1904)61
•11246
7(1771
B
6
B
»
496)47.4
11061471
4971041
1140000
i^oiaai
REPLACEMENT COST 11979 DOLLARS II
ANNUAL REHEAT COST!
174146
911499
TOTAL ANNUAL COSTl
ANNUAL HEP COST DP POWERtHlLLS/KWHRI I
1146064
0.11
1969491
O.iT
1088170
o.ia
771)741
a.il
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
RAH MATERIAL HANDLING AND PREPARATION
ITEM
DESCRIPTION NO.
MATERIAL
LABOR
CONVEYOR FROM CALCINATION
PLANT
STOHABE SILO ELEVATOR
CONCRETE STORAGE SILO
UOOFT HORIZONTAL* IOHP
126. fT HIGH* 90 HP
LI70B4.PT1«*B.BPT DIA j
1
I
1
177761.
1172O.
112068.
11269,
1717.
111S74.
73.2PT STRAIGHT Slot
STORAGE HT
STORAGE SILO HOPPER BOTTOM
IfiMlTM UIBBATING EEEDEB
BEtLAIM MIT CONVEYOR
FEED BIN ELEVATOR
e»«n BIN
BIN VIBRATING FEEDER
BIN HEIGH FEEDER
SLAKER
SLAKER PRODUCT TANK
SLAKER PRODUCT TANK AGITATOR
LIME SYSTEM OUST COLLECTORS
SLAKER PRODUCT TANK SLURRY
PUMPS
SLIlRBV PEED TANK
60 DEGREE* £S
1,SMB
124. «T MQR1IDNTAL> SUP
JOET UICU. 10UP
IOPT HtA. 1SPT STIA1AUT
1101 HT* COVERED* CS
I.9HP
UFT, 12IN ICRBNt I HP
6.TPH* 10. HP
IOHP
POLYPROPYLENE BAG TYPE
I2OO FCM.T.IUP
114.GPM. 60PT HEADj
4, HP* 2 OPERATING
AND 1 SPARES
141442. GAL* 2B.OFT DIA*
1
.
,
l
f
2
2
2
2
2
*
I
1
19114.
•Bfa
tiii».
40171.
aiai,
176SB.
B917.
100721.
BUB.
11079.
16994.
10171.
1091S.
12410.
1*4.
2BI1.
1114.
SIB*.
2160.
1296.
•691.
6912.
102*.
990*.
2117.
24679.
2B.9FT HT* FLAKEGLASS-
LINED CS
SLURRY PEED TANK AGITATOR
tniBBv Prrn TANK PUMPS
91. HP
67.CPM* 6O FT HEAD.
l
6
49O79.
14471.
1691.
4916.
I.HPt 4 OPERATING AND
2 SPARE
....... ._...___..
TOTAL EQUIPMENT COST
797449.
G-15
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
fCRURBINB
ITEH
DESCRIPTION
NO. MATERIAL
LABOR
I.D. FANS
20. DIN H20» WITH IftftO.
MP MOTOR AND BR1V§
ft >1*12TB.
46644.
Cur LI 04»I41-
RUBBER LINING
MI*T ILtMINATOR
SLURRV HEADER AND NOZZLES
CRIBS
SPHERES
TOTAL TCA SCRUBBER COSTS
REHEATERS
SOOTBLOWERS
EFFLUENT HOLD TANK
2*0772, OALf I4, OPT DIAf
14.OIT UT» VLAKIOLASfa
973*46.
14111*.
2*9689.
41 2 404 T
378629.
ft 140*860.
ft 11*1*27,
*S • 202286.
ft 196*72.
241512.
99»t»,
120971,
131*22.
LINED CS
EFFLUENT HOLD TANK AGITATOR
COOLING SPRAY PUMPS
61. HP
12T1.GPM 100PT MEAD*
14. UP. 4 OPIRATtMB
6 2*1*88.
1 »9872,
1*011.
20*86,
AND ft SPARE
ABSORBER RECYCLE PUMPS
MAKEUP WATER PUMPS
87*1. 6PM j 100FT HEAD*
4BS.HP. 8 aPERATINB
AND ft SPARE
2349IGPN« 200. FT HEAD'
214. HPj 1 OPERATING
12 6*1111.
S 21912.
71710,
2498.
AND 1 SPARE
.n.i, ea,,.DM.u* rn«T ".7177^" ""i".^?
G-16
-------
OLD PREMISES
500 MW
LIME WET SCRUBBING
MASTE DISPOSAL
ITEM DESCRIPTION NO. MATERIAL LABOR
ABSORBER BLEED RECEIVING 9T61t.GALi IT.OPT D|A« 1 1*1*6. 1961T,
1».QHT HT. I "
LINED CS
ABSORBER BLEED TANK AGITATOR 16.HP - 1 121*6. 1T66.
POND FEED SLURRV PUMPS 66J.CPM. 110,PT HEAD t 14«9I, 1ST!.
4O.MB. 1 BiERATlNB
AND 1 SPARB
POND tuPERNATE PUMPSJTI.GPM. I»Z,PT HEAD*iIOBT*.nig.
AND 1 SPARE
TBTAl gQIIIPMtMT COJT 4T>69. ttAlt.
G-17
-------
OLD PREMISES
500 MW
PROJECTED CAPITAL INVESTMENT RtOUIHbMENTS - LXAMPLt CAM OLO PREHSIS LIML
EQUIPMENT
MATERIAL
LABOR
PIPING
MATERIAL
LABOR
DUCTrfORK
MATERIAL
1AAOR
FOUNDATIONS
MATERIAL
LABOR
PQND CI1NSTRIICTIDN
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
MATERIAL
O LABOR
H. INSTRUMENTATION
no MATERIAL
LABOR
min oiiics
MATERIAL
LABOR
SEKVlCES AND MISCELLANEOUS
SUBTOTAL DIRECT INVESTMENT
ENGINEERING DESIGN AND SUPERVISION
CONSTRUCT inn EXPENSES
CONTRACTOR FEES
CONTINGENCY
SUBTOTAI FIXED INVESTMENT
ALLOWANCE FOR STARTUP AND MODIFICATIONS
INTEREST DURING CONSTRUCTION
SUBTOTAL CAPITAL INVESTMENT
LAND
HOfiKlNG CAPITAL
TUTAL CAPITAL INVESTMENT
Lime Wet Scrubbing CASF 002
INVESTMENT* THUUSAHP5 »' »««<> nOI I ARS
SAM t!AJ£RIAL
HANDLING AND
PREPARATION
757.
438.
«$6.
210.
0.
0.
64.
129.
o.
94.
80.
106.
226.
93.
13.
0.
0.
70.
2724.
243.
436.
136.
272.
3B14.
305.
458.
4577.
10.
12Bi
4714.
SCRUBBING
9682.
836.
2553.
912.
• 1718.
1*84.
112.
233.
0.
222.
373.
536.
1024.
506.
82.
0.
O.
520.
20295.
1827.
3247.
1015,
2030.
2B4I4.
2273.
3410.
34096,
2.
933.
35052.
WASTE
DISPOSAL
68,
22,
847.
282.
0.
0,
17.
34.
8577.
2.
3.
126,
263.
9,
8.
0,
0.
270.
10529,
948.
1685.
526,
1053.
14741.
1179.
1769,
17689,
1096,
495.
19279.
TOTAL
10507,
1296.
3845,
1004.
1718.
lias,
192.
396,
B477.
318.
456.
770.
1514.
608.
104.
0,
0.
860.
33549.
3019.
5368.
1677.
3355.
46968.
3757.
5636.
56362.
1107.
1576.
59045.
DISTRIBUTION
PERCENI
OF DIRECT
INVESTMENT
31.3
3.9
11. S
3.0
5.1
4, 1
0.6
1.2
29.6
0.9
1.4
2.3
4.5
i.a
0.3
0.0
0.0
2,6
100,0
9.0
16.0
3.0
10tO
140.0
11.2
16,8
168,0
3,3
4.7
176.0
-------
I
M
\O
LIME SLURRY PROCESS .- RASlSl 500 1W UNIT. 1981 STARTUP
PRnjfcCTFU 1IFFT1ME REVEIIUF REQUIREMENTS - EXllHPLf CASE ULD PREMS1S LIME
TOTAL CAPITAL INVESTMENT 1
SULFUR
OLD PREMISES
500 MW
Lime Wet Scrubbing CASS 002
t 59045000
AOJ
BYPRODUCT ANN
RATE* SLUDGE R
YEARS ANNUAL POWER UNIT POWER UNIT BY EQUIVALENT FIXATION FEE
AFTER OPERA- HEAT PUEL POLLUTION TONS/YEAR 1/TtlN
POME" TlOn; REQUIREMENT, CONSUMPTION* CONTROL
UNIT KW.HR HILL 1011 BTU TONS COAL PROCESS.
START /KW /YEAH /YEAR TUNS/YEAR
1 7000 31900000 1500000 39700
2 7000 31500000 1500000 397OO
3 7UOO 31500000 1500000 39700
4 7000 31500000 1500000 397OO
9 7000 31500000 1900000 39700
b 7nnn aisnnoon iSooooo JOT.VI
7 7000 31900000 1900000 39700
8 7000 31500000 1500000 19700
9 7000 31500000 1500000 39700
in 7nnn ?isnoooo isnnnnn 397on
11 looo 22500000 10714OO 2B4OO
12 5000 22500000 1071400 28400
13 9000 22500000 10714OO 28*00
14 5000 22500000 1071400 28400
IS Soon 22900000 1Q71400 28*00
16 3500 15750000 750000 19dOO
17 «nn 157SOOOO 750000 19800
IB 35QO 15750000 750000 19800
19 3500 15750000 75OOOO 19600
20 3500 15750000 790000 19800
21 1500 6750000 321400 8500
>2 linn 6750000 32140O 85OO
23 1500 6750000 321*00 8500
24 1500 6750000 321400 8500
25 1500 6750000 321400 8500
26 1500 6750000 32140Q 8*0.0
27 1500 6750000 321400 8500
28 Unn 6750000 321400 8500
29 1500 6750000 321*00 8500
30 1500 6750000 3214QO B5QQ
URY
SLUDGE
191700
191700
191700
191700
191700
iQ!7nn
191700
191700
191700
141700
137OOO
137000
137OOO
137000
137000
93900
99900
95900
99900
99900
41100
41100
41100
41100
41100
41100
41100
411OO
41100
41100
DRY
SLUDGE
0,0
0.0
0,0
0.0
0,0
o.n
0,0
0.0
0.0
0.0
O.O
0,0
0.0
0,0
o.o
0,0
o.o
0,0
o.o
0,0
0.0
0.0
0,0
0.0
0,0
0.0
0,0
0.0
0,0
0,0
US1ED..GROS!
UAL REVEKUI
EOUIREMENT
EXCLUDING
SLUDCE
FIXATION
CUST,
I/YEAR
23061800
23359000
23692900
24066500
2*482100
74942100
25*49100
26009500
2661*800
_212J0100_
23553300
2*073700
2*64*800
29269400
22010600
22933300
23111200
237*0600
2*427400
1606*8^0
16329900
16630100
}6967700
1T345IOO
17764600
16226300
10739600
19300800
19919100
s
E
TOTAL
ANNUAL
SLUDCE
FIXATION
_£Q5Ji
I/YEAR
0
0
0
0
0
o
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
NET ANNUAL CUMULATIVE
INCREASE NET INCREASE
IN TOTAL IN TOTAL
REVENUE
t
23061800
23359000
23692900
2*066500
2*482100
23449100
26005500
2661*800
27280309
23553300
2*073700
2*644800
25269400
25951000
22010600
22535300
23111200
23740600
2*427*00
1606*800
16329900
16630100
16967700
173*5100
17764600
16228300
1B739600
19300800
19919100
REVENUE
;OUliEHEHU_
t
23061600
46*20800
70113700
_i4LBD2QD_
116662300
1436n«400
1690939QO
.liSOliOQfl—
221673600
.2*09.91100.
272507400
296961100
346499300
3.724.463.00.
394*96900
416992200
4*0103400
«.63fti*QOO_
466271400
904336200
920666100
937296200
394263900
971609000
5l93.736.Qfi
607601900
6263*1900
6*5642300
669557400
TOT 127500 573750000 27321000 723000
LIFETIME AVERAGE INCREASE IN UNIT REVENUE RETIREMENT
DOLLARS PER TON OF C3AL BURNED
MILLS PER KILDUATT-HUUR
CENTS PER MILLION BTU HEAT INPUT
DOLLARS PER TON OF SULFUR REMOVED
REVENUE REOUIREMfcNT DISCOUNTED AT 11.6* TO INITIAL YEAR,
IEVFI1IFO INCHEASF IM UNIT REVENUE REQUIREMENT EOUIVAL
DOLLARS PER TON OF C3AL BURNED
MILLS PER KILOWATT-HOUR
CENTS PER MILLION BTU HEAT INPUT
HOLLARS PER TCJN Of S.JLFIIK REMOVED
3492500
DOLLARS
ENT tO DISCOUNTED
REQUIREMENT
669957*00
2*. 36
10.**
116.00
920.99
197776300
OVER LIFE
16.57
7.96
66.4*
701.99
0
0,0
0.0
0,0
0.0
0
OF POHER
0,0
0.0
0.0
0.0
669557400
2*. 36
10.**
116.00
920.55
197778300
UNIT
16.37
7.96
88.**
701.39
UNIT COSTS INFLATED AT 6,001 PCR YEAR
-------
LIME SLURRY PROCtSS ,- BASl!.! 900 Irf UNIT. 19B1 STARTUP
PROJECTPU REVENUE RFQUlREMtNTS - EXAMPLE CASfc 01 D PRfcHSIS L IMF
OLD PREMISES
500 MW
Lime Wet Scrubbing
ISJ
o
ANNUAL OPERATION KU-HR/KW • 7000
27.39 TONS PER HUUR
TC1TAI CAPITAI INVESTMENT
DRV
SLUDGE
AUNUAL
DIRECT
COSTS
RAW MATERIAL
LIHE
-10* 0. K TUNS
»0.00/TON
3198600.
SIIBTOTAI BAU MATERIAL
COSTS
nRERATlllG LABOR AND
SUPERVISION
UTILITIES
STEAM
PROCESS MATER
ELECTRICITY
MAINTENANCE
LABOR AND MATERIAL
ANALYSES
SUBTUTAI CONUEHSIOM COSTS
34610.0 HAN-HR
532390.0 K L8
199660. O K CAL
93578740.0 KWH
5SBO.O MR
12,50/MAN-HR
2.00/K LB
0.12/K GAL
0.029/KHH
17.00/HR
432600
106*800
tLftfifl
1993800
2295100
9* Boo
S*9«fnO
SUBTOTAL BlRgCT COSTS
8683700
crisis
QgPRgClATION
1878700
COST UF CAPITAL AND TAXES, 17.20X OF UNDEPRECIATED INVESTMENT
INSURANCE c INTERIM REPLACEMENTS. i.i7« OF TOTAL CAPITAL INVESTMENT
OVERHEAD
PLANT. bO.OK or CONVERSION COSTS LESS UTILITIES
10195800
6JO.BOfl-
ADMINISTRATIVEj RESEARCH* AND SfcRVICE*
in.OK of npEBATlMr. i «anR ANQ
16698OO -
SUBTtlTAL INDIRECT COSTS
.110
EQUIVALENT UNIT REVENUE REQUIREMENT* HILLS/KWH
6.99
HEAT RATE 9000. BTU/KMH
HEAT VALUE OF CUAL
10900 BTU/LB
COAL RATE 1900000 TONS/VR
-------
NEW PREMISES
500 MW
LIME WET SCRUBBING
CA11 OO4
••• INPUTS •••
•OILfR CHARACTERISTICS
HECAWATTS • 300.
BOILER HEAT RATE • 9SOO, BTU/KKH
EXCESS AIR • If. PERCENT* INCLUDING LEAKAGE
HOT GAS TEMPERATURE • SOO. OEG P
COAL ANALYSIS. NT I AS FIRED I
M 0 N S CL ASH H20
l.gQ 8.6n l.lo >.16 a.in li.in 4.Ha
l PUB IHIEttHEAO . O*.B
A«M miiBHBAP. • gO.Q BJRCgNT
mi UP n« en*L • UTOB.
JMIISIDN.
PtYASH RIHOVAL • LBS/H BTU
oo.T n.a«
HITHIM iCRuaatR 10.0 O.QS
en«T n» UPSTREAM EIVA«II «i=Mnuii t»eiUB»n
ALKALI
i IMP
97.11 UT « B«V Itttl
SOLUBLE HGO • 0.0
INERTS • ».»i
MOISTURE CONTENT I S.OO LB HJO/100 LBS DRV LlHI
FLY ASH I
SOLUBLE CAO • 0.0 NT I
SOLUBLE MCO • 0.0
INERTS • 100.00
RAH MATERIAL HANDLING AREA
NUMBER Of RBOUMPANT ALKALI PREPARATION UNITS •
G-21
-------
GRUBBER 8Y1TEM
NEW PREMISES
500 MW
LIME WET SCRUBBING
NUHB8R Of OPERATING SCRUBBING TRAINS •
NUMBER OF RHOUNOANT SCRUBBING TRAINS •
NUMBER OF *80S •
NUMBER OF GRIDS •
HEIGHT OF SPHERES PIR BED • S.B INCHES
UOU10-TO.GAS RATIO • S3. GAL/1000 ACP(SATDI
SCRUBBER GAS VELOCITY • 12tl FT/SEC
INDUCED ORAPT SCRUBBER FAN OPTION
SCRUBBER PRESSURE • l»iT PSIA
STOICH10HETRV • I. 19 MOLE CAO ADDED AS LIMB
_ PIR HOLl
-------
NEW PREMISES
500 MW
LIME WET SCRUBBING
SUPERFICIAL GAS VELOCITY (PACE VELOCITY) • 23.0 FT/SEC
maa.aoaa
G-23
-------
NEW PREMISES
500 MW
LIME WET SCRUBBING
EXAMOLt CASE NEW PRiMStS LIMi CASE Oa«
••• OUTPUTS ••*
HOT BAS TH SCRUBBER
MOLE PERCENTLB-MOLE/HRLB/HR
€02
UCI
S02
02
N2
MJO
12.338
0.21*
S.JfcO
73.227
6.6S4
0.22931*03
a.Li49E*a>
O.»914i*03
a. toiAE*aa
0.13T3E*06
a.isi6E*aa
0.99231*06
0.2306E*03
0.3882E«07
a.H9iE«a6
SO2 enNeENTRATlON IN SCRUBB»« 1MLET CAS • 1148. PPM
E mz. PPH
• 3.28 LBS /
HILL ION ITU
FLVASH EMISSION • 0.03 LBS/HlLLlON BTU
. a.an e»AiNS/Sc» IHITI a« IAT. LI/H«
SOLUBLE CAP IN >LV A»H • 0. L»/HR
Ufl
NGO
SOLUBLE MOO IN PLY ASH •
HOT GAS PLOH RATE • ,113*6*07 SCFH (60 DIG ft 14,T PIU)
• .16871*07 ACFH (300. DIG >» 16.T M1AI
enaitBg»oNBlNC CBAL JIKINC RATI • .tatni^nA LB/HH
unr BAI HUM to I TV • O.OA» LI mayn B«v BA«
HST BULB TtMPEHATUBB • H4. BBC >
NET GAS FRON SCRUBBER
MOLB PgBCENT Lg-MOLg/HR LR/MR
CD2
HCL
«n»
01
IIS
H20
11. SIT
0.000
n.nia
3.183
TO. 449
12.T82
0.2246E«a3
0.37166*00
a.4444E*a>
0.1011E*03
0.11T9E*fl6
0.2*931*03
a.9RR4E*Q6
0«20I8E*02
a.i»ia**a4
0.32331*06
0.3BS2E»OT
0.449IE«06
S02 CONCENTRATION IN SCRUBBER OUTLET GAS • 121. PPM
FLVASH EMISSION • 0.02 IBS/MILLION BTU
• fl.OPT CRA1NS/SCF IMETI OR 74. LB/HR
TOTAL HATER PlgMIlP • 4T1. C.PM
PleMIlP . 4T1
INCLUDING 11
.2 GPM ENTRAINHENT.
MET GAS FLOW RATE • .12328*07 SCFH (60 DIG fi M,7 PSU)
• .lli4E«OT tCFH (1?4. PEC fm 14.T PS1AI
HBT GAS SATURATION MUHIOITV • O.OBT Li H2D/LB DRY CAS
G-24
-------
FLUE CAS TO STACK
NEW PREMISES
500 MW
LIME WET SCRUBBING
HOLB PERCENT
LB-MOLE/HR
LB/HR
enj
HCL
S02
at
Hi
HJO
ll.*9R
0.000
0.023
9. ITS
70.3B2
12.921
0.22*68*09
Q.3T26E«00
0.*4*9E«02
O.IOUE«03
0.1)T9E»06
0.292*1*03
.9BB*E»06
.2oaeE»o2
.2(901*0*
.3239E«06
.3B32E*OT
.43*76*06
CALCULATED 102 REMOVAL EFFICIENCY • SB.T i
SPECIFIED S02 EMISSION • 0.60 POUNDS PER MILLION 8TU
CALCULATED S02 CONCENTRATION IN STACK OAS •
218. PPM
FIVASH EMISSION • 0.02 HI/MILLION »TU
• O.OOT CMAINS/SCP (M|T) OK
7*. LB/HR
STACK GAS FLOW RATE • ,1234B*OT SCPN (60 OE6 Pi 1«.T FEU)
T Ag»M I1T1. ngtt f. IA.1 0
-------
BALANCE INPUTS
RAtNF&LLtIN/VEARi
30.
POND SEEPAGE(CM/SEC)*LO**a
POND eVAPORATtnNMN/VEAR>
50.
NEW PREMISES
500 MW
Lime Wet Scrubbing
MATER BALANCE OUTPUTS
WATER AVAILABLE
RAINFALL
ALKAL I
7*6. 0PM
3. SPM
TOTAL
748. CPM
372601. LB/HR
l?71t I.B/HR
373873. LB/HR
WATER REQUIRED
HUMIOIF ICATIQN
CNTB4 INMCrjT
DISPOSAL WATER
HVORATIDN WATPB
CLARIFIER EVAPORATION
PDNO PVAPORATTRN
SEEPAGE
TOTAL WATER REQUIRED
MCT JATER REOUIRFO
460.
11.
175.
12.
0.
bll.
93.
1263.
51§.
GPM
GPM
GPM
GPH
GPM
GPM
GPM
GPM
GPM
229999.
9604
87310.
5903.
0.
256151.
46261.
631232.
257360.
LB/HR
L R /HR
LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
LB/HR
G-26
-------
SCRUBBER SYSTEM
TOTAL NUMBER OF SCRUBBING TRAINS (OPERAT ING*REOUNOANT» • 3
S02 REMOVAL * 38,6 PERCENT
PARTICULATE REMOVAL IN SCRUBBER SYSTEM
90.0 PERCENT
TCA PRESSURE DROP ACROSS 3 BEDS • 8,6 IN. H20
NEW PREMISES
500 MW
Lime Wet Scrubbing
TOTAL SYSTEM PRESSURE DROP « 14.7 IN. H20
OVERRIDE TOTAL SYSTEM PRESSURE ORQP » 20.0 IN. H20
SPECIFIED LIOUID-TO-GAS-RATIO • 59. GAL/1000 ACF(SATD)
LIME ADDITION • Oi2543E*09 LB/HR DRY LIME
SPECIFIED LIME STOICHIOMETRY
• 1.29 MOLE CAO ADDED AS LIME
PCR MOLE >snj*?uri)
CAD FROM FLY ASH » o.o HOLE PER MOLE iSQ2*2HCD ABSORBED
THTAL SHLUBLE MCfl
a O.B HOLg PPR MOLE
-------
SLLJRRV
SPECIES
CASU3 .1/2 H2U
C45O4 .JH20
CAC03
fNSCILUBLES
H20
CA+*
MG**
SQ3--
S04--
n _
A0»
L8-.MOLE/HR
0.2*286+03
0. 10316+03
0.88086*02
0.18316*05
0.24916+02
0.0
0.3333E*00
0.37716*01
0.4110E+02
o.o
L3/HR
NEW PREMISES
0.31356*05 500 MW
0.1773?*OS .... T r.un TT^i C 111
0.88176*04 Lime WeL Sciubbillg
0.79A2E*C3
0.32986*06
0.99836*03
0.0
0.42876*02
0.3622E+03
0.14S7E*04
0.0
TOTAL FLOW RATE
0.3914E*06 LB/HR
711. CPM
TOTAL SUP6RNATE RETURN
5PFCTES
LR.MDl E/HB
a/Htt
H2O
CA++
SOS—
S04--
CL-
TOTAL FLOW RATE
0.17326+05
0.23576*02
0.0
0.5067E+00
0.35686+01
0.38896*02
O.a
a 0.31486+06
0.31216*06
0.94476*03
0.0
0.40576*02
0.34286*03
0.13796*04
0.0
LB/HR
630,
GP1
TO LTHP Si
SPECIES
L3-MOLE/HR L3/HR
H2Q
0.77336*04
0. 1Q33E*02
0.13976*06
Q.4g2BE*03
MC+*
SH3-.
0.0
0.22686*00
0.0
0.18166*02
S04-
CL-
0.15976*01
0.17416*02
0.15346*03
Q.61706*03
AOi
0.0
0.0
TOTAL FLOW RATE > o.i409E*06 LB/HR
• 282. GPM
LIME SLURRY FEED
SPECIES
LS-HOLS/HR LB/HR
f&CHI .1/2 H20
CAS04 ,2H20
CA(OH)2
0.0
0.51186-01
0.*393E*03
0.0
0.88096*01
0.32376*05
G-28
-------
NEW PREMISES
500 MW
LIME WET SCRUBBING
kULUHLE «l>fl
INSOLUBLE!
H20
CA*«
MC»*
Sf»__
504—
CL.
A0«
0.0
0.74298*04
0.114*1*02
0.0
0.22*11*00
0.13466*01
0.17411*02
0.0
0.0
0.72*7E*Ol
0.11188*06
0.46096*01
0.0
0.111*8*02
0.14896*01
0.617O6«O1
0.0
TOTAL FLOM RATE • 0.1680E*06 IB/MR
?oa. (IBM
SUPERNATE KETURN TO SCRUBBER OR EHT
LB.MOLi/Ha
L8/MR_
HiO
).9»T1B*Q4 0.1T24E»06
CA**
MC*«
$03—
tn*—
CL-
An.
,130IE*02
.a
.27991*00
.19T1E*O1
.2149E*02
.a
0.91198*01
8.0
.2241E»02
o.ii94E*ea
O.T617I»0)
0.0
TOTAL FLOW RATI • Q.17191*06 Li/HR
146.
iL'URRY TH IgRugaBR
SPECICS
IB-HOIE/HR LB/HR
CAS01 ,1/1 H20 0.26001*09 0.1S9»E*OT
CASO4 .2H20
CAC01
iNsm iim'Ei
H2Q
CA*«
HG*«
«nt._
SO*-.
CL.
A0<
0.110*E*Oi
0.9431E*04
0.19601*07
0.26671*0*
0.0
0.9731B«02
0.40178*01
0.4*006*0*
0.0
. 1900E*O7
.94408*06
.»*7E*OI
,1911E*OB
.10608*06
.0
.49908*04
,1B7|8*OI
.11608*06
.0
TOTAL PLOW RATI • 0.41918*08 LB/HR
• 76111. CPU
G-29
-------
FLUE GAS COOLING SLURRY
SPCCTES
LB^MBL E/HB
3/HR
NEW PREMISES
500 MW
CASO3 .1/2 H2d
CAS04 ,2H20
42)1
CA+*
MT.++
S03— •
S04—
AOa
TPTAI PI dW RATP
0. 1891E+04
0.8030E+03
0.6859E+Q3
0.142&E+06
0.1939E+03
0.0
o!2936E*02
0,3200E*03
0.0
9 n.3o&ae+fl7
0.244iE4>n6
0.13826*06
0.2568E*07
0.7773E*04
0.0
0.3338E*03
0.2821E*04
0.11356*03
0.0
1 R/HR
Lime Wet Scrubbing
5539,
GP1
G-30
-------
OJ
PARTICIPATE REMOVAL INVESTMENT AND OPERATING COST
PARTICIPATE EMISSION REGULATION (LB ASH/MILLION BTUII 0.03
WPSUL CONTENT IX)I
«SM CONTENT (ittT
8TU RAT ING l
Rflll ER TYPE 1
NO. OF SCRUBBERS!
SCRUBBFR VELOCITY (FT/MI!
PLANT SIZE (MWII
nPFRATING HRS/YPI
PUMPING RATE (GAL/1000 ACF)|
SCA RATIOl
(ACTUAL SO.FT./CALC. SQ.FT.!
3.30
11700
DRY PULUERIZtO enAL
4
7SO.O
500
47*0
20.00
1.1OO
FLUE GAS TEMPERATURE (COLO) (F)l
FLUE RAS TEMPERATURE IHOT1 (Fl:
COST OF ELECTRICITY (»/KWHR|i
COST ftf STEAM (I/THOUSAND IBII
FIRST YEAR CAPITAL CHARGE FACTOR)
BAGHOUSE RATIO (OPER. SO. FT. /ACTUAL Sfl,FT.)l
BAG COST (»/SQ,FT.)l
BAG LI*E(VFARS||
FLUE GAS REHEAT TEMPERATURE (F)l
CHEMICAL ENGINEERING PLANT INDEXI
300.0
0.03
Z.OO
0,180
0,70
?t°°
PS,
Jii.O
ELECTROSTATIC PRECIPITATORS
500 MW
Lime Wet Scrubbing
COLO
HOT
BAGHOUSE FABRIC FILTERS
SCRUBBERS
REQUIRED REMOVAL EFFICIENCY (XII
nRIPT VELHCITV (FT/Mll
SPECIFIC COLLECTION AREA (SQ.FT./ACFHI 1
COLLECTION AREA (SU.FT.tl
TOTAL CORONA POWER (KW)I
AIIXfllARV pnwFB (Kull
FAN POWER (KW)|
PUMP PnWER IKWIl
TOTAL POWER (Krftl
OPERATING AlR/ClOTU RAT|Ol
INSTALLED AIR/CLOTH RATIOI
REQUIRED PRESSURE DROP (INCHES II
DIA1ETL-R (FEET)I
RFOIIlniD REHEAT (RTU/HRII
STEAM SUPPLY/YR (THOUSAND LBH
INSTALLED COST (1979 DOLLARSII »
FIRST YEAR CAPITALIZED COSTl t
ANIIUAL POWtR COSTl t
ANNUAL OPERATING AND
IIAIMTI-NAMCF CnST (19V9 UnilAR^Il 1
99.70
2T.19
277.7*
468176. 7
663.6
407,4
264.0
1339,0
1.0
6562679
118)469
183115
1 12899
99,70
20.00
377,99
972309.6
1012. B
919.2
403.0
2331.0
1.0
1 1J176132
» 2199762
1 319737
1 169411
99.70
866133.3
490,?
1320.1
1810.3
2.4
1.9
9.0
1 16303990
t 294007)
t 24B320
t 7«T?B
99.70
16019.9
3267.8
19307,7
60. 8
30
6*268960. O
337769.0
i 22732816
» 4099484
t 2648436
i M929O9
REPLACLMENT COST (1979 DOLLARS 11
ANNUAL REHFAT COSTl
26512B
675838
TOTAL ANNUAL COSTi
AHNUALIZEO COST OF POWER(HILLS/KWHK11
1479479
0.63
2684910
1.14
3527Z49
1.4 9_
8616367
3.44.
-------
POND DESIGN
OPTIMIZED TO MINIMIZE TOTAL CDST PLUS OVERHEAD
PflND OtHENSIONS
NEW PREMISES
500 MW
Lime Wet Scrubbing
3EPTH OF POND
DEPTH OF EXCAVATION
LENGTH OF POND PERIMETER
I PNCTH OF DIVIDER
LENGTH PERIMETER FENCE
AREA Op BOTTOM
ARFA of INSIDE MALI 5
AREA OP OUTSIDE WALLS
AREA OF RECLAIM STORAGE
AREA OP PUNO
ARFA OF PQWIJ SITF
22.17
4.10
U263.
2591.
15270.
1291.
148.
100.
1QS.
1397,
1727.
FT
FT
FT
PT
FT
THOUSAND
THOUSAND
THOUSAND
THOUSAND
THOUSAND
THOUSAND
Y02 '
VD2
YD2
YD2
Y02
YD2
AREA OF PONO SITE
397. ACRES
VOLUME OF EXCAVATION
uni IIMP nF RECLAIM JTQRAGE
1883,
793.
THOUSAND YD3
THOUSAND YD3
VOLUME OF SLUDGE TQ BE
mspnsgp nvER LIFE OP PLANT
9802.
S076.
THOUSAND Y03
ACRE FT
anun rngTS tTHfluSAMnS nc
n EASING LAND
EXCAVATION
DIKE CONSTRUCTION
LININGt 12. IN. CLAY)
snnntNC DIKE WALLS
ROAO CONSTRUCTION
OCR1MFTPR CCSTS, FENCE*
RECLAMATION EXPENSE
MONITOR WELLS
PDNO CONSTRUCTION
LAND COST
POND SITE
OVERHEAD
_____-_—.....— _..-^-.——~_.
LABOR
578.
4678 1
2399.
1398.
94.
40.
4.
10179.
._.__..«>___..
MATERIAL
62.
12.
153.
4.
231.
__«__-__—
TOTAL
578.
4678.
2399.
1398.
156.
93.
229.
994.
a.
10409.
1784.
12193,
8889.
_-_.___
TOTAL
21082.
G-32
-------
NEW PREMISES
500 MW
RAW MATERIAL HANDLING AND PREPARATION
INCLUDING 2 OPERATING AND I SPARE PREPARATION UNITS
ITPM
DESCRIPTION
NP.
MATERIAL
LABOR
CONVEYOR PROM CALCINATION
1300PT HORIZONTAL* 3QHP
1
177763.
31269.
PLANT
STORAGE SILO ELEVATOR
CONCRETE STORAGE SILO
105.FT HIGH* 50 HP
76283. FT3*40.2FT OIA ,
60.2FT STRAIGHT SIDE
1
2
33741,
205763.
3214.
419981,
STORAGE HT
STORAGE SILO HOPPER BOTTOM
RECLAIM VIBRATING FEEDER
RECLAIM BELT CONVEYOR
FEED 3IN ELEVATOR
FEED BELT CONVEYOR
FEED CONVEYOR TRIPPER
FEED BIN
BIN VIBRATING FEEDER.
BIN UEIGM PEEDEH
«l AKPQ
SLAKEH PRODUCT TANK
«i AKPR ponnurr TANK AGITATOR
1 IMP SVSTPM OUST COLLECTORS
60 DEGREE* CS
3.5HP
15S.FT HORIZONTAL/ SHP
SOFT HIGHj 50HP
SOFT HORIZONTAL! SHP
30FPMj 1HP
10FT OIA/ 19FT STRAIGHT
crnp HT. CQVPRP.O. ri
3.5HP
12FTj 12IS SCREHj 1HP
6.TPH^ 11. HP
IOHP
DOLYPROPVL5NE 9AC TYPE
2
2
1
1
1
i
3
3
?
3
3
3
5
23981.
6339.
23349.
32370.
10334.
16240,
12423,
26138.
13406.
1 97694.
13242.
19618.
33242.
17163.
648,
3321.
1836.
864.
3401,
8263,
3240.
1944.
8912.
10369.
4536.
11881.
2200 CFM/7.5HP
SLAKER PRODUCT TANK SLURRY
PUMP;
1*9. GPM, 60FT HEAD*
4.HPj 2 OPERATING
3
10253.
3025.
AND 1 SPARES
SLURRY FEED TANK
I574LS.GAL4 29.9FT OIA/
29.9FT HT/ FLAKF.GLASS—
1
33200.
26504.
LINED CS
SLURRY FEED TANK AGITATOR
SLURRY FEED TANK PUMPS
54. HP
75,GPMt 60 FT HEAOj
2. HP/ <• OPERATING AND
1
8
32939,
26096.
4197.
5999.
4 SPARE
TOTAL EQUIPMENT COST
952573. 572529.
G-33
-------
SCRUBBING
NEW PREMISES
500 MW
Lime Wet Scrubbing
INCLUDING 4 OPERATING AND 1 SPARE SCRUBBING TRAINS
DESCRIPTION
NO. MATERIAL
LABOR
l.n. PANS
2Q.Q1N H20.I WITH 1580.
44OB429.
614B3.
HP MOTOR AND DRIVE
SHELL
RUBBER LINING
1311117,
1292106.
MIST ELIMINATOR
SLURRY HEADER AND NOZZLES
267296,
926OQ7.
GRIDS
SPHERES
579348,
79Q199.
TOTAL TCA SCRUBBER COSTS
4366Q29.
319718.
REHEATERS
. 5 2193402.
133789.
snnTBi'nwERS
352B3B.
151216.
EFFLUENT HOLD TANK
251163.CALf 35.OFT DIAj 5 239720.
202782.
35,OFT Hit FLAKEGLASS-
LINED CS
urn n TANK ACITATDR
66.HP
34TST5.
1377B1.
COOLING SPRAY PUMPS
1384.CPM 10QPT HEADj
10
89717.
26703.
64.HP* 4 OPERATING
ANO fc SPARE
ABSORBER RECYCLE PUHPS
9514.GPM* 100FT HEADj
15
864979.
93017.
3 OPERATING
AND 7 SPARE
MAKEUP WATER PUMPS
2768.GPMi 200.FT HEAD/
24234.
2644.
233.HP* 1 OPERATING
AMP I SPARE
TOTAL EQUIPMENT COST
13008947, 1129126,
G-34
-------
WASTE DISPOSAL
NEW PREMISES
500 MW
Lime Wet Scrubbing
ITEM
DESCRIPTION
NO. MATERIAL
LABOR
ABSORBER BLEED RECEIVING
TANK
62724,GAL/ 17.5FT OlA«
35.OPT HTj FLAKCLASS-
20681.
1652*.
LINED CS
ABSORBER BLEED TANK AGITATOR
38. HP
23630.
1873.
POND FEED SLURRV PUMPS
TU.GPMi 130.PT1 HEAD
O.HPj 1 OPERATING
15227.
3992,
AND 1 SPARE
PONO SUPERNATE PUMPS
630.0PM, 192.FT HEAD, 2
31.HP, 1 OPERATING
11212.
1222,
AND 1 SPARE
TBT&I PQUTPMENT COST
70781.
23611.
G-35
-------
NEW PREMISES
500 MW
OJ
PROJECTED CAPITAL INVESTMENT REQUIREMENTS
Lime
- kXAMHLb CASE NkH PKEIISIS LIME
INVESTMENT* THOUSANDS
Wet Scrubbing
0 CASE 004
i OF 19BO DC11I ARS
RAW MATERIAL
HANDLING AND
PRkPARATION SCRUBBING
EQUIPMENT
HATERIAL
LABOR
PIPING
MATERIAI
LABOR
DUCTWORK
HATERIAL
LABOR
•OUNOATIUNS
MATERIAL
LABOR
PONO CONSTRUCTION
STRUCTURAL
MATERIAL
LABOR
ELECTRICAL
HATERIAL
LABOR
INSTRUMENTATION
MATERIAL
LABOR
MATERIAL
LABOR
SERVICES AND MISCELLANEOUS
SUBTOTAL DIRECT INVESTMENT
ENGINEERING DESIGN AND SUPERVISION
CONSTRUCTION EXPENSES
CONTRACTOR FEES
CONTINGENCY
SUBTOTAL FIXED INVESTMENT
ALLOWANCE fOR STARTUP AMD MODIF ICAT IUNS
INTEREST Dim i no CONSTRUCTION
SUBTOTAL CAPITAL INVESTMENT
LAND
WORKING CAPITAL
TOTAL CAPITAL INVESTMENT
913.
573.
All.
231.
0.
0.
74.
110.
0.
}09.
88.
113.
248.
128.
18.
0.
0.
66.
3261.
294.
922.
16J.
848.
SflBH.
391.
763.
6242*
19.
184.
_644 L».
13009.
M?9-
696.
2297.
IBS).
289.
o.
2B7.
483.
719.
1311.
632.
102.
0.
0.
943.
26803.
2412.
42BB.
AlRp.
3210.
6272.
51300,
4.
1509.
52(111.
WASTE
DISPOSAL
71.
24,
BIS,
289,
0,
0,
17.
34,
10AOO.
2,
'•
126,
266.
9.
8,
0.
Of
291,
12380,
1114,
19B1.
619.
3219,
19111.
2897.
23696,
1796.
697.
—26181,
TflTAL
14032.
172S.
4749.
1176,
2297.
1854,
227,
469.
10409.
19R
574,
994.
1B2S.
769.
128.
0,
0.
860,
42444.
3820.
6791.
2122.
_ _LJ03i,
K6919-.
5094.
9932.
81237.
1819.
2390.
85442-.
DISTRIBUTION
PERCENT
OF DIRECT
INVESTMENT
33.1
4,1
11.2
2.8
5.4
4.4
0.5
1.1
14. 5
0,9
1.4
2.2
4.3
1.8
0.3
0.0
0.0
2,0
100.0
9.0
16.0
5.0
ISfrrft
12. O
23,4
185.4
4.3
9.6
_2o na
-------
o
PRU.IFCTFO REVENUE REQUIREMENTS - EXAMPLE CASE NCW PREMS1S LINE
DISPLAY SHEET FDR YEAR. 1
ANNUAL OPERATION KH-HR/KH • 4730
29,36 TONS PER HOUR CRY
TOTAL CAPITA! INVESTMENT R?fl9hOOO
ANNUAL QUANTITY UNIT COST, »
HIRFCT COSTS
RAW MATERIAL
1 IMF 6O.1 K TONS 4O.OO/TDN
SUBTUTAI RAM MATER IAI
rnuuFRSinN LH«TS
nPERATIIIG LAROR AND
SUPERVISION 2B«io.o HAN-HR U.SO/MAN-HR
UTILITIES
STEAM AJBOIO.O K LB 2,00/K LB
pnnrFSs U«TFB 14^140.0 K C.AL O.II/K GAL
ELECTRICITY 39*98(80.0 KWH 0.029/KHH
MAINTENANCE
LABOR AND MATERIAL
AMAIVSES 4390.0 HR 1T.AO/HR
SUBTUTAI CONVERSION COSTS
VURTtlTAI n IBCCT CflSTS
IMOIRFCT CHSTS"
"nvlwllol
PLtnT AND ALHlNlSTRATlVE ( 60,0* OF COMVERSIUM CUSTS LESS UTILITIES)
FIRST YEAR OPERATING AND MAINTENANCE COSTS
LEVELIZED CAPITAL CHARGES! 14 7% OF TOTAL CAPITAL INVESTMENT)
FIRST VEAfl AMNIIAI REVFNIIF REQUIREMENTS
EQUIVALENT FIRST YEAR UNIT REVENUE REQUIREMENTS, HILLS/KHH
IEVELUEO OPERATING AND MAINTENANCE I 1,886 T1H|S FIRST YEAR OPER, £ HAIN.I
LEVEL IZED CAPITAL CHARGES! LA 7% (IF TOTAL CAPITAL INVESTMENT)
LEVEL 1ZED ANNUAL REVENUE REQUIREMENTS
EQUIVALENT LEVELIZED UNIT REVENUE REQUIREMENTS, HIILS/KNH
HEAT RATE 9900. BTU/KHH - hEAl VALUE OF COAL 11700 BTU/LB
CASE OO4
SLUOGC
TflTAl
ANNUAL
COST,*
NEW PREMISES
500 MW
Li me weL UCLUU
2404400
39JAOO
876000
ITSnO
1149300
2873100
TT9OO
DATABO
17S30OD
19B9200
9738200
175fiOOOO
797Q«?nn
9.43
18366200
12560000
30926200
13.08
COAL RATE 960100 TONS/VR
-------
PEDCO ENVIRONMENTAL, INC., INVESTMENT/COSTS
(MID-1980 DOLLARS)
G-38
-------
LIME FGD
CAPITAL INVESTMENT
500 MW,3.48% S.90%
LIME PREPARATION
CONVEYORS
SLAKERS AND PUMPS
STORAGE SILOS
STORAGE TANKS
PUMPS AND MOTORS
EQUIPMENT COST, $
546000.
161000.
1249000.
261000.
36000.
SUB TOTAL - LIME PREP
2253000.
U)
VO
SO 2 SCRUBBING
ABSORBERS
FANS AND MOTORS
HEAT EXCHANGERS
SOOT BLOWERS
VALVES AND DUCTING
MOLD TANKS
PUMPS AND MOTORS
15973000.
2040000.
3100000.
1196000.
1617000.
1037000.
2982000.
SUB TOTAL - S02 SCRUB 27945000.
-------
CAPITAL INVESTIMENT (CONTD)
o
SLUDGE DISPOSAL
CLARIFIERS
VACUUM FILTERS
CHEMICAL STORAGE
MOBILE EQUIPMENT
TANKS AND AGITATORS
PUMPS AND MOTORS
986000.
0.
44000.
62000.
95000.
245000.
SUB TOTAL - SLUDGE DISP
TOTAL INSTALLED COST
RAW MATL INVENTORY
(working cap)
SLUDGE POND
1432000.
31630000.
304000.
7986000.
DI = total installed cost + sludge pond
-------
CAPITAL INVESTMENT (CONTD)
o
INDIRECT COSTS
INTEREST DURING CONSTRUCTION
FIELD OVERHEAD
ENGINEERING
FREIGHT
OFFSITE
TAXES
SPARES
ALLOWANCE FOR SHAKEDOWN
3962000.
3962000.
3163000.
395000.
1188000.
474000.
158000.
1996000.
TOTAL INDIRECT COST
CONTINGENCY
CONTRACTOR FEE
LAND COST
TOTAL CAPITAL INVESTMENT
TOTAL INVESTMENT PER KW
15298000.
11044000.
3313000.
154000.
69729000.
139.46
-------
RAW MATERIAL
LIME
FIXATION CHEMICAL
LIME FGD
OPERATING COST
500 MW,3.48% S.90% REG
QUANTITY RATE
11.3 TON/HR $ 50.00 /TON
4.6 TON/HR $ 20.00 /TON
ANNUAL COST, $
3219000.
527000.
UTILITIES
WATER
ELECTRICITY
REHEAT
591.9 GPM
16711.6 KW
92.0 MMBTU/HR
$ 0.200 /kgal
$ 25.00 MILLS/KWH
$ 1.25 /MMBTU
32000.
1903000.
524000.
-t-
LABOR
DIRECT LABOR
SUPERVISION
76.00 MANHR/DAY
15 % OF DIRECT LABOR
$ 10.00 /MANHR
277000.
42000.
MAINTENANCE
LABOR AND MATERIAL
SUPPLIES
4.35 % OF TOTAL CAPITAL INVESTMENT
15 % OF LABOR AND MATERIAL
2889000.
433000.
OVERHEAD
PLANT
PAYROLL
SLUDGE HANDLING
50 % OF OPERATING LABOR AND MAINT
20 % OF OPERATING LABOR
264000. TON-MILE/YR
$ 2.00 /TON-MILE
1821000.
64000.
528000.
SUB TOTAL - OPERATING AND MAINTENANCE
12259000.
------- |