EPA-600 /7-90-022a
December 1990
INTEGRATED AIR POLLUTION CONTROL SYSTEM
VERSION 4.0
VOLUME 1: USER'S GUIDE
by
Mehdi Maibodi, A. L. Blackard, and
Robert J. Page
Radian Corporation
Post Office Box 13000
Research Triangle Park, NC 27709
EPA Contract No. 68-02-4286
Work Assignment 116
Project Officer
Norman Kaplan
Air and Energy Engineering Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Washington, D.C. 20460
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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.
ABSTRACT
The Integrated Air Pollution Control System Version 4.0 was developed
for the U.S. Environmental Protection Agency's Air and Energy Engineering
Research Laboratory to estimate costs and performance for emission control
systems applied to coal-fired utility boilers. The model generates a material
balance and an equipment list from which capital investment and revenue
requirements are estimated based upon user-specified input data. Included in
the model are conventional and emerging technologies for controlling sulfur
dioxide, nitrogen oxide, and particulate matter emissions. Conventional and
emerging technologies included in the model are overfire air/low N0x burners,
lime injection multistage burners, advanced silicate process, physical coal
cleaning/coal switching and blending, spray humidification, electrostatic
precipitator, fabric filter, lime spray drying, wet limestone flue gas
desulfurization, dry sorbent injection, natural gas reburning, selective
catalytic reduction, atmospheric fluidized bed combustion, pressurized
fluidized bed combustion, integrated gasification combined cycle, and
pulverized coal burning boiler.
i i
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CONTENTS
Abstract i i
Figures xi
T abl es xiv
Abbreviations and Symbols xviii
Metric Equivalents xx
VOLUME 1
INTEGRATED AIR POLLUTION CONTROL SYSTEM
USER'S GUIDE
1.0 Introduction 1-1
1.1 System Overview 1-1
1.2 Background 1-1
1.3 Model Description, Organization, and Capability .... 1-2
2.0 Operation 2-1
2.1 System Requirements 2-1
2.2 Installation 2-1
2.3 Execution Guidelines 2-2
2.3.1 Select Economic Format 2-2
2.3.2 Select Input File 2-3
2.3.3 Edit Input Data 2-4
2.3.3.1 Run Description Comments 2-5
2.3.3.2 Boiler Specific Data 2-5
2.3.3.3 Run of Mine Coal Characteristics . . . 2-9
2.3.3.4 Clean Coal Characteristics 2-10
2.3.3.5 Technology Modules to Implement .... 2-11
2.3.3.6 Fan 2-13
2.3.3.7 Economic 2-14
2.3.3.8 Rerun with New Emission Rate 2-18
2.4 List Parameter Data 2-19
2.5 Save Input Data 2-21
2.6 Execute 2-23
3.0 Using Batch Files 3-1
3.1 Batch File 3-1
4.0 Troubleshooting 4-1
4-1 Troubleshooting 4-1
iii
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CONTENTS
(Continued)
VOLUME 2
INTEGRATED AIR POLLUTION CONTROL SYSTEM
TECHNICAL DOCUMENTATION MANUAL
1.0 Introduction 1-1
1.1 System Overview 1-1
1.2 Background 1-1
1.3 Model Description, Organization, and Capability .... 1-2
2.0 Precombustion Controls 2-1
2.1 Coal Switching and Blending 2-1
2.1.1 Process Description 2-1
2.1.1.1 Switching 2-1
2.1.1.2 Blending 2-4
2.1.1.3 Applicability of Low Sulfur Coals . . . 2-5
2.1.2 Battery Limits 2-5
2.1.3 Details of Physical/Performance Models 2-9
2.1.4 Capital Cost Model 2-9
2.1.4.1 Process Capital Costs 2-9
2.1.4.2 Indirect Capital Costs 2-12
2.1.5 Operating and Maintenance Cost Model 2-12
2.2 Physical Coal Cleaning 2-13
2.2.1 Process Description 2-13
2.2.2 Battery Limits 2-15
2.2.3 Details of Physical/Performance Models 2-15
2.2.4 Capital Cost Model 2-18
2.2.5 Operating and Maintenance Cost Model 2-18
2.3 References 2-18
3.0 In-situ Combustion 3-1
3.1 Low N0x Combustion (LNC) 3-1
3.1.1 Process Description 3-2
3.1.1.1 Low Excess Air 3-2
3.1.1.2 Low N0X Burners 3-2
3.1.1.3 Overfire Air 3-4
3.1.1.4 Low NO Concentric Firing System . . . 3-4
3.1.2 Battery Limits 3-7
3.1.2.1 Low Excess Air 3-7
3.1.2.2 Low NO Burners 3-7
3.1.2.3 Overfire Air 3-8
3.1.2.4 Low N0x Concentric Firing System . . . 3-9
iv
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CONTENTS
VOLUME 2
(Continued)
3.1.3 Details of Physical Performance Models 3-9
3.1.3.1 Low Excess Air 3-10
3.1.3.2 Low N0x Burners 3-10
3.1.3.3 Overfire Air 3-12
3.1.3.4 Low NOx Concentric Firing System
and Low NO Burner/Overfire Air . . 3-13
3.1.4 Capital Cost Model 3-13
3.1.4.1 Process Capital Cost Model 3-14
3.1.4.2 Indirect Capital Costs 3-14
3.1.5 Operating and Maintenance Cost Model 3-16
3.2 Natural Gas Reburning 3-17
3.2.1 Process Description 3-17
3.2.2 Battery Limits 3-19
3.2.3 Details of Physical/Performance Models 3-19
3.2.4 Capital Cost Model 3-20
3.2.4.1 Process Capital Costs 3-20
3.2.4.2 Indirect Capital Costs 3-21
3.2.5 Operating and Maintenance Cost Model 3-21
3.3 Natural Gas Substitution 3-24
3.3.1 Process Description 3-24
3.3.2 Battery Limits 3-25
3.3.3 Details of Physical/Performance Models 3-25
3.3.3.1 Sizing Procedures for Estimating
Capital Costs for NGS 3-25
3.3.3.2 Emission Reduction Performance .... 3-26
3.3.4 Capital Cost Model 3-27
3.3.4.1 Process Capital Costs 3-27
3.3.4.2 Indirect Capital Costs 3-27
3.3.5 Operating and Maintenance Cost Model 3-27
3.4 Lime Injection Multistage Burner (LIMB) 3-27
3.4.1 Process Description 3-27
3.4.2 Battery Limits 3-31
3.4.3 Details of Physical Performance Models 3-33
3.4.4 Capital Cost Model 3-34
3.4.4.1 Process Capital Cost 3-34
3.4.4.2 Indirect Capital Cost 3-34
3.4.5 Operating and Maintenance Cost Model 3-34
3.5 References 3-37
v
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CONTENTS
VOLUME 2
(Continued)
4.0 Post Combustion 4-1
4.1 Electrostatic Precipitators 4-1
4.1.1 Process Description 4-1
4.1.2 Battery Limits 4-3
4.1.3 Details of Physical/Performance Models 4-6
4.1.4 Capital Cost Model 4-8
4.1.4.1 Process Capital Costs 4-8
4.1.4.2 Indirect Capital Costs 4-11
4.1.5 Operating and Maintenance Cost Model 4-ll
4.2 Fabric Filter 4-14
4.2.1 Process Description 4-14
4.2.2 Battery Limits 4-16
4.2.3 Details of Physical/Performance Models 4-18
4.2.4 Capital Cost Model 4-21
4.2.4.1 Process Capital Costs 4-21
4.2.4.2 Indirect Capital Costs 4-23
4.2.5 Operating and Maintenance Cost Model 4-23
4.3 Gas Conditioning 4-26
4.3.1 Spray Humidification 4-26
4.3.1.1 Process Description 4-27
4.3.1.2 Battery Limits 4-27
4.3.1.3 Details of Physical Performance Model . 4-29
4.3.1.4 Capital Cost Model 4-30
4.3.1.5 Operating and. Maintenance Cost Model . 4-30
4.3.2 Sulfur Trioxide (S03) Conditioning 4-33
4.3.2.1 Process Description 4-33
4.3.2.2 Battery Limits 4-33
4.3.2.3 Details of Physical Performance Models 4-33
4.3.2.4 Capital Cost Model 4-34
4.3.2.5 Operating and Maintenance Cost Model 4-34
4.4 Lime/Limestone Wet FGD 4-34
4.4.1 Process Description 4-34
4.4.2 Battery Limits 4-38
4.4.3 Details of Physical Performance and Cost Models 4-39
4.5 ADVACATE Process 4-42
4.5.1 Process Description 4-42
4.5.2 Battery Limits 4-46
4.5.2.1 Reagent Feed System 4-46
4.5.2.2 S02 Removal System 4-47
vi
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CONTENTS
VOLUME 2
(Continued)
4.5.2.3 Flue Gas System 4-48
4.5.2.4 Waste Handling System 4-48
4.5.2.5 General Support 4-48
4.5.3 Details of Physical Performance and Cost Models 4-48
4.5.3.1 Process Capital Cost Model 4-49
4.5.3.2 Indirect Capital Cost 4-49
4.5.3.3 Operating and Maintenance Cost Model . 4-49
4.6 Spray Drying FGD 4-52
4.6.1 Lime Spray Drying 4-52
4.6.1.1 Process Description 4-52
4.6.1.2 Battery Limits 4-57
4.6.1.3 Details of Physical Performance and
Cost Models 4-58
4.6.1.4 Capital Cost Model 4-59
4.6.1.5 Operating and Maintenance Cost Model . 4-60
4.6.2 Duct Spray Drying 4-68
4.6.2.1 Process Description 4-68
4.6.2.2 Battery Limits 4-69
4.6.2.3 Capital Cost Model 4-69
4.7 Dry Sorbent Injection 4-69
4.7.1 Process Description 4-69
4.7.2 Battery Limits 4.73
4.7.3 Details of Physical Performance and Cost Models 4-74
4.7.3.1 Process Capital Cost Model 4-74
4.7.3.2 Indirect Capital Costs 4-74
4.7.3.3 Operating and Maintenance Cost Model . 4-74
4.8 Selective Catalytic Reduction (SCR) 4-77
4.8.1 Process Description 4-77
4.8.2 Battery Limits 4-80
4.8.3 Details of Physical Performance and Cost Models 4-81
4.8.3.1 Catalyst Volume 4-81
4.8.3.2 Ammonia Injection 4-84
4.8.3.3 Pressure Drop 4-85
4.8.4 Capital Cost Model 4-85
4.8.4.1 Process Capital Cost Model 4-86
4.8.4.2 Indirect Capital Costs 4-90
4.8.5 Operating and Maintenance Cost Model 4-90
4.9 References 4-94
vii
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CONTENTS
VOLUME 2
(Continued)
5.0 Combustion Technologies 5-1
5.1 Atmospheric Fluidized Bed Combustion (AFBC) . . !'.*.! 5-1
5.1.1 Process Description 5-1
5.1.2 Battery Limits 5-3
5.1.3 Details of Physical Performance Models 5-5
5.1.4 Capital Cost Model 5-7
5.1.4.1 Process Capital Costs 5-7
5.1.4.2 Indirect Capital Costs 5-10
5.1.5 Operating and Maintenance Cost Model 5-10
5.2 Pressurized Fluidized Bed Combustion (PFBC) 5-13
5.2.1 Process Description 5-13
5.2.2 Battery Limits 5-13
5.2.3 Details of Physical Performance Model 5-15
5.2.4 Capital Cost Model 5-15
5.2.4.1 Process Capital Costs 5-15
5.2.4.2 Indirect Capital Costs 5-16
5.2.5 Operating and Maintenance Cost Model 5-16
5.3 Integrated Gasification Combined Cycle (IGCC) 5-18
5.3.1 Process Description 5-18
5.3.2 Battery Limits 5-20
5.3.3 Details of Physical Performance Models 5-24
5.3.4 Capital Cost Model 5-26
5.3.4.1 Process and Indirect Capital Costs . . 5-26
5.3.4.2 Other Indirect Capital Cost 5-30
¦ 5.3.5 Operating and Maintenance Cost Model 5-30
5.4 Pulverized Coal-Fired Plant 5-36
5.4.1 Process Description 5-36
5.4.2 Battery Limits 5-37
5.4.3 Details of Physical Performance Models 5-37
5.4.4 Capital Cost Model 5-38
5.4.4.1 Process Capital Costs 5-38
5.4.4.2 Indirect Capital Costs 5-40
5.4.5 Operating and Maintenance Cost Model 5-40
5.5 References 5-43
viii
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CONTENTS
(Continued)
VOLUME 3
INTEGRATED AIR POLLUTION CONTROL SYSTEM
PROGRAMMER'S MAINTENANCE MANUAL
1.0 Introduction 1-1
1.1 System Overview 1-1
1.2 Background 1-1
1.3 Model Description, Organization, and Capability .... 1-2
1.4 Run-Time System Files 1-4
1.5 System Flow Chart 1-5
1.6 System Module Hierarchy Chart 1-5
1.7 System Data File Formats 1-8
1.7.1 Parameter Files 1-8
1.7.2 Batch Data Files 1-22
1.7.3 Discrete Files 1-24
1.7.4 ASCII Field Definition Files 1-25
1.7.5 Help Database Files 1-26
1.8 Procedures for Building the IAPCS Program 1-26
1.9 Program Requirements and Installation 1-40
1.10 References 1-42
2.0 FORTRAN Model Code 2-1
2.1 FORTRAN Language Source Code Files 2-1
2.2 FORTRAN Subroutine Summary 2-3
2.3 FORTRAN Subroutine Hierarchy Chart 2-8
2.4 Description of FORTRAN Subroutines 2-10
2.4.1 Action Diagrams 2-13
2.4.1.1 Action Diagram for MODEL Subroutine . . 2-13
2.4.1.2 Action Diagram for DRIVER Subroutine . 2-17
2.4.2 FORTRAN Module Descriptions 2-18
2.5 FORTRAN Coding Conventions 2-33
2.6 Main FORTRAN Variables 2-35
2.6.1 Arrays 2-35
2.6.2 Scalar Numeric Variables 2-37
2.6.3 Logical Flag Variables 2-38
2.7 Usage of FORTRAN Common Blocks 2-38
2.8 Usage of FORTRAN to C Interface Files 2-55
ix
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CONTENTS
VOLUME 3
(Continued)
3.0 FORTRAN Code Listings 3-1
3.1 FORTRAN Source Code File Listings 3-1
4.0 C Language Code For User Interface 4-1
4.1 C Language Program Source Code Files 4-1
4.2 Summary of C Subroutines 4-1
4.3 C Subroutine Hierarchy Chart 4-3
4.4 Description of C Subroutines 4-5
4.4.1 Action Diagrams for Major C Subroutines 4-5
4.4.2 C Subroutine Details 4-9
4.5 Commercial C Language Support Packages 4-15
4.6 Main C Variables 4-15
5.0 C Language Code Listings 5-1
5.1 C Source Code File Listings 5-1
DISKETTE 1
INTEGRATED AIR POLLUTION CONTROL SYSTEM
EXECUTABLE FILES
(1.2 MB, 5 1/4 inch diskette)
DISKETTES 2 AND 3
INTEGRATED AIR POLLUTION CONTROL SYSTEM
SOURCE CODES
(Two 1.2 MB, 5 1/4 inch diskettes)
x
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FIGURES
VOLUME 1
INTEGRATED AIR POLLUTION CONTROL SYSTEM
USER'S GUIDE
* * *
VOLUME 2
INTEGRATED AIR POLLUTION CONTROL SYSTEM
TECHNICAL DOCUMENTATION MANUAL
Number Page
2-1 Effect of Coal Rank on Furnace Sizing 2-2
2-2 Coal Supply Regions 2-6
2-3 Level 4 Coal Preparation Plant 2-15
3-1 Distributed Mixing Burner Utility Boiler Design 3-3
3-2 Conceptual Diagram of Distributed Mixing Burner 3-3
3-3 Schematic Diagram of an Overfire Air System (OFA) 3-5
3-4 Tangential Firing System Incorporating Low NOx Concentric
Firing System for NOx Control-Coal Firing 3-6
3-5 Injection Angles for Fuel and Air--Utah Power
& Light Company 3-6
3-6 Natural Gas Reburn--for Wall-fired Boiler 3-18
3-7 Lime Injection Multistage Burner System 3-32
4-1 Typical Dry Electrostatic Precipitator 4-2
4-2 ESP Battery Limits 4-4
4-3 ESP Module for Designing the Duct Layout 4-5
xi
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FIGURES
VOLUME 2
(Continued)
Number Page
4-4 Duct Layout for Industrial Boilers and Utility
Boilers Below 250 MW 4-7
4-5 Duct Layout for 250- to 499- MW Boilers 4-7
4-6 Fabric Filter System 4-15
4-7 Fabric Filter Battery Limits 4-17
4-8 Fabric Filter and Duct Layout for Boilers Less Than 250 MW . 4-19
4-9 Fabric Filter and Duct Layout for Boilers Between
250 and 649 MW 4-19
4-10 Fabric Filter and Duct Layout for Boilers Greater
Than 650 MW 4-20
4-11 Simplified Process Flow Diagram of Spray Humidification
System 4-28
4-12 Lime/Limestone FGD System Flow Diagram 4-36
4-13 ADVACATE FGD System (Retrofit Plant - Case 1 and 2) .... 4-43
4-14 ADVACATE FGD System (Retrofit Plant - Case 3 and 4) .... 4-44
4-15 Lime Spray Dryer Process Flow Diagram 4-55
4-16 Flow Diagram of Dry Sorbent Injection FGD 4-71
4-17 Possible SCR Configurations 4-79
5-1 Conventional AFBC Boiler Flowsheet 5-2
5-2 Generalized Block Flow Diagram of Combined Cycle Coal
Gasification Power Generation 5-19
xii
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FIGURES
(Continued)
VOLUME 3
INTEGRATED AIR POLLUTION CONTROL SYSTEM
PROGRAMMER'S MAINTENANCE MANUAL
Number Page
1-1 IAPCS System Flow Chart 1-6
1-2 IAPCS System Module Hierarchy Diagram 1-7
1-3 Software Compile/Link Diagram 1-28
2-1 FORTRAN Subroutine Hierarchy Chart 2-9
2-2 FORTRAN Subroutine Call Tree for MODEL Routine 2-11
2-3 Action Diagram for MODEL Subroutine 2-13
2-4 Action Diagram for DRIVER Subroutine 2-17
4-1 C Subroutine Hierarchy Chart 4-4
xiii
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TABLES
VOLUME 1
INTEGRATED AIR POLLUTION CONTROL SYSTEM
USER'S GUIDE
VOLUME 2
INTEGRATED AIR POLLUTION CONTROL SYSTEM
TECHNICAL DOCUMENTATION MANUAL
Number Page
2-1 Technical Factors Affecting Coal Switching 2-3
2-2 Coal Supply Regions 2-7
2-3 Consumption Data of Bituminous and Subbituminous
Coals in the U.S. from 1982 to 1986 2-10
2-4 Process Capital Costs for Coal Switching/Blending
from Bituminous to Subbituminous Coals 2-11
2-5 Indirect Capital Costs for Coal Switching/Blending:
EPRI Methodology 2-13
2-6 Estimated Characteristics and Costs of Raw and
Cleaned Coals 2-17
3-1 Selection Criterion for Low N0x Combustion Technologies
Based on Fuel and Firing Type 3-10
3-2 Process (Direct) Capital Cost Equations for Low NOx
Combustion Applied to Power Plants (June 1982 $) 3-15
3-3 Indirect Capital Costs for Low NO Combustion:
EPRI Methodology ..... 3-16
3-4 Process Capital Costs for Natural Gas Reburning 3-21
xiv
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TABLES
VOLUME 2
(Continued)
Number Page
3-5 Indirect Capital Costs for Natural Gas Reburning:
EPRI Methodology 3-22
3-6 Operating and Maintenance Cost Procedures for
Natural Gas Reburning 3-23
3-7 Process Capital Costs for Natural Gas Substitution 3-28
3-8 Indirect Capital Costs for Natural Gas Substitution:
EPRI Methodology 3-29
3-9 Operating and Maintenance Cost Procedures for Natural
Gas Substitution 3-30
3-10 Process Capital Cost Equations for LIMB 3-35
3-11 Indirect Capital Costs for LIMB: EPRI Methodology 3-36
3-12 Operating and Maintenance (O&M) Equations
for LIMB Process 3-37
4-1 Estimated Particulate Removal Efficiencies for Cold-Side
ESPs as a Function of Specific Collection Area and
Fly Ash Resistivity 4-9
4-2 Process Capital Costs for ESPs 4-10
4-3 Indirect Capital Costs for ESPs: EPRI Methodology 4-12
4-4 Operating and Maintenance Costs for ESPs 4-13
4-5 Process Capital Costs for Fabric Filters 4-22
4-6 Indirect Capital Costs for Fabric Filters: EPRI Methodology 4-24
4-7 Operating and Maintenance Costs for Fabric Filters 4-25
4-8 Process Capital Costs for Spray Humidification 4-31
4-9 Indirect Capital Costs for Spray Humidification:
EPRI Methodology 4-32
4-10 Operating and Maintenance Cost Procedures for
Spray Humidification 4-32
xv
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TABLES
VOLUME 2
(Continued)
Number Page
4-11 Indirect Capital Costs for SO, Conditioning:
EPRI Methodology 4-35
4-12 L/LS FGD Design and Performance Parameters 4-41
4-13 Process (Direct) Capital Cost Equations for ADVACATE .... 4-50
4-14 Indirect Capital Costs for ADVACATE: EPRI Method 4-51
4-15 Annual Cost Equations for ADVACATE 4-53
4-16 Lime Spray Drying Base Case 4-61
4-17 Process Capital Costs for Lime Spray Drying ($1987) .... 4-64
4-18 Operating and Maintenance Cost Procedures for
Lime Spray Drying ($1987) 4-65
4-19 Process (Direct) Capital Cost Equations for Dry
Sorbent Injection 4-75
4-20 Indirect Capital Costs for Dry Sorbent Injection:
EPRI Method 4-76
4-21 Annual Cost Equations for Dry Sorbent Injection 4-78
4-22 Process (Direct) Capital Cost Equations for Hot-Side
Selective Catalytic Reduction Applied to New
Power Plants 4-87
4-23 Process (Direct) Capital Cost Equations for Cold-Side
Selective Catalytic Reduction Applied to New
Power Plants 4-89
4-24 Indirect Capital Costs for SCR: EPRI Methodology 4-91
4-25 Annual Cost Equations for Selective Catalytic Reduction . . 4-92
5-1 Process Capital Cost Equations for New Overbed Feed AFBC . . 5-8
5-2 Equipment Reuse Factor as a Fraction of New AFBC
Process Area Cost 5-9
xvi
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TABLES
VOLUME 2
(Continued)
Number Page
5-3 Indirect Capital Costs for AFBC Systems: EPRI Methodology . 5-11
5-4 Indirect Capital Costs for New PFBC Plants:
EPRI Methodology 5-17
5-5 Process and Indirect Capital Cost Equations for
Texaco's IGCC Process 5-27
5-6 Existing Reusable Equipment as a Percentage of
Base Plant Costs for IGCC 5-29
5-7 Indirect Capital Costs for IGCC Systems:
EPRI Methodology 5-31
5-8 Operating and Maintenance (O&M) Cost Equations for
Texaco IGCC Process: Combined Cycle Phase 5-32
5-9 Operating and Maintenance (O&M) Cost Equations for
Texaco IGCC Process: Gasification Phase 5-33
5-10 Maintenance Costs as a Fraction of Total Plant
Cost for Gasification Phase 5-34
5-11 Process Capital Cost Equations for Pulverized
Coal-Fired Power Plants 5-39
5-12 Indirect Capital Costs for Pulverized Coal-Fired
Plants: EPRI Methodology 5-41
xvii
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ABBREVIATIONS AND SYMBOLS
ABBREVIATIONS
AEERL -- Air and Energy Engineering Research Laboratory
ADVACATE -- Advanced Silicate Process
AFBC
--
atmospheric fluidized bed combustion
AFDC
--
allowance for funds during construction
ASCII
--
American Standard Code for Information Interchange
AUSM
--
advanced utility simulation model
CE
--
Chemical Engineering
CG
--
coal gasfication
CS
--
coal switching
CS/B
--
coal switching and blending
CSO
--
coal switching option
DOS
--
disk operating system
DSD
--
duct spray drying
DSI
--
dry sorbent injection
EPA
--
Environmental Protection Agency
EPRI
--
Electric Power Research Institute
ESP
--
electrostatic precipitator
FBC
--
fluidized bed combustion
FF
--
fabric filter
FGD
--
flue gas desulfurization
FPD
--
fuel price differential
FSI
--
furnace sorbent injection
ft
--
feet
GC
--
gas conditioning
IAPCS
--
Integrated Air Pollution Control System
IGCC
--
integrated gasification combined cycle
K
--
kilobyte
kW
--
kilowatt
kWh
killowatt hour
xviii
-------
ABBREVIATIONS AND SYMBOLS
(Continued)
LE
LIMB
L/LS FGD
LNB
LNC
LSD
MB
NAPAP
NCC
NGR
NSPS
OFA
O&M
PCBB
PCC
PFBC
PM
RAM
SCA
SCR
sec
SD
SH
SI
sq ft
TAG
TVA
SYMBOLS
N0*
so2
S°3
-- life extension
-- lime injection multistage burner
-- lime/limestone flue gas desulfurization
-- low-NOx burner
-- low-NOx combustion
-- lime spray drying
-- megabyte
-- National Acid Precipitation Assessment Program
-- National Computer Center
-- natural gas reburning
-- new source performance standard
-- overfire air
-- operating and maintenance
-- pulverized coal burning boiler
-- physical coal cleaning
-- pressurized fluidized bed combustion
-- particulate matter
-- random access memory
-- specific collection area
-- selective catalytic reduction
-- second
-- spray drying
-- spray humidification
-- sorbent injection
-- square feet
-- Technical Assessment Guideline
-- Tennessee Valley Authority
-- nitrogen oxides
-- sulfur dioxide
-- sulfur trioxide
xix
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METRIC EQUIVALENTS
Readers who are more familiar with the metric system may use the
following factors to convert the nonmetric units used in this report to that
system.
Non-metric
Multiolied bv
Yields Metric
acfm
0.000472
acms
acre
4047
m2
atm
101.325
kPa
Btu
1.055
kJ
cfm
0.000472
cms
dscf
0.0283
dscm
ft
0.305
m
ft2
0.093
m2
ft3
28.317
L
gal.
3.785
L
HP
0.746
kW
in.
2.54
cm
in. H20
0.249
kPa
lb
0.454
kg
micron
1.0
|im
mile
1.609
km
psia
6.895
kPa
ton
907.2
kg
yd2
0.836
m2
yd3
0.765
m3
#F
5/9(°F-32)
c
XX
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SECTION 1.0
INTRODUCTION
1.1 SYSTEM OVERVIEW
The Integrated Air Pollution Control System (IAPCS) was developed for
the U. S. Environmental Protection Agency's Air and Energy Engineering
Research Laboratory (US EPA-AEERL) to estimate costs and performance for
emission control systems applied to coal-fired utility boilers. The model
generates a material balance and an equipment list from which capital
investment and revenue requirements are estimated based upon user-specified
input data. The model includes conventional and emerging technologies for
controlling sulfur dioxide (S02), nitrogen oxides (N0x), and particulate
matter (PM) emissions. The various technology modules can be combined, with
interaction and integrated effects for various control configurations
reflected in the material balance and cost and performance estimates.
1.2 BACKGROUND
The IAPCS computer model was developed to estimate cost and performance
of air emission control equipment for coal-fired utility boilers. The IAPCS
model evolved over the years from a FORTRAN-coded mainframe computer model
known as the Shawnee Model which was developed by the Tennessee Valley
Authority (TVA). The first version (unpublished) of IAPCS (IAPCS-1), a
mainframe computer model, was completed in November 1983 and was housed at
U.S. EPA's National Computer Center (NCC). An IBM PC version of IAPCS
(IAPCS-2) was published in September 1986, and this version incorporated a
number of enhancements and upgrades to the various pollution control modules.
A third version of IAPCS (IAPCS-3 was not published) incorporated additional
enhancements and added several new technology modules, including selective
catalytic reduction (SCR), natural gas reburning (NGR), and gas conditioning
(GC). The latest version, IAPCS Version 4.0, includes further enhancements to
technology modules and a number of new technology additions.
1-1
-------
1.3 MODEL DESCRIPTION, ORGANIZATION, AND CAPABILITY
IAPCS Version 4.0 is a personal computer-based model for cost and
performance estimates of pollution control systems for coal-fired utility
boilers. In this current and latest version a C language User Interface has
been added to the original model to facilitate the input of data for the
FORTRAN model.
IAPCS Version 4.0 user's manual is organized into three volumes and
three diskettes: Volume 1: User's Guide; Volume 2: Technical Documentation
Manual; Volume 3: Programmer's Maintenance Manual; Diskette 1: Executable
Files; and Diskettes 2 and 3: Source Codes in Fortran and C Language and other
files necessary to create an executable file. Instructions for compiling the
program to produce an executable file from the source codes can be found in
Volume 3: Programmer's Maintenance Manual, Section 1.8: Procedures for
Building the IAPCS Program.
The IAPCS Version 4.0 documentation format was selected to facilitate
future maintenance and enhancement of the IAPCS model. This includes
correcting some of the software errors, correcting some of the existing
deficiencies, and enhancement of the modeling system with new capabilities.
Conventional and emerging technologies which are included in the IAPCS
Verson 4.0 are the following:
Physical coal cleaning (PCC)/coal switching and blending (CS/B or
CSO)
Overfire air/low N0x burners (OFA/LNB)
Natural gas reburning (NGR)
Lime injection multistage burners (LIMB)
Advanced silicate process (ADVACATE)
t Electrostatic precipitator (ESP)
Fabric filter (FF)
Gas conditioning (GC)
Lime/limestone flue gas desulfurization (LLS/FGD)
Lime spray drying/duct spray drying (LSD/DSD)
Dry sorbent injection (DSI)
Selective catalytic reduction (SCR)
Atmospheric fluidized bed combustion (AFBC)
1-2
-------
Pressurized fluidized bed combustion (PFBC)
Integrated gasification combined cycle (IGCC)
Pulverized coal burning boiler (PCBB)
The program will accept any reasonable configuration of these technologies.
Some of the exceptions are as follows:
Spray humidification cannot be utilized with DSI or LSD.
LSD or DSI is not to be preceded by a FF or an ESP.
Identical control devices in series are not permitted.
Control technology interactions are shown in the material balance tabulation
at the exit of each module.
Parameter files are an important feature of the IAPCS Version 4.0
program. The parameter file has specific default values for program operation
and calculation. Based on a recent program the user may then modify these
default values for preference and site-specific needs.
1-3
-------
-------
SECTION 2.0
OPERATION
2.1 SYSTEM REQUIREMENTS
IBM PC or compatible with 640 K RAM and math coprocessor
Operating system - Microsoft DOS 3.10 (or higher)
Hard disk with 2 MB free space
High density (1.2 MB) 5 1/4 inch* disk drive
Commercial support packages required - none
2.2 INSTALLATION
1. Required files
IAPCS4.EXE
IAPCXHLP.NDX
IAPCXHLP.DBT
IAPCXHLP.DBF
t IAPCXHLP.H
DISCRETE.EPR
DFFASC.EPR
PARMFILE.EPR
MMATRIX.DAT
2. Configuration system files set:
Files = 20
Buffers = 20
3. Copying the files
Place the diskette in Drive A
Make a subdirectory on your hard disk by typing
MD IAPCS
CD IAPCS
Copy A:*.* C:*.*
You have now completely copied the IAPCS Version 4 model to your
hard disk. Place the master disk in a safe place and use only the
working copy from now on.
Readers more familiar with metric units may use the factors at the end
of the front matter to convert to that system.
2-1
-------
2.3 EXECUTION GUIDELINES
The program requires approximately 600 K RAM available memory to run.
The user should be certain that memory resident programs and device
drivers are kept to a minimum. To use the model, type IAPCS4, and press
the ENTER key. The IAPCS main menu will appear on the screen.
The time and date are shown at the top on either side. Eight options are
given for user selection. The status window at the bottom presents output
format, parameter file name, and technologies implemented. Pressing F1 will
access the help file. The help function, it should be noted, does not appear
for all program screens. To execute the model, the following steps are
necessary:
2.3.1 Select Economic Format
Locate the cursor on this option and press the ENTER key
Integrated Air Pollution Control System
1) Select Economic Format
2) Select Input File
3) Edit Input Data
4) List Parameter Data
5) Save Input Data
6) Print Options
7) Execute
8) Quit
Use cursor keys. Highlight choice then
*** Level Sensitive HELP available with F1 ***
Two Economic Format Options appear: TVA and EPRI. Keep in mind that the TVA
option will not work for all technologies included in this model, while the
EPRI Economic Format can be applied to all technologies.
16:28:14
MAIN MENU
11/16/89
FORMAT EPRI FILE
Technologies
2-2
-------
After selecting the desired Economic Format (in this case EPRI) the Main Menu
Screen will appear. The input file must now be selected.
2.3.2 Select Input File
Choose this option. One or more files with extensions EPR will appear
on the screen. These are the EPRI formatted parameter file names. These
parmfiles contain the default values of all necessary inputs which can be
changed. Select a parmfile (in this example case, PARMFILE.EPR). The current
path can be changed by pressing ESC and then typing the appropriate drive and
subdirectory.
16:28:47
INPUT FILE
11/16/89
Integrated Air Pollution Control System
Current Path: A:\IAPCS4
PARMFILE.EPR CASE.EPR
Use cursor keys. Highlight choice then -»J Esc to change Drive/Directory
status
FORMAT EPRI
FILE
Technologies
2-3
-------
After selection, the main menu will reappear, and the parmfile name can be
found in the lower status window after "File". Also note that since the
default technology for this parmfile is FGD, designation will appear after
"Technologies" (this can be changed as shown later).
2.3.3 Edit Input Data
To edit the input data, move to the third selection (Edit Input Data)
and press ENTER.
16:29:52
MAIN MENU
11/16/89
Integrated Air Pollution Control System
1) Select Economic Format
2) Select Input File
3) Edit Input Data
4) List Parameter Data
5) Save Input Data
6) Print Options
7) Execute
8) Quit
Use cursor keys. Highlight choice then
T
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-4
-------
There are 27 items under Edit Input Data option. The contents of each item
are the default values which exist in the PARMFILE.EPR. A total of 9 items
are presented per screen. By pressing PgDn key (or by moving the cursor) the
other items can be examined.
2.3.3.1 Run Description Comments--
The first item is Run Description Comments which allows the user to
input comments on two lines for identification purposes.
2.3.3.2 Boiler Specific Data-
Move the cursor to item (2), Boiler Specific Data, and press .
Pressing "ESC" at any time will return the user to the Main Menu.
16:32:10
EDIT INPUT DATA
11/16/89
Integrated Air Pollution Control Syata
(1) Run Description Comments
(2) Boiler Specific Data
(3) Run of Mine Coal Characteristics
(4) Clean Coal Characteristics
(5) Technology Modules to Implement
(6) Rerun with New Emission Rate
(7) System Wide
(8) Uncontrolled Coal
(9) Fan
"7T
Use cursor keys. Highlight choice then
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-5
-------
16:32:29
EDIT INPUT DATA
11/16/89
Integrated Air Pollution Control System
(10) Economic
(11) LSD
(12) Low Nox Burners/Overfire Air
(13) Fabric Filter
(14) ESP
(15) LIMB (SI)
(16) Natural Gas Rebuming
(17) DSI
(18) FGD System
Use cursor keys. Highlight choice then
Esc to Main Menu
status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
16:34:38
EDIT INPUT DATA
11/16/89
Integrated Air Pollution Control System
(19) FGD Economic
(20) Cost based
(21) Spray Humidification
(22) Selective Catalytic Reduction
(23) Gas Substitution
(24) Atmospheric Fluidized Bed Combustion
(25) Integrated Gasification Combined Cycle
(26) Pressurized Fluidized Bed Combustion
(27) Pulverized Coal Burning Boiler
Use cursor keys. Highlight choice then
J
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-6
-------
Boiler Specific Data can be changed at this point.
16:37:57
BOILER DATA
11/16/89
Integrated Air Pollution Control System
Boiler Firing Method
1-WALL
Boiler Size, MWe
Capacity Factor, dimensionless
Retrofit Status (l=New, 2-Retrofit)
2-RETROFIT
Temperature at Air Heater Exit Temperature, Degrees Farenheit
500.00
65.000
310.000
Use cursor keys. Highlight choice then
J
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies F6D
16:38:02
BOILER DATA
11/16/89
Integrated Air Pollution Control System
Coal Type
2-USER INPUT COAL CHARACTERISTICS
Typical Coal Type
1-ARMSTRONG, PENNSYLVANIA
Boiler Bottom Type
1-DRY
Use cursor keys. Highlight choice then
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-7
-------
When boiler specific data is selected, a small pop out window screen with
boiler information will appear. The first line is Boiler Firing Method. The
default value here is "wan". Pushing the ESC key will accept the default
value. Otherwise, the cursor should be moved to the appropriate firing type
and ENTER pressed. The pop out window feature appears on the screen for many
selections in the Edit Input Data menu.
16:42:40
BOILER DATA
11/16/89
Integrated Air Pollution Control System
Boiler Firing Method
1-WALL
I We
1-WALL
2-TANGENTIAL
3-CYCLONE
4-STOKER
r, dimensionless
s (l=New, 2=Retrofit)
Air Heater Exit Temperature, Degrees Farenheit
500.00
65.000
310.000
Use cursor keys. Highlight choice then
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-8
-------
2.3.3.3 Run of Mine Coal Characteristics-
After the last item in boiler specific data has been entered the Edit
Input Data screen appears. The third item (Run of Mine Coal Characteristics)
can be selected. ROM Coal contains Illinois #6 coal values as defaults.
These values can be changed as desired. Keep in mind that the summation of
ash, moisture, volatile matter, and fixed carbon content should be 100%
(approximate analysis). Alkalinity content in ash is defined as the weight
percent of alkali (e.g., Ca, Mg, Na, etc.) in ash.
11/16/89
Integrated Air Pollution Control System
ROM Heating Value 10100
ROM Sulfur Content, % 4.0000
ROM Ash Content, % 16.000
ROM Coal Cost, $/ton 0.00
ROM Na20 Content in Ash, % 0.600
ROM Alkalinity Content in Ash, % 6.500
ROM Chlorine Content in Ash, % 0.100
TT
Use cursor keys. Highlight choice then
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
16:37:17
ROM COAL
11/16/89
Integrated Air Pollution Control System
ROM FeO Content, %
ROM Moisture Content, %
ROM Volatile Matter Content, %
ROM Fixed Carbon Content, %
20.000
12.000
33.000
39.000
Use cursor keys. Highlight choice then
J
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-9
-------
2.3.3.4 Clean Coal Characteristics--
The Clean Coal Characteristics menu (option 4 in Edit Input Data screen)
provides data concerning the switch and cleaned coal options. The example
here is of a West Virginia low sulfur bituminous coal. This section is used
for coal switching and blending or physical coal cleaning. By setting the
sulfur content equal to zero, the program searches the data base to find a
coal with similar low sulfur characteristics and appropriate coal price
differential (clean coal cost is presented as the cost differential in dollars
per ton between the existing coal and the switch/clean coal).
16:38:50
CLEAN COAL
11/16/89
Integrated Air Pollution Control System
Clean Heating Value
Clean Sulfur Content, %
Clean Ash Content, %
Clean Coal Cost, $/ton
Clean Na20 Content in Ash, %
Clean Alkalinity Content in Ash,
Clean Chlorine Content in Ash, %
12058
0.890
16.000
5.000
0.600
6.500
0.100
TT
Use cursor keys. Highlight choice then
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
16:38:56
CLEAN COAL
11/16/89
Integrated Air Pollution Control System
Clean FeO Content, %
Clean Moisture Content, %
Clean Volatile Matter Content, %
Clean Fixed Carbon Content, %
20.000
12.000
33.000
39.000
Use cursor keys. Highlight choice then
J
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-10
-------
2.3.3.5 Technology Modules to Implement--
In the Technology Modules to Implement section (section 5 on Edit Input
Data screen) three categories are listed: precombustion, in-situ, and
postcombustion technologies. Any of these categories can be selected by
pressing the page up or page down keys. Highlight the desired category and
press ENTER. The selected technology will appear on the lower part of the
screen. To undo the selected technology(ies) repeat the above process.
16:39:39
TECHNOLOGIES
11/16/89
Integrated Air Pollution Control System
Boiler Path:
Pre Combustion Technologies
(1) Coal Supply Options (PCC, CS/B)
Use cursor keys. Highlight choice then
J
PgUp/PgDn move thru Boiler Path
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
Boiler Path:
Integrated Air Pollution Control System
In-Situ Technologies
(1) Low NOx Combustion
(2) Limestone Injection Multi-stage Burner (LIMB)
(3) Natural Gas Reburning
(4) Integrated Gasification Combined Cycle
(5) Pressurized Fluidized Bed Combustion
(6) Pulverized Coal Burning Boiler
(7) Atmospheric Fluidized Bed Combustion
Use cursor keys. Highlight choice then
J
PgUp/PgDn move thru Boiler Path
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-11
-------
16:40:03
TECHNOLOGIES
11/16/89
Integrated Air Pollution Control System
Boiler Path:
Post Combustion Technologies
(1) Lime Spray Drying (SDA, DSD)
(2) Duct Sorbent Injection
(3) Gas Conditioning
(4) Electrostatic Precipitator
(5) Fabric Filter
(6) Flue Gas Desulfurization
(7) Selective Catalytic Reduction
a
Use cursor keys. Highlight choice then
PgUp/PgDn move thru Boiler Path
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-12
-------
2.3.3.6 Fan--
The default input values from PARMFILE.EPR for FAN (Edit Input Data,
option 9) are presented here as an example. Any of these values can be
changed by placing the cursor on the appropriate value and typing in the
desired value. Press the "ESC" key or press page down to return to the Edit
Input Data screen. All the technologies are similar in principle to this
example and, as such, are not presented here.
Integrated Air Pollution Control System
Engineering and Home Office Fees, % Process Capital (FAN) 10.000
General Facilities, % Process Capital (FAN) 10.000
Project Contingency, % Process Capital (FAN) 0.000
Process Contingency, % Process Capital (FAN) 0.000
Sales Tax, % Process Capital (FAN) 0.000
Royalty Allowance, % Process Capital (FAN) 0.000
Maintenance Labor and Material, % Total Process Capital (FAN) 4.000
Use cursor keys. Highlight choice then
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
11/16/89
Integrated Air Pollution Control System
Inventory Capital, % Process Capital (FAN)
Fan Retrofit Factor, dimensionless (FAN)
0.0000
1.0000
Use cursor keys. Highlight choice then
"J
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGO
2-13
-------
2.3.3.7 Economic--
Under the Economic section (number 10 on the Edit Input Data) economic
assumptions and indices can be changed, and scope adder costs can be added, if
needed. Costs can be presented in constant or current dollars.
16:41:34
ECONOMIC
11/16/89
Integrated Air Pollution Control System
0 & M Levelization Factor (Calc if 0), Dimensionless - decimal 0.00000
Capital Levelization Factor (Calc if 0), Dimensionless - decimal 0.00000
ITC Investment Tax Credit, % 0.000
B1 Book Life, Years 30.000
PI Tax Life, Years 20.000
CD Cost of Debt, % 11.000
DR Debt Ratio, % 50.000
Use cursor keys. Highlight choice then «-'
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
16:41:38
ECONOMIC
11/16/89
Integrated Air Pollution Control System
CP Cost Preferred Stock, %
PR Preferred Ratio, %
CE Cost of Common Stock, % (Common Ratio*
TX Federal and State Income Tax, %
EI Inflation Rate, %
PTI Property Tax and Insurance, %
ER Real Annual Escalation Rate, %
100%-PR-DR)
11.500
15.000
15.200
38.000
6.000
2. 000
0. 000
Use cursor keys. Highlight choice then
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-14
-------
The user input the desired year of capital cost and O&M cost and the Chemical
Engineer (CE) cost indices and their corresponding year and month (YYMM).
These are from Chemical Engineering magazine. If CE indices for the
appropriate year are not available, the IAPCS model will estimate the cost
adjustment. The model uses inflation to predict the cost adjustment for a
future year. However, if the desired year is before the CE indices year, the
model will perform a linear interpolation between 1982 (base year) and the
date of the input CE indices in estimating the cost adjustment.
16:42:02
ECONOMIC
11/16/89
Integrated Air Pollution Control System
TDM Depreciation Method(1-ACCEL.ACRS DEPR, 2-2 SLD, 3-3ACRS SLO)
3-STRAIGHT-LINE BASED ON ACRS CLASS
DURAT Idealized Time Required for Construction (Yrs)
Discount Rate, % Calculated from Above if 0
Administrative and Support Labor Factor (% of O&M Labor)
Current $ (0) or Constant $ (1)
0-CURRENT DOLLARS
3.000
0.000
30.000
"7T
Use cursor keys. Highlight choice then
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
16:42:06
ECONOMIC
11/16/89
Integrated Air Pollution Control System
Year of Capital Costs (YYMM) 8806
Year of O&M Costs (YYMM) 8806
Date of CE indices, YYMM 8806
Consumer Price Index for the desired base year 373.200
CE Plant Index for Corresponding Year and Month of Cost 343.00
CE Material Index for Corresponding Year and Month of Cost 374.20
CE Labor Index for Corresponding Year and Month of Cost 265.00
Use cursor keys. Highlight choice then ^
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-15
-------
16:42:26
ECONOMIC
11/16/89
Integrated Air Pollution Control System
Consumer Price Index for Correspoding Year and Month of Cost 373.20
Scope Adder for Beyond Technology Limits (dollars) 0
Labor Cost Multiplier for Geographic Differences 1.0000
Material Cost Multiplier for Geographic Differences 1.0000
Consumables Cost Multiplier for Geographic Differences 1.0000
Use cursor keys. Highlight choice then
TT
Esc to Main Menu
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-16
-------
The O&M and capital levelization factors can be input to the model for total
annualized cost calculations. However, if these values are set to zero, the
model estimates the levelization factors using the methodology outlined in the
Electric Power Research Institute Technical Assessment Guide
(EPRI-TAG-P-4463-SR). The O&M levelization factor is calculated as follows:
L = CRF (K +K2 + + Kn)
LF » O&M levelization factor
CRF » capital recovery factor for the economic life
K - (1 + i)/(l + r)
i - inflation rate (assuming constant)
r » discount rate
n = book life
Capital recovery factor are those costs incurred by contraction of the
facility that must be recovered during its life. They consist of returns on
equity and debt (discount rate), depreciation, income taxes, and other costs
such as insurance and local taxes. The weighted cost of capital is used as
the discount rate.
Levelized annual capital charges = weighted cost of capital + depreciation
+ annual interim replacement - levelized accelerated tax depreciation
- levelized investment tax credit + levelized income tax + insurance and
property taxes.
Any additional costs which are not included in the direct capital can be added
as scope adder costs. This cost is added to the total plant cost which is a
summation of direct capital cost and indirect costs (the scope adder cost is
assumed to include all indirect costs).
2-17
-------
2.3.3.8 Rerun with New Emission Rate-
By selecting option six of the Edit Input Data menu (Rerun With New
Emission Rate) the user can enter the target emission rate in lb/million BTU,
and the program will calculate the percent removal required.
16:50:51
OPTIMIZATION
11/16/89
Integrated Air Pollution Control System
Technologies
(6) Flue Gas
Desulfurization
Use cursor keys. Highlight choice then
One technology may be optimized
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGO
16:50:59
OPTIMIZATION
11/16/89
Integrated Air Pollution Control System
Optimizing
(6) Flue Gas Desulfurization
Enter the target emission rate: 0.00
(#/mmBTU)
Use cursor keys. Highlight choice then
One technology may be optimized
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGO
2-18
-------
2.4 LIST PARAMETER DATA
List Parameter Data is the fourth option in the Main Menu screen. This
option organizes and allows the user to View/Print the parameter data based on
different screen/technologies. By selecting the second option (to screen) the
user can see the following screen:
16:44:46
LIST PARMATER DATA
11/16/89
Integrated Air Pollution Control System
Send Output to Printer
Send Output to Screen
Send Output to Printer and Screen
Send Output to a File
I
Use cursor keys. Highlight choice then «J
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FSD
2-19
-------
To review the rest of the screen press any key. ESC can be pressed at anytime
to return to the main menu.
Screen #1 - (1) Run Description Comaents
0.0000 Plant and Boiler Description Card
0.0000 Technology Description Card
4.0000 Output Option
Press any key to continue...
2-20
-------
2.5 SAVE INPUT DATA
The sixth option on the Main Menu 1s "Save Input Data". The revision
which has been made up to this point can be saved in three different files.
By choosing the "Save Data in New File" the user can create his own default
parmfile (It is not necessary to type an extension for the file name; the
program will automatically give the file name the .EPR extension). Saving the
file under Batch will allow the user to create a batch file for a number of
different runs which can be executed as explained later (Warning: For
operating in the Batch environment, no more than 30 changes can be made in the
Parmfile data excluding boiler specific data and coal characteristics).
| 16:45:16
SAVE INPUT DATA
11/16/89
| Integrated Air Pollution Control System
Current Path:
A:\IAPCS4
Save data in
Save data in
Save data in
currently selected file
new file
batch file format
Use cursor keys. Highlight choice then -«>
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies F6D
2-21
-------
16:46:16
SAVE INPUT DATA
11/16/89 1
Integrated Air Pollution Control System Q
Current Path:
A:\IAPCS4
Enter the new data file name: NEW
(no extension)
Use cursor keys. Highlight choice then
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
11/16/89
16:46:34
SAVE INPUT DATA
Integrated Air Pollution Control System
Current Path:
A:\IAPCS4
Enter batch data file name
(fully qualified)
BATCH.DAT
Use cursor keys. Highlight choice then *
Status
FORMAT EPRI
FILE PARMFILE.EPR
Technologies FGD
2-22
-------
2.6 EXECUTE
After the input data has been revised, the program can be executed.
Option 7, Execute, on the Main Menu should be selected and ENTER pressed. An
output file is generated with an extension of .OUT. To review this output,
the user should select quit and exit the program. The output file can be
viewed with a text-file editor.
To generate costs using the BATCH file (here called BATCH.DAT), type
after the DOS prompt >IAPCS4 2 PARMFILE.EPR BATCH.DAT. The number, 2,
specifies that the parmfile is in EPRI format (1 specifies TVA format).
16:28:14
MAIN MENU
11/16/89
Integrated Air Pollution Control System
1) Select Economic Format
2) Select Input File
3) Edit Input Data
4) List Parameter Data
5) Save Input Data
6) Print Options
7) Execute
8) Quit
T
Use cursor keys. Highlight choice then
*** Level Sensitive HELP available with F1 ***
Status
FORMAT EPRI
FILE
Technologies
2-23
-------
SECTION 3.0
USING BATCH FILES
3.1 BATCH FILE
The file saved under the BATCH file can be revised by any ASCII word
processor, if desired. The format of the BATCH file is as follows:
1 Run description comment, line 1
2 Run description comment, line 2
3 Firing type, (1 = wall, 2 = tangential, 3 = cyclone, 4 = stoker)
boiler size (MW), capacity factor (%), status (1 = new, 2 = retrofit),
installation date (not used), exit temperature (#F), coal type
(1 = default coal, 2 = user input), typical coal type (1 = Pennsylvania,
2 = Ohio, 3 = West Virginia, 4 = Illinois, 5 = Montana, 6 = North
Dakota), coal cleaning (Y/N), boiler bottom type (1 = dry, 2 = wet),
output option (0 = none, 1 = private, 2 = screen, 3 = printer & screen,
4 = file), number of module (1-8), to implement, up to 8 modules
(1 = LNC, 2 - LIMB, 3 = coal cleaning, 4 = GC, 5 = ESP, 6 = FF, 7 = LSD,
8 = L/LSFGD, 9 = DSI, 10 = NGR, 11 = IGCC, 12 = PFBC, 13 = PCBB,
14 = AFBC, 15 = none, 16 = SCR), number of modules to rerun, technology
number
4 High heating value, sulfur percent, ash percent, coal cost, Na^O
percent, alkalinity of ash percent, chlorine content percent, Fe^Oj
content percent, moisture content percent, volatile matter, fixed carbon
content
5 Clean coal characteristics, similar to Row 4 (this row appears if clean
coal option is selected; otherwise it is eliminated)
6 Up to 5 lines will appear with 6 entries per line. Each entry consists
of the parameter line number and appropriate changes made to the
parameter value. The BATCH file has a specific format which can not be
altered. That means a space or another character cannot be added.
However, the existing values can be overwritten (make sure the scroll
lock or any other appropriate key is on to overwrite the values).
Always make certain that an extra space in the Batch file has not been
added; otherwise, the program will cause an error.
3-1
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SECTION 4.0
TROUBLESHOOTING
TROUBLESHOOTING
The following potential problems may occur while running the program.
1. Batch file errors:
a. Input file entries are not properly aligned, possibly due to
editing errors.
b. More than 30 changes have been made to the parameter values
(excluding boiler specific and coal characteristics changes)
2. An input item or parameter has an unreasonable value (possibly
zero or negative).
3. A math coprocessor is not being used.
4. Insufficient memory. Make certain that no other programs are
residing in the RAM and that the computer has at least 600 K
RAM of memory. Use the DOS CHKDSK command to display the amount
of available RAM. Then check the CONFIG.SYS and AUTOEXEC.BAT
files for RAM memory usage.
5. Insufficient memory while executing the model. Save the changes
in a new Parmfile, and exit the model. Return to the IAPCS model,
retrieve the new Parmfile, and then execute the model.
4-1
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TECHNICAL REPORT DATA
(Please read htWuclions on the reverse before completing)
1. REPORT NO. 2.
EPA-600/7-90-02 2 a
3. RECIPIENTS ACCESSION NO
PB91-133512
4. TITLE AND SUBTITLE
Integrated Air Pollution Control System, Version 4.0;
Volume 1: User's Guide
0. REPORT OAT E
December 1990
6. PERFORMING ORGANIZATION COOE
7. AUTHOR(S)
M. Maibodi, A. L. Blackard, and R. J. Page
8. PERFORMING ORGANIZATION REPORT NO.
EPA/SW/DK-91/074a
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Radian Corporation
P. O. Box 13000
Research Triangle Park, North Carolina 27709
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-4286, Task 2/116
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Air and Energy Engineering Research Laboratory
Research Triangle Park, North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
Task final; 6/89 - 9/90
14. SPONSORING AGENCY CODE
EPA/600/13
is.supplementary NOTEs^ggj^L project officer is Norman Kaplan, Mail Drop 62, 919/541"
2556. Volume 2 is the Technical Documentation Manual and Volume 3 is the
Programmer's Maintenance Manual.^or diskette see: PB91-506469 and PB91-506477
16. abstract ,-j^g integrated Air Pollution Control System (IAPCS) was developed for the
U.S. EPA's Air and Energy Engineering Research Laboratory to estimate costs and
performance for emission control systems applied to coal-fired utility boilers. The
model can project a material balance, and equipment list, and capital investment
and revenue requirements based on user-specific input data. Included in the model
are conventional and emerging technologies affecting S02, NOx, and particulate mat-
ter pre-combustion, in-situ, and post-combustion emission controls. A variety of
technology modules built into the model can be incorporated and combined. Cost and
performance estimates can be analyzed in terms of integrated technologies. Conven-
tional and emerging technologies included in IAPCS Version 4.0 are overfire air/
low NOx burners, lime injection multistage burners, physical coal cleaning,
coal switching and blending, spray humidification, electrostatic precipitator, fabric
filter, lime spray drying, wet limestone flue gas desulfurization, dry sorbent injec-
tion, natural gas reburning, selective catalytic reduction, atmospheric fluidized bed
combustion, pressurized fluidized bed combustion, integrated gasification combi-
ned cycle, and pulverized coal burning boiler.
17. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
b. IDENTIFlERS/OPEN ENDED TERMS
c. COSATI Field/Group
Pollution Nitrogen Oxides
Mathematical Models Particles
Coal
Combustion
Electric Power Plants
Sulfur Oxides
Pollution Control
Stationary Sources
Integrated Air Pollution
Control System
Particulate
13 B
12 A 14 G
21D
21B
10 B
07B
18. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
47
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
i
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