EGTEI user manual
Contents
1. 3rd step Effective collecting plate area determination Method for AECP determination Back corona Temperature T Mass mean Diameter MMDin Design penetration Gas viscosity ug Electric field at sparking Ebd Eavg n Average section penetration ps Section collection penetration pc D MMDrp SCA dry flue gas volume per second v 95 ay 14 Nm Flue Gas dry A sec Effective Collecting Plate Area Accp 56 617 m2 Choose if the back corona effect may occur or not by answering Y or N in cell D14 This effect could be avoided with injection of SO to reduce dust resistivity This option is developed in a next step Regarding plant data or ref box ESP1 temperature T and Mass Mean Diameter MMD must be fill in cells D15 and D16 20 Report 30 09 2014 Reference box ESP 1 Values for AECP determination Parameter Temperature T 410 500 Mass mean Diameter MMDin 4 21 Sneakage SN 0 07 Raping reentrainment RR 0 14 Most penetrating size MMDp 2 Rapping puff size MMDr 5 Free space permittivity 0 8 845E 12 Loss factor LF 0 2002 4th step Economic analysis General equipment for ESP unit can be improved with option such as diffuser plates hoppers auxiliaries insulation etc Following the user choice parameter a and b are automatically selected from ref box ESP2 Choose Y or N for options in cell D36 Plate area inferior limit m2 b AECP lt 4645 m2 0 6275 AECP gt 4645 m2 0 8431 AECP2. LSFO FGD Y N SO2 emissions saved Is there valorisation of waste Capital Costs Absorber unit cost Reagent preparation unit cost Waste handling unit cost Base balance plant cost Total cost for LSFO FGD unit Indirect installation cost Home office cost Total investment cost Operating Costs Fixed O amp M Costs Variable Operating costs Reagent price Specific limestone demand Reagent consumption Reagent cost Electricity price Electricity consumption Electricity cost By product price By product generated By product amount By product management cost 28 Y t SO2 year Y N mh ay ay hy chy ath ah oh year 40 ton CaCO3 1 46 t CaCO3 t SO2 24 276 t CaCO3 year year 60 000 MWh 61 040 MWh year year 0 15 ton By product 2 730 t By product t SO2 abated 45 484 t By product year year Report 30 09 2014 A summary is provided presenting the main input parameters and the summary of results for two cases in the example presented the figures are the same as no low sulphur fuel is used Summary for LSFO FGD SO2 emissions avoided 16 661 t SO2 year Outlet SO2 concentrations obtained 200 mg Nn amp SO dry ref O Inlet SO2 concentrations 1311 mg Nm SO dry ref O Efficiency required 85 Total investment 145 109 924 Total annual costs 19 535 468 year Spec SO2 reduction cost 1 173 t SO2 abated Spec investment per kWth 116 kWth Electricity penalty 1
3. Libert galit Fraternit y du D veloppement Agence de l Environnement durable et de la Maltrise de l Energie i PA et de l nergie N REPUBLIQUE FRANCAISE Karlsruhe Institute of Technology 4 ww Minist re de l cologie EGTEI EXPERT GROUP ON TECHNO ECONOMIC ISSUES Long range Transboundary Air Pollution Manual for EGTEI cost calculation tool for reduction techniques for LCP EGTEI technical secretariat 30 September 2014 Report 30 09 2014 Report 30 09 2014 Table of content Wiss Introductio re eena e eaea a den ack Ea aa Ar EEE eae eE aE Aeee EE EEE ENERE enced 5 2 Solid liquid gaseous fuels emission calculation 6 1 step Basic ASSUMptiOnS da sun ics anand dinar anna arias 6 2 step Plant Characteristics ssi sic2 ats Rau tentent nd nl ar nt 6 3 step Operating CHA AC 1k oc ee en PE ene eR ne Em mE eR eT 6 4 step Boiler and Fuel Characteristics c ccccccccscsccsscssscessscessscesscessssessssessssessueessnsessseesens 7 5 step Fuel COM OSU ION sat Sn hs Mir ss tn td ns 7 SUMMA RE RE CS en 9 ds PING X ANA SISTER e nn ne a T ne shane Mead eau ae 10 1 step Details on NO Pollutant Abatement Techniques 10 2 step Economic ANA VSISS LS ne et da ne 7 nns 11 3 step Cost Calculation Utilities and Catalyst 12 SORTIE AE RS A ee 13 4 POISE Wet Fabre FIRE RS ee M nn a A
4. 1 835 123 year A summary is provided presenting the main input parameters and the summary of results Report 30 09 2014 Summary for DSI FGD SO2 emissions avoided 7 924 t SO2 year Outlet SO2 concentrations obtained 200 mg Nm SO dry ref O Inlet SO2 concentrations 729 mg Nim SO dry ref O De SOx efficiency 72 5 Total investment 80 114 390 Total annual costs 17 902 914 year Spec SO2 reduction cost 2 259 t SO2 abated Spec investment per kWth 64 kWth Electricity penalty 0 86 Share capital costs to total costs 40 2 Share operating costs to total costs 59 8 Summary for low sulphur fuel and DSI FGD SO2 emissions avoided 16 661 t SO2 year Outlet SO2 concentrations obtained 200 mg Nm SO dry ref O2 Inlet SO2 concentrations 1311 mg Nm SO dry ref O Efficiency 84 7 Total investment 80 114 390 Total annual costs 26 684 972 year Spec SO2 reduction cost 1 602 t SO2 abated Spec investment per kWth 64 kWth Electricity penalty 0 86 Share capital costs to total costs 27 0 Share operating costs to total costs 73 0 33
5. Example of A C ratio is provided in ref box PJFF1 According to combustion plant characteristics thermal capacity coal characteristics moisture ash content etc and process management parameters capacity factor excess air ratio flue gas flow rate v is determined All these input data are automatically provided in Solid fuels emission calc sheet Following deduster design i e Air to Cloth ratio or filtration velocity A C Net Cloth Area Anc is calculated Air to cloth ratio for pulse jet fabric filter Air to cloth ratio A C 130602 m s Volumetric gas flow vflue gasA dry Nm Flue Gas dry A s Net cloth area And Gross cloth area Agc Reference box PJFF1 Air to Cloth ratio Air to Cloth ratio cm s 1 00 2 33 If PJFF is used after a dry FGD then A C 0 66 1 00 should be in the following range mo 14 Report 30 09 2014 This value is increased in Gross Cloth Area Acc with a security factor f given by ref box PJFF2 Reference box PJFF2 Conversion Net to Gross Cloth Area Level of Net cloth Area m Multiplicator factor for gross cloth area 0 2 370 1 5 1115 1 25 2 230 1 17 3 350 1 125 4 460 1 11 5 580 1 1 6 690 1 09 7 810 1 08 8 920 1 07 10 040 1 06 12 270 1 05 16 730 1 04 4th step Determination of the total filtration area Atot Dividing the deduster structure into compartments allows better cleaning procedure increase maintenance system efficiency and avoid shutting do
6. as specified below 5th step Fuel Composition a Broad fuel composition Report 30 09 2014 Broad Coal Composition Lower Heating Value LHV MJ kg Sulphur mass fraction Xs Sulphur w w waf Ash mass fraction Xash Ash Moisture mass fraction Xmoist Moisture Spec stoich wet flue gas volume v 5 7 95 Nm Flue Gas stoich wet kg Coal Spec excess air volume IV atoich dry 1 64 Nm Excess Air kg Coal Spec moisture volume v 0 54 Nm moisture kg Coal Spec dry flue gas volume v S any 9 05 Nm Flue Gas A dry kg Coal Oxygen concentration Coz aci 3 80 Oo dry Oxygen correction factor fo2 corr 0 87 O corr Factor to ref O2 This box is ONLY relevant if broad data has been chosen in D46 Enter the coal specifics in cells D52 D55 The cells below are calculated from the given data there are no entries to be made in these cells In the liquid fuels sheet there is another box to be filled with empirical correlation data to calculate the LHV cells H52 and H53 As output the SO and Dust boiler outlet emissions are calculated Broad Biomass Composition Lower Heating Value LHV 4 MJ kg LHV Sulphur mass fraction xs Sulphur w w waf Ash mass fraction Xash Ash Moisture mass fraction Xmoist Moisture Spec stoich wet flue gas volume v 5 well 3 14 Nm Flue Gas stoich wet kg Biomass Spec excess air volume I stoich dry 0 62 Nm Excess Air kg Biomass Spec moist
7. lt 4645 m2 0 6276 AECP gt 4645 m2 0 8431 Basic unit All standard option Ref box ESP3 presents material factors which increase ESP unit price following the type of material used Choice the ESP material in cell D40 Material Factor Carbon Steel 1 Stainless steel 304 1 30 Stainless steel 316 1 7 Carpenter 20 CB 3 1 9 Monel 400 2 3 Nickel 200 3 2 Titanium 4 5 Choose if SO injection is used or not in cell D43 Choose if the ESP is installed in a new plant or in an existing one cell D46 This last option adds a retrofit factor to the total investment cost Choose if by products can be valorized or not in cell D47 21 Report 30 09 2014 Economic Analysis Dust emissions saved With option Effective Collecting Plate Area Arc a b ESP material SO3 injection precaution Equipment cost Direct installation cost Indirect installation cost Is it a new PJFF unit Is there valorisation of by products Total Investment Capital Cost p a Fixed O amp M Costs Variable Operating Costs Pressure drop value Fan efficiency Fan utility electricity consumption ESP power requirement utility electricity cost SO3 injection rate SO3 consumption cost By Product management cost Total variable costs For operating cost 3 input parameters are required Include the pressure drop value and fan efficiency in cells D54 and D56 see ref box ESP4 Include SO injection rate in cell
8. will be calculated from the data entered in step 3 as described below 3rd step Cost Calculation Utilities and Catalyst Reference Box Calculated Utilities SR used in Calculation Stoiciometric Ratio SCR see above Stoiciometric Ratio SNCR for No Of catalyst layers guidance 10 5 mbar mbar 45 Enter the necessary data in the cells 073 075 Entries are only necessary for either SCR or SNCR depending on the technique to be used f guidance is needed to appoint these values refer to the reference box in N52 R60 The total pressure drop for the chosen technique will be displayed in either O77 or O78 12 Report 30 09 2014 Spec Cat Volume Total Cat Volume Total Cat Lifetime h Lifetime Reduction Biomass Co fi E Total Cat Lifetime Biomass No Of cat Regenerations Cat Lifetime acc To operating re Annualised catalyst cost Insert catalyst data in the blue cells in between O83 and O90 The values in the green cells will be calculated automatically f guidance is needed to appoint these values refer to the reference box in N62 R68 Summary Summary spec NOx emissions saved 450 mg Nm NO dry ref O spec NOx emissions saved 517 mg Nm NO dry act O2 total NOx emissions saved 67455 ta Share thereof 1 measures 2 998 0 tla 44 4 thereof 2 measures 3 7475 tla 55 6 The summary box in C97 F102 contains the final data of the total NO emission reducing measures The
9. D59 All the range of these parameters is provided see ref box ESP7 Reference Box ESP 4 Calculated Utilities Pressure drop range mbar 25 50 Fan efficiency range 40 70 Reference Box ESP 7 SO3 conditionning F SO3 injection rate kg h 10 80 Sulfur cost t 70 22 Report 30 09 2014 Summary A summary table is provided 23 Report 30 09 2014 6 Desulphurisation techniques Three techniques are considered Sheets Solid fuels_deSO2 Liquid fuels_deSO2 LSFO FGD Limestone forced oxidation flue gas desulphurisation LSD FGD Lime spray dryer flue gas desulphurisation DSI FGD Dry sorbent injection flue gas desulphurisation with lime Costs of the 3 techniques are estimated in sheet Solid fuels_deSO2 with the help of sheet solid fuels_fabric_filter_DSI for the last technique Dry sorbent injection technique has been developed for lime The use of sodium bicarbonate remains to be developed 1st step concentration to be obtained Include the SO concentration to be obtained at stack cell D6 Which SO2 concentration at stack do you want to achieve SO2 stack concentration target Current Gap to goal Inlet SO2 concentration mg Nms ref O2 dry 84 75 1311 47 mg Nm 3 ref O2 dry 2d step information on reagent characteristics and costs Reagent and by product characteristics and prices Purity of limestone for LSFO FGD Price of limestone for LSFO FGD Purity of lime for
10. O2 Do you want to install SCR Yes No Do you want to install SNCR The technology choice is suitable The technology choice fits with the emission go Decide finally whether to install SCR or SNCR by entering Y or N in D26 and D27 10 Report 30 09 2014 D28 displays if your choice is suitable This means that N appears if both SCR and SNCR are selected marked with Y in the cells above because it is not possible reasonable to install both of them D29 shows if the chosen technology will fulfill the emission goal given in D7 2d step Economic Analysis NOx emissions saved Spec Equipment Investment see Ref Box Total Investment 37 500 000 Capital Cost p a 3 372 791 Fixed O amp M Costs 750 000 Set specific equipment investment costs for primary measures D36 f guidance is needed to appoint this value refer to the reference box further on the right in N34 Q44 Total costs per year and ton for primary measures will be displayed in D41 D42 Secondary Measures SNCR if SNCR Y SNCR NOx emissions saved 1 499 tla Capital Costs Spec Equipment Investment ie Total Investment 20 000 000 Capital Cost p a 1 798 822 a Operating Costs Fixed O amp M Costs 400 000 a Stoichiometric Ratio 1 75 reagent consumption 1 014 ta reagent cost 456 089 a utility electricity consumption 0100 MWhh utility electricity cost 52 560 a pressure drop cons 0 062 M
11. 0 ton By product By product generated 2 783 t By product t SO2 abated By product amount 46 373 ay product year by product management cost 927 461 A summary is provided presenting the main input parameters and the summary of results 30 Report 30 09 2014 Summary for LSD FGD SO2 emissions avoided 16 661 t SO2 year Outlet SO2 concentrations obtained 200 mg Nm SO dry ref O Inlet SO2 concentrations 1311 mg Nm SO dry ref O Efficiency 84 7 Total investment 130 534 038 Total annual costs 19 093 029 year Spec SO2 reduction cost 1 146 t SO2 abated Spec investment per kWth 104 kWth Electricity penalty 1 10 Share capital costs to total costs 61 5 Share operating costs to total costs 38 5 Summary for low sulphur fuel and LSD FGD SO2 emissions avoided 16 661 t SO2 year Outlet SO2 concentrations obtained 200 mg Nim SO dry ref O Inlet SO2 concentrations 1311 mg Nm SO dry ref O Efficiency 85 Total investment 130 534 038 Total annual costs 19 093 029 year Spec SO2 reduction cost 1 146 t SO2 abated Spec investment per kWth 104 kWth Electricity penalty 1 10 Share capital costs to total costs 61 5 Share operating costs to total costs 38 5 31 Report 30 09 2014 DSI FGD f DSI FGD has been selected input Y or N in cell D213 to choose between valorization of by products or waste disposal All investments and operating costs are then automatically
12. 39 Share capital costs to total costs 66 8 Share operating costs to total costs 33 2 Summary for low sulphur fuel and LSFO FGD SO2 emissions avoided 16 661 t SO2 year Outlet SO2 concentrations obtained 200 mg Nim SO dry ref O Inlet SO2 concentrations 1311 mg Nm SO dry ref O Efficiency required 85 Total investment 145 109 924 Total annual costs 19 535 468 year Spec SO2 reduction cost 1 173 t SO2 abated Spec investment per kWth 116 kWth Electricity penalty 1 39 Share capital costs to total costs 66 8 Share operating costs to total costs 33 2 29 Report 30 09 2014 LSD FGD If LSD FGD has been selected input Y or N in cell D149 to choose between valorization of by products or waste disposal All investments and operating costs are then automatically calculated Secondary Measures LSD FGD if LSD FGD Y LSD FGD Y N Y Y N SO2 emissions saved t SO2 year Is there valorisation of waste y n Capital Costs Absorber unit cost Reagent preparation and waste handling units cost Base balance plant cost Total cost for LSD FGD unit Indirect installation cost Home office cost Total investment cost Operating Costs Fixed O amp M Costs Reagent price 80 ton CaO Specific reagent demand 1 20 t CaO t SO2 Reagent consumption 20 El t CaO year Reagent cost 1 8 Electricity price 60 000 MWh Electricity consumption ml 2 o on Electricity cost 2 878 448 By product price 20 0
13. 60 h a Resulting capacity factor i 4 100 0 For guidance see Reference Box Input either or h a To provide information about the capacity factor either insert the percentage of the full load time per year in G31 or the actual number of full load hours per year in G32 Inserting data in both G31 and G32 should be avoided The resulting capacity factor is displayed in G33 f guidance is needed to appoint this value refer to the reference box further on the right in J30 L35 Utility costs MWh Spec Power requirement of pressure drop Wh mbar Nm The values for typical utility costs and power requirements for pressure drops need to be provided in K31 to K34 4th step Boiler and Fuel Characteristics Boiler Characteristics Excess Air Ratio A see Reference Box Excess Air Carbon in Ash Xia wiw in ash Ash retained in Boiler of total ash S retained in Boiler of total sulphur Insert typical boiler characteristics in D 40 43 f guidance is needed to appoint this value refer to the reference box further on the right in N39 045 Please indicate whether you want to use broad or detailed fuel input data Coal d detailed b broad Biomass if co firing d detailed b broad Decide whether to use broad or detailed fuel input data for both coal and biomass if applicable by inserting d or b in cells D46 and D47 The values refer to two different calculation options
14. Bag prices er Bags cost CE Choose filter bag media in the list of media presented Cell D56 All prices for media material are referenced on PE material This value can be modified according to ref box PJFF6 or if more suitable data is available cell D57 Ref box PUFF5 presents 8 media and their associate relative price 16 Report 30 09 2014 Reference box PJFF5 Bag cost factors for various materials 7th step Cage cost determination Include length and diameter of bags in cells D64 and D65 Ref box PJFF7 provides default values Include cage price in cell D69 This last value is given in ref box PJFF6 Cage cost for pulse jet application Lenght Diameter Cage price per m2 filtering media 20000 m2 filtering media Total cage cost 828 175 Reference Box PJFF6 Price Utilities Pe media pre 02 Cage price m2 filtering media 16 25 Reference Box PJFF7 Filter dimension Lenght m 3 9 Diameter mm 120 180 17 Report 30 09 2014 8th step Economic analysis Choose if the FF is installed in a new plant or in an existing one cell D83 This last option adds a retrofit factor to the total investment cost Economic Analysis Dust emissions avoided At Equipment cost Direct installation cost Indirect installation cost Is it a new PJFF unit ls there valorisation of by products Total Investment Capital Cost p a Operating Costs C40 Fixed O amp M Costs Variable Operatin
15. LSD FGD Price of lime for LSD FGD Purity of lime for DSI FGD Price of lime for DSI FGD t CaCO3 t CaO t CaO Y N t sodium bicarbonate Fill in cells D10 and D11 purity and price of limestone respectively when used for LSFO FGD Fill in cells D12 and D13 purity and price of lime respectively when used for LSD FGD Fill in cells D14 and D15 purity and price of lime respectively when used for DSI FGD Remark the use of sodium bicarbonate is not yet developed If you just want to test one technique fill in the information for this technique Reference Box 1 reagents provides range of values observed 24 Report 30 09 2014 Reference Box 1 reagents CaCO3 purity may range from 90 to 98 From questionnaires 94 to 96 are observed in 4 plants CaCO3 prices depend on quantity bought and quality From questionnaires prices range from 11 to 16 CaCO3 in a 2465 MWth plant and 32 to 36 t CaCO3 in a 630 MWth plant and 40 t CaCO3 in another 630 MWth plant for similar purity of CaCO3 94 to 96 Quicklime or CaO used in LSD FGD has a purity range from 94 to 96 93 is encountered Price is about 5 times price of limestone Price range is 80 to 150 t CaO according to the specific surface Price and purity to be completed for sodium bicarbonate 3rd step information on by product prices in case of valorization of disposal By products from LSFO FGD Commer
16. S SR NU AN cr 14 1 step information on by product disposal cost or by product valorisation cost 14 2 step concentration to be Obtained sessions 14 3 step Determination of the gross Cloth area Age siens 14 4 step Determination of the total filtration area Atot 15 5 step Baghouse compartments cost determination 15 6 step Bag cost d termination eee eee ere eee On ne rh ae 16 7 step Cage cost d termination nee nd ne manne an 17 8 step Economic ANA AIS Ne rs 18 SUMMER Sn 4 19 5 Electrostatic Precipitation es nn nn de MN ne OR RTE nn RAS eer 20 1 step information on by product disposal cost or by product valorisation cost 20 2 step Dust reduction achieveMent cc csscssecsessessevsesssesessssssessessesvesseseestuveseeeseusssestviaenense 20 3 step Effective collecting plate area determination 20 4 step Economic ANA SIENNE USA ee ne eekly ate sn aras 21 SLIT TARY PERS aaae Ae ted EU EE SE D EE NE PS 23 6 Desulphurisation techniques fn ns amit wit Sonate tite Sn tee 24 Report 30 09 2014 1 step concentration to be obtained nain ne panne Beaten 24 2 step information on reagent characteristics and COSTS cccccccesssescssesseesesetsteesteteteeees 24 3 step information on by product prices in case of valorization of disposal 25 4 step choice of the technique of reduction 26 5 step COOGAN ANY SI Says ccs cites Gn tiene ts
17. Wh Mio pressure drop cost 77 981 a This box is only applicable if SNCR is chosen as secondary measure Set specific equipment investment costs for SNCR D49 f guidance is needed to appoint this value refer to the reference box further on the right in N34 Q44 Chose catalyst in D54 by marking NH with y or n The opposite will be set automatically for urea in D50 Insert the electric consumption in D59 The values for the cells D55 D68 will be calculated from the data entered in step 3 as described below 11 Report 30 09 2014 SCR Y N Y N NOx emissions saved 1 499 tla Capital Costs Spec Equipment Investment a ekwih Total Investment 50 000 000 Operating Costs 1 000 000 0 a Stoichiometric Ratio 0 90 reagent consumption 521 ta reagent cost 234 560 a utility electricity consumption 010 MW utility electricity cost 52 560 a pressure drop cons 0 435 MWh Mio pressure drop cost 3 821 058 a annualised catalyst costs 2 463 750 a This box is only applicable if SCR is chosen as secondary measure Set specific equipment investment costs for SNCR D75 f guidance is needed to appoint this value refer to the reference box further on the right in N34 Q44 Chose catalyst in D80 by marking NH with y or n The opposite will be set automatically for urea in D81 Insert the electric consumption in D85 The values for the cells below D82 D95
18. al investment need to be estimated in cell G4 Depreciation time years Interest rate p a Capital Recovery Factor 90 p a Depreciation time and interest rate are necessary to calculate the capital costs cells J3 4 The capital recovery factor in J5 will be calculated automatically from this data 24 step Plant Characteristics Gross Electric Efficiency n LHV Set overall plant characteristics such as thermal capacity of the plant and gross electric efficiency in cells D20 and D21 Please enter the appropriate NOx boiler outlet emission concentration NO boiler outlet emissions fload nox ary o2red 600 mg Nm NO dry ref O2 For guidance see Reference Box The actual value of NO boiler outlet emissions has to be entered in D24 f guidance is needed to appoint this value refer to the reference box further on the right in N20 R26 3rd step Operating Characteristics Biomass Co Firing Yes No Biomass share wiw Coal share 100 1 ww NAA for liquid fuels and natural gas Report 30 09 2014 Insert information about biomass co firing in cells D31 33 A general yes or no y or n needs to be set in D31 If y is chosen fill in cell D32 with the share percentage of biomass The coal share will then be calculated in D33 The calculations are only valid for a biomass share below 20 weight based Capacity Factor full load hours of 87
19. alues vary for liquid and gaseous fuel but the methodology stays alike Summary Co Firing Fuel Spec Used Lower Heating Value LHV Sulphur mass fraction xs Ash mass fraction Xash Spec wet flue gas volume v 2 wet Annual wet flue gas volume v 3 wet year Spec dry flue gas volume v 95 any Annual dry flue gas volume V 355 ary year Oxygen concentration coz act Oxygen correction factor fo2 corr SO boiler outlet emissions load s02 gry re102 NO boiler outlet emissions load nox ary reto2 Dust boiler outlet emissions load dry reto2 Moisture Sulphur mass fraction x real s SO boiler outlet emissions load A summary table with the final results is provided below These results will be used for further calculations in the following sheets as basis for the cost calculations Report 30 09 2014 3 NOx analysis Sheets Solid fuels NOx Analysis Liquid fuels NOx Analysis Natural gas NOx Analysis 1st step Details on NO Pollutant Abatement Techniques Which NOx emission goal at stack do you want to achieve NO ELV for goal achievement calculation 2000 manne NO dry ref O2 equivalent NO ELV at actual O2 229 6 mg Nm NO dry act O2 Current Gap to goal Insert NO achievement goal in cell D5 Thereof the current gap is calculated in D7 NOx Emissions Primary Measures Do you want to upgrade 1 measures BE New NOx Boiler Out
20. calculated the example is developed with the use of a low sulphur coal For this technique the sheet Solid fuel_Fabric_Filter DSI is used for the calculation of the investment and operating cost of the fabric filter Input the concentration of dust not to be exceeded in cell D12 The Air to cloth ratio A C is fixed but all other parameters required have to be filled in For that please refer to sheet solid fuels fabric filter In the example below a low sulphur fuel is also used Secondary Measures DSI FGD DSI FGD Y N SO2 emissions saved ls there valorisation of waste Capital Costs PJFF Reagent preparation unit injection device unit cost Operating Costs 1 602 288 year Fixed O amp M Costs Reagent price Specific limestone demand Reagent consumption Reagent cost Electricity price Electricity consumption Y Y N 7 924 t SO2 year y n 61 626 454 18 487 936 80 ton CaO 3 67 t CaO t SO2 29 066 t CaO year 2 325 258 year 60 000 MWh 37 557 MWh year Electricity cost PJFF By product price By product generated By product amount By product amount recovered with PUFF By product concentration inlet FF 2 253 411 year 40 00 ton By product 8 479 t By product t SO2 abated 67 181 t By product produced year 67 031 t By product recovered year 4 482 mg by product Nm3 ary refO2 By product management cost Bag replacement cost 32 2 681 258 year
21. cial price in case of valorisation By product disposal or other destination costs By products from LSD FGD Commercial price in case of valorisation By product disposal costs By products from DSI FGD From lime Commercial price in case of valorisation By product disposal costs t By product t By product t By product t By product t By product P Fill in cells D20 and D21 commercial gypsum price or by product cost in case of disposal for LSFO FGD Fill in cells D23 and D24 commercial by product price or by product cost in case of disposal for LSD FGD Fill in cells D26 and D27 commercial by product price or by product cost in case of disposal for DSI FGD Reference Box 2 by products provides range of values observed Reference Box 2 by products LSFO FGD commercial grade gypsum price depends on chlorine content purity colour Commercial grade gypsum can be used in wallboard cement or plaster manufacturing also soil conditioner Price can be low due to saturation of the market Questionnaires provide a range between 0 15 to 2 t by product Disposal prices depend on the waste disposal treatment Landfill or other treatment such as incineration By product prices range from 0 33 to 89 t by product according to the questionnaires obtained 25 Report 30 09 2014 Reference Box 2 following by products LSD and DSI FDG f collected separately from fly ash i
22. e one RAS ne taie 27 Report 30 09 2014 1 Introduction EGTEI is mandated by UNECE in the scope of the CLRTAP to develop technical and economic data for relevant processes and related abatement techniques for stationary sources The methodology for cost estimation of abatement options of SO2 NO and TSP Total Suspended Particulates for Large Combustion Plants LCP with a thermal capacity of more than 50 MW aims at providing cost data for the following reduction techniques applied on large combustion plants using coal heavy fuel oil and natural gas as well as biomass in co combustion with coal Only boilers are considered gas turbines could be examined in the next steps Reduction techniques considered are the following ones e NOx primary measures SNCR Selective Non Catalytic Reduction and SCR Selective Catalytic Reduction e TSP electrostatic precipitator ESP and fabric filter FF e SOz wet flue gas desulphurisation by limestone forced oxidation LSFO Limestone Forced Oxidation semi dry LSD Lime Spray Dryer and dry desulphurisation DSI Duct Sorbent Injection Remark use of lime is only presented in this report but use of sodium bicarbonate will be included in the next update of the tool end 2014 Costs are estimated for different regulatory objectives in term of ELVs Emission Limit Values assuming one boiler linked to a chimney This manual explains how to use the EXCEL tool developed to estimate c
23. final cost data can be found in the cells D41 D42 1 measures D64 D68 SNCR and D91 D95 SCR as displayed in the screenshots of the 2 step Background Information Investment Data for COAL fired power plants A few tables at the bottom of the excel sheet starting in line 104 display data collected from EGTEI experts via questionnaires This data is meant to provide background and reference information It can be used to compare results or to estimate uncertain values Nevertheless there might be applications which are not comparable with this data and can therefore deliver differing but still correct and meaningful results 13 Report 30 09 2014 4 Pulse Jet Fabric Filter Sheet Solid fuels Fabric_Filter 1st step information on by product disposal cost or by product valorisation cost By products from PJFF Commercial price in case of valorisation t By product By product disposal costs t By product Cells D8 and D9 to be filled If by products are sold include a negative figure 2d step concentration to be obtained Include the dust concentration to be obtained at stack cell D12 Which Dust emission goal at stack do you want to achieve Dust stack emission to be obtained 20 0 mgm O2ref dry Current Gap to goal 99 88 Inlet dust concentration 16 458 mg Nm O2ref dry 3rd step Determination of the gross cloth area Acc Include the Air to Cloth ratio or filtration velocity A C in cell D17
24. g Costs Pressure drop value Fan efficiency Fan utility electricity consumption Compressed to actual air flow ratio Air compressor consumption Bag life By Product management cost Utility electricity cost Bag replacement cost C Total variable costs For operating cost 3 input parameters are required Include the pressure drop value and fan efficiency in cell D91 and D92 Include bag lifetime in cell D96 All the range of these parameters is provided in ref box PJFF8 Reference Box PJFF8 Data Utilities Pressure drop range mbar 25 50 Fan efficiency range 40 70 Bag life operating hour 15 000 40 000 Compressed to actual air flow ratio 0 002 18 Report 30 09 2014 Summary A summary table is provided 19 Report 30 09 2014 5 Electrostatic Precipitator Solid fuels ESP or Liquid fuels ESP sheet 1st step information on by product disposal cost or by product valorisation cost By products from ESP Commercial price in case of valorisation t By product By product disposal costs t By product Cells D5 and D6 to be filled If by products are sold include a negative figure 2d step Dust reduction achievement Include the dust concentration to be obtained at stack in cell D9 Which Dust emission goal at stack do you want to achieve Dust stack emission to be obtained mg Nm3 O2ref dry Current Gap to goal 9 Inlet dust concentration 16 4 mg Nm O2ref dry
25. let Emission mg Nm NO dry ref O2 Reduction achieved with 1 33 3 Gap Closure to emission goal 50 0 Reduction required with 2 Secondary Measures NOx emissions before 2 measures 400 mg Nm NO dry ref O2 Does literature suggest SNCR NN Yes No See Reference Box New NOx outlet emissions 40 0 mgNm NO dry ref O2 Total reduction achieved 75 0 Degree of Over Achievement to ELV 25 0 Decide whether to upgrade 1 measures Low NOx Burner LNB by entering y or n in cell D11 If yes insert boiler outlet emissions after the planned upgrade in cell D12 f guidance is needed to appoint this value refer to the reference box further on the right in Q9 S16 The already achieved reduction and the reduction goal to be achieved with 2 measures will be displayed in cells D13 D15 Enter planned NO outlet emissions after 2 measure in cell D20 Cell D19 shows a literature based suggest whether to use SNCR technology or not regarding the given data For more information check the reference boxes on the right N9 S16 Be aware of the fact that there might be exceptions from this recommendation Because of a lack of literature date for other fuel types this value is only available for solid fuels The reduction results of the chosen measures are shown below in cells D21 and D22 Conclusion of technol choice NOx stack emissions with selected technologie mg Nm NO dry ref
26. n case of retrofit and use of the ESP in place dry by product may be land filled or used as soil conditioner The predominant mode of dry FGD by product elimination is disposal as fly ash separation is in fact rarely done According to one expert cost for waste disposal may reach 200 t bp due to the fact the product is in a pulverised dry form When sold to the cement industry if the product is without fly ash a positive cost may be encountered 40 t bp 4th step choice of the technique of reduction The user may choose to combine the use of a low sulphur coal and the use of a reduction technique This is mainly useful for DSI FGD and LSD FGD but not for LSFO FGD Input Y in cell D35 if you want to combine the use of a low sulphur fuel and a reduction technique If Yes input the sulphur content in cell D36 Note that the sulphur content must be lower than the sulphur content of the initial coal sheet solid fuels emissions calc Choice of the emission reduction technique Primary Measures Do you want to use a lower sulphur content coal Yes No What is the sulphur content of the low sulphur coal Sulphur w w waf Concentration achieved with low sulphur content fuel not valid mg Nm8 ref O2 dry Gap Closure to emission goal of Cell D7 n a Reduction required with secondary measure 84 75 Secondary Measures Inlet SO2 concentrations mg Nms ref O2 dry Do you want to estimate costs for LSFO FGD Yes No Do y
27. osts of reduction techniques for combustion plants with a thermal capacity larger the 50 MWth It is associated to the documents e Estimation of costs of reduction techniques for LCP methodology 30 September 2014 e Estimation of costs of reduction techniques for LCP examples of results obtained 30 September 2014 e EXCEI tool for cost estimation of reduction techniques for LCP version a 30 September 2014 Report 30 09 2014 2 Solid liquid gaseous fuels emission calculation Sheets Solid fuels emission calc Liquid fuels emission calc Natural gas emission calc There are a few minor differences between the three sheets concerning specific values but the general method is the same Therefore only the example of solid fuels is executed in detail below but can easily be adapted to the iquid fuels and natural gas sheet if necessary In this sheet the general data of the power plant for calculating the NOx SO and dust emissions based on the efficiency capacity factor and fuel input needs to be defined by the user 1st step Basic Assumptions Ref O2 content O2 ref Vol Fixed O amp M Costs of total Investment There are a few basic assumptions that have to be taken into account concerning the regarded power plant In cell G3 the reference O concentration which can be found in the relevant national law is inserted The percentage of fixed Operations and Management O amp M costs of the tot
28. ou want to estimate costs for LSD FGD Yes No Do you want to estimate costs for DSI FGD Yes No New SO2 outlet emissions mg Nm8 ref O2 dry 1311 471 Total reduction required 84 750 Degree of Over Achievement to ELV 0 Retrofit factor Coal factor Input Y in cells D44 D45 or D46 for the technique you want to test LSFO FGD LSD FGD or DSI FGD If you want to take a margin of security compared to the concentration target input in cell D6 input a lower concentration in cell D47 In case of retrofit in an existing plant input a retrofit factor in cell D50 Reference box 5 retrofit factor provides the following information 26 Report 30 09 2014 Reference box 5 retrofit factor retrofit factor can range from 1 to 1 4 in case of very congested site 5th step economic analysis Primary measure SO2 emissions saved 8 737 t SO2 year Spec Additional cost of low sulphur coal sde coal Total Investment No investment Capital Cost p a No capital cost year Annual additional costs 8 782 058 year 1 756 412 t coal year If a low sulphur coal has been selected input the low sulphur coal additional cost in cell D74 LSFO FGD If LSFO has been selected input Y or N in cell D86 to choose between valorization of by products or waste disposal All investments and operating costs are automatically calculated 27 Report 30 09 2014 Secondary Measures LSFO FGD if LSFO FGD Y
29. ure volume v 0 75 Nm moisture kg Biomass Spec dry flue gas volume v PS aryl 3 01 Nm Flue Gas A dry kg Biomass Oxygen concentration Coz act 4 34 Oo dry Oxygen correction factor fo2 cor 0 90 O corr Factor to ref 02 This box is relevant ONLY for solid fuels if you use co firing D31 with broad biomass data D47 Enter the biomass composition data in cells H52 H55 The cells below are calculated from your data there are no entries to be made in these cells b Detailed fuel composition Detailed Coal Composition Mass percentages water and ash free waf O N Mass abs x ss 66 15 3 69 5 70 1 70 Mass waf x Lower Heating Value LHV pec dry flue gas volume vf 95 Report 30 09 2014 This box is relevant ONLY if detailed data has been chosen in D46 Enter the water and ash free shares in mass percentages of H O N S ash and moisture of the used coal cells E71 J71 The carbon content will be calculated from the H O N S ash and moisture contents Enter the equivalent compositions for biomass in line 79 if applicable f guidance is needed to appoint these values refer to the reference boxes further on the right cell numbers vary among the three worksheets From this input data the LHV of the fuel the SO and dust boiler outlet emissions as well as the specific dry and wet flue gas volumes are calculated Some of the required v
30. wn the process for cleaning period Ref box PUFF3 presents common values for compartment division Reference Box PJFF3 Filter dimension Compartment division 1 30 extra compartment 0 2 Include the number of compartments and extra compartments in cells D34 and D36 Baghouse division Gross cloth area AGC Number of compartments Compartment Area Ab Number of extra compartments Total cloth area Atot 5th step Baghouse compartments cost determination Choose between a pre assembled or field assembled unit The last one is recommended for unit size over 2000 m Choose in cell D42 15 Report 30 09 2014 Then two following criteria are optional stainless steel and thermal insulation chose Y or N in cells D44 and D45 Depending on the user choice factors a1 to b3 are selected from ref box PJFF4 Cost for baghouse compartments Compartment Area A mp Pre assembled unit or field assembled unit Basic unit Stainless Steel Thermal insulation Cost for baghouse compartments Reference box PJFF4 Price parameters for baghouse compartments 2010 Baghouse type Component a b m2 Basic unit 55 604 124 Pre assembled unit SS 26 789 97 Insulation 3 088 36 Basic unit 422 647 90 Field assembled unit ss 143 808 34 Insulation 89 879 10 The cost for all baghouse compartments is then calculated 6th step Bag cost determination Media material Reference price for PE material
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