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IECM User Manual - Carnegie Mellon University

1. 15 Total O amp M Costs 508 Costs are in Constant 2005 dollars 4 Total Cost Sulfur Removal O amp M Cost results screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Variable Cost Component Makeup Selexol Solvent This is the annual cost of makeup Selexol Makeup Claus Catalyst This is the annual cost of makeup catalyst used in the Claus plant Makeup Beavon Stretford Catalyst This is the annual cost of makeup catalyst used in the Beavon Stretford plant Sulfur Byproduct Credit This is the annual profit for sulfur sold on the market Disposal Cost This is the annual cost of all wastes generated by the sulfur recovery processes and disposed Selexol Electricity This is the annual cost of electricity used by the Selexol based sulfur capture process area It is based on the electricity price of the base plant and the power consumed in the process areas Claus Electricity This is the annual cost of electricity used by the Claus plant process area It is based on the electricity price of the base plant and the power consumed in the process areas Beavon Stretford Electricity This is the annual cost of electricity used by the Beavon Stretford process area It is based on the electricity price of the base plant and the power consumed in the process are
2. FG Recycle amp Purification 2c se 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Integrated Environmental Control Model User Manual O2 CO2 Recycle e 287 0O2 CO Recycle Flue Gas CO storage input screen CO2 Compression The concentrated CO product stream obtained from sorbent regeneration is compressed and dried using a multi stage compressor with inter stage cooling CO Product Pressure The CO product may have to be carried over long distances Hence it is necessary to compress and liquefy it to very high pressures so that it maybe delivered to the required destination in liquid form and as far as possible without recompression facilities en route The critical pressure for CO is about 1070 psig The typically reported value of final pressure to which the product CO stream has to be pressurized using compressors before it is transported is about 2000 psig CO Compressor Efficiency This is the effective efficiency of the compressors used to compress CO to the desirable pressure Unit CO Compression Energy This is the electrical energy required to compress a unit mass of CO product stream to the designated pressure Compression of CO to high pressures requires substantial energy and is a principle contributor to the overall energy penalty of a CO capture unit in a power plant Total CO Compression Energy This is the electrical energy required to compress the CO pro
3. Process Type 2 Selexol CO2 Capture A Costs are in Constant 2000 dollars b 1 Diagram f 2Syngas f 3 CapitalCost 4 0 amp MCost 5TotalCost aE ICLRILOEE Selexol CO Capture Cost Factors results screen Important Performance and Cost Factors This screen displays information that is a key to the model calculations The data is available else where in the model Net Plant Size MW This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties Annual Operating Hours hours This is the number of hours per year that the plant is in operation If a plant runs 24 hours per day seven days per week with no outages the calculation is 24 hours 365 days or 8 760 hours year Fixed Charge Factor fraction The fixed charge factor is one of the most important parameters in the IECM It determines the revenue required to finance the power plant based on the capital expenditures Put another way it is a levelized factor which accounts for the revenue per dollar of total plant cost that must be collected from customers in order to pay the carrying charges on that capital investment Cost of CO Avoided Capture Plant e CO Emissions lbs kWh This is the amount of CO vented to the air for every kilowatt hour of electricity produced in the power plant that is using a CO Capture technology e Cost of Electricity
4. Configure Plant Set Parameters Get Results fo z CO2 Capture PALGI E O B a a Capital Cost Process Area Gas Turbine retro new e Heat Recovery Steam Generator retro new Steam Turbine retro new HRSG Feedwater System retro new R Process Type Power Block 1 Gas Turbine 2 SteamCycle OR 5 Capital Cost 6 O amp M Cost Power Block Retrofit Cost input screen Power Block Retrofit Cost Input Parameters Gas Turbine The Gas Turbine retrofit factor is a ratio of the costs of retrofiting an existing facility versus a new facility using the same equipment Heat Recovery Steam Generator The Heat Recovery Steam Generator retrofit factor is a ratio of the costs of retrofiting an existing facility versus a new facility using the same equipment Steam Turbine The Steam Turbine retrofit factor is a ratio of the costs of retrofiting an existing facility versus a new facility using the same equipment HRSG Feedwater System The Boiler Feedwater retrofit factor is a ratio of the costs of retrofiting an existing facility versus a new facility using the same equipment Power Block Capital Cost Inputs This screen is only available for the Combustion Turbine and IGCC plant types Integrated Environmental Control Model User Manual Power Block 377 378 e Power Block 7 IECH Interface ioj xi Fie Edit View
5. Air Cooled Condenser Performance Input Screen The parameters are described briefly below Ambient Air Temp Dry Bulb Avg This refers basically to the ambient air temperature measured by a thermometer This input specifies annual average ambient temperature Inlet Steam Temperature That is the temperature of exhaust steam entering the air cooled condenser system That is calculated as a function of the steam turbine backpressure The difference between inlet steam and ambient air temperatures significantly affects the performance and cost of the dry cooling system Fan Efficiency This parameter specifies the electricity efficiency of fan drive system That is a percent of electrical power inputs to the fans 22 e Water Systems Integrated Environmental Control Model User Manual Condenser Plot Area per cell This parameter specifies the footprint or plot area of one cell One cell typically consists of multiple condenser bundles and is served by a large axial flow fan located at the floor of each cell Turbine Back Pressure This parameter specifies the quantity of steam turbine backpressure For the plant installed with a wet cooling system the steam backpressure ranges from 1 5 to 2 0 inches of Mercury inches Hg whereas the steam backpressure for the plant installed with a dry cooling system ranges from 2 0 to 8 0 inches Hg Turbine back pressure affects the steam cycle heat rate and indirectly has an
6. Water Gas Shift Reactor Syngas result screen Major Syngas Components Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H2 Total mass of hydrogen Methane CH Total mass of methane Ethane C2He Total mass of ethane Propane C3Hs Total mass of propane Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbonyl sulfide Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of hydrochloric acid Carbon Dioxide CO2 Total mass of carbon dioxide Water Vapor H20 Total mass of water vapor Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Oxygen O2 Total mass of oxygen Total Total of the individual components listed above This item is highlighted in yellow Integrated Environmental Control Model User Manual Water Gas Shift Reactor 325 Water Gas Shift Reactor Capital Cost Results 7 IECH Interface 326 e Water Gas Shift Reactor File Edit View Go Window Help Configure Plant Set Parameters Get Results By Prod Mgmt Sulfur Removal SHEE Power Block Water Gas Shift Process Area Costs ae Water Gas Shift Plant Costs High Temperature Reactor Low Temperature Reactor 2 General Facilities Capital 6 608 Heat Exchangers 3 Eng amp Home Office Fees 4 405 Project Contingency Cost 6 608 Process Contingency Cost 2 203 Interest Charges AFUDC 10 56 7 Royalty Fees 0 2203 8 Preproductio
7. In Furnace Controls Flue Gas result screen The Flue Gas result screen for In Furnace Controls displays a table of quantities of gas components entering and exiting the combustion zone For each component quantities are given in both moles and mass per hour It also displays quantities of gas components exiting the convective zone in moles per hour Each result is described briefly below Major Flue Gas Components Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Integrated Environmental Control Model User Manual Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow In Furnace Controls Capital Cost Results This screen is only available for the Combustion Boiler plant type 7 IECH Interface Fie Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results 02 CO2 By Prod Control Control Capture Mgmt eeds Combustion NOx Process Area
8. Choose session window To add additional session to your graph use the Add button immediately to the right of this area A session chooser window will be displayed as shown in the figure above Up to five additional sessions can be selected The sessions may come from multiple session database files For more information on session databases see Session Database Files The sessions you add will be reflected in the graph chooser window All those shown will be displayed in a graph when you click the Ok button on the graph chooser window Difference Graphs Graph Session Chooser Mid Orsstieccstoupt ooo cumune provan ha Combustion CCS user manual idb Combustion Ba ser manual idb The graph chooser window can be used to display the difference in a variable across multiple sessions 396 e Working with Graphs Integrated Environmental Control Model User Manual Graph Window The graphing window can also display the difference between the currently selected variable and the same variable in one to five other sessions The result is a unique method of examining differences between key results across different modeling sessions The first step to graphing difference graphs is the click the Difference check box at the top of the graph chooser window The next step is to select other sessions to compare with the current session This is described in Selecting Multiple Sessions on page 395 Finall
9. cseccssseessseecceeecsseeceseeceseeeesaeecseeecesaeeneeeesaes 275 Amine System Capital Cost Results 0 ccc ceeseeeseecssceecesecnseecsaeeceseesseeeesaeeeseaeessnereaeeesea 275 MEA Scrubber Process Area Costs cccsscssseecescecessaeecssecsseesseessseeeesaeeesaeeeenes 276 MEA Scrubber Plant Costs s sssisisccacsstiaseslicssiaseavssnaaicasneaisneensshaasawissesteunas 278 Amine System O amp M Cost Results cee ceeeeeeseecsscecssececneeeesaeecsaeecsscecseecssaeeesseecneessneeesee 279 Nariable Cost Components sti nanie E E a a aeS 279 Fixed Cost Components 22 3 cicsscslecssugeusgtasdaysdashatia a E a A RE EERS 280 Amine System Total Cost Res ltsiini riiui ninaa e E aE aa ES 281 Cost Compo ente toia E Ea a EEn TET Ri EEES 281 Amine System Cost Factors Results eesseeseesseessesereeerttesrtsrtsressressreretesetessrerseresereereserese 282 Important Performance and Cost Factors ssseesseeseeesreesreerreeerresrseresereseresereeereee 282 Cost of CO Ayolde d a te teeta E S 283 O2 CO2 Recycle 285 OCO Recycle Configuration ae aaae seh cA ania Mone wile E AOE E bee Als 285 O5 CO Recycle Performance Inputs 00 eeseeescecsseeeeseeceseecsneecsseecsseecesaeeeseaeecaeeseseeeees 286 O CO Recycle CO Storage Inputs 2 0 eee ceseeececesseecesseeeccesseeecessaeeeeecesaesessaseeees 287 O5 CO Recycle Retrofit Cost Inputs eee eeeeceeeseeeeseeenseecsaeecsseessseeessaeeessaeesneesseeeeee 2
10. L Plant Pef 7 3 MassInOut U 5 TotalCost 6 Cost Summary Overall IGCC Plant Gas Emissions result screen Stack Gas Component Each result is described briefly below Nitrogen N2 Total mass of nitrogen Integrated Environmental Control Model User Manual Overall IGCC Plant 67 Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total Gases Total of the individual components listed above This item is highlighted in yellow Total SOx equivalent SO Total mass of SO as equivalent SO Total NOx equivalent NO3 Total mass of NO as equivalent NO Overall IGCC Plant Total Cost Results 68 e Overall IGCC Plant zix File Edit View Go Window Help Configure Plant Set Parameters Get Results Air Gasifier Sulfur i By Prod Separation Area Removal Fuel Mgmt CO2 Capture Power Block Technology 1 Air Separation Unit Gasifier Area Particulate Control Sulfur Control alp le o B 9 0 ia us
11. Costs are in Constant 2005 dollars Process Type Cold Side ESP z 2 Flue Gas 3 Capital Cost 4 O amp M Cost 3 Total Cost Cold Side ESP Capital Costs results screen Direct Capital Costs Each process area direct capital cost is a reduced form model based on regression analysis of data collected from several reports and analyses of particulate control technology units They are described in general below The primary factors in the model that effect the capital costs of the cold side ESP are the specific and total collection areas of the T R plate sets and the flue gas flow rate through the ESP The primary model factors that effect the capital costs of the fabric filter are the fabric filter type the air to cloth ratio the number of bags and compartments and the flue gas flow rate through the fabric filter Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen The parameters are described below Particulate Collector This area covers the material and labor flange to flange for the equipment and labor cost for installation of the entire collection system Ductwork This area includes the material and labor for the ductwork needed to distribute flue gas to the inlet flange and from the outlet flange to a common duct leading to the suction side of the ID fan Fly Ash Handling The complete fly ash handling cost includes the conveyor syst
12. Configure Plant Set Parameters Get Results CO2 Capture Power Block Lae Stack gmt Percent Total Annual Fixed Cost i i 26 63 Annual Variable Cost 9 401 Annualized Capital Cost 64 07 zis S 2 mle le meo Process Type 1 Sulfur Capture System Costs are in Constant 2005 dollars 2 Capital Cost 3 O amp M Cost 4 Total Cost Sulfur Removal Total Cost results screen Integrated Environmental Control Model User Manual Sulfur Removal 341 The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Sulfur Removal Unit Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taki
13. Integrated Environmental Control Model User Manual Contents xi By Product Management 349 By Product Management Performance Inputs c ceeseesseeceseceeeeeeesseeesaeecseeesseeeesaeeees 349 By Product Management Sequestration Input 0 0 00 ee eesecsseeesseceeeeecssseeesseecseeesteeeesaeeees 350 By Products Management Bottom Ash Pond Diagram ceeeeeesceceeeeeeseeeceeeceeseeeeeee 350 By Products Management Flue Gas Treatment Diagram cceesceceeeeceeeeceseneeceeseeeeeee 351 By Products Management Fly Ash Disposal Diagram eeseeesceeeseeeceeeeeeseeeneesseeeeee 353 By Products Management Geological Resevoir Diagram esceeeseeceeeeeesneeeneeseneeeee 354 CO Transport System 355 CO Transport System Configuration ce eeseeescecsseecessneecseesaeecseecsseeesseeesssaeessereneeeeee 355 CO Transport System Financing Inputs ee eeeeecceeseeeceseesseeceseeeesaeecsaeecseeesseaeessaeers 356 CO Transport System Retrofit Costs Inputs 0 0 0 eeeeesecsseeeseseeceeeeesaeessaeecseeeeseeeeseaeers 357 Capital Cost Process Area vs ois cin aul eh iis a e a ea 358 CO Transport System Capital Cost Inputs eeeeeceeeseecsneeceeseceseeeesaeecsaeecseeesneeecesaeers 359 CO Transport System O amp M Cost Inputs eee eeeeeeeesseceeeseeecesseeeecesseeecessseeseesesaaees 360 CO Transport System Diagram cee eeeeceseecsseecceeecescecesaeecsaeecseecsseeecesseecsaeesaeessneeesee
14. Configure Plant Set Parameters Get Results Capture Power Block Game Fixed Cost Component 33 87 Operating Labor Oil 1 777 Maintenance Labor Other Fuels 4 331e 02 Maintenance Material Misc Chemicals 0 0 Admin amp Support Labor Electricity 2 339 Water 0 4464 Slag Disposal 1 511 izis t a mel e alelo Costs are in Constant 2005 dollars Taye 74 capiaicon WOE G TotalCon Gasifier O amp M Cost results screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Variable Cost Component Coal This is the annual cost of the coal used by the gasifier Oil This is the annual cost of the oil consumed by the gasifier Other Fuels This is the annual cost of any other fuels used by the gasifier Misc Chemicals This is the annual cost of the miscellaneous chemicals used by the gasifier Electricity The cost of electricity consumed by the processes in the gasifier area Water This is the annual cost of the water used by the gasifier Slag Disposal This is the solid disposal cost per year for the GE entrained flow reactor Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Integrated Environmental Control Model User Manual Gasifier 131 Fixed Cost Comp
15. Hydrochloric Acid HCD 0 5750 0 4025 0 1725 1 048e 02 7 338e 03 27 39 11 74 1 253 0 8771 Bis ele Sulfur Dioxide S02 39 12 Sulfuric Acid equivalent S03 0 3534 0 2474 0 1060 1 415e 02 9 902e 03 Nitric Oxide NO 54 36 38 05 16 31 0 8156 0 5709 Nitrogen Dioxide NOJ 2 861 2 003 0 8583 6 582e 02 4 607e 02 Ammonia NH3 oo oO 0 0 00 0 0 Argon At 3481 2437 1044 69 53 48 67 CRA AH amp WH _ cil 4 Process Type FG Recycle amp Purification 7 MEE eoe 4 Coptalon OEM Con 7 6 TotalCon O gt CO Recycle Flue Gas DCC Gas result screen Major Flue Gas Components Each result is described briefly below Nitrogen N2 Total mass of nitrogen Integrated Environmental Control Model User Manual Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow O 2 CO2 Recycle Purificati
16. Le gt T R RCM 2 Performance 3 RetroftCost 4 CapitalCost 5 0 amp MCost Wet Cooling Tower Config Input Screen The parameters are described briefly below Air Flow Draft Control Type This option determines the type of air flow draft Natural or Forced The Natural draft utilizes buoyancy to make natural rising of air through the tower whereas the Forced draft uses the fan at the intake to force air through the tower The choice of draft type has an effect on tower evaporation loss Currently only Forced draft type is available Slip Stream Treatment System This option determines whether a slip stream treatment system is loaded The choice Yes or No of a slip stream treatment system depends on site specific quality of cooling water in the closed loop recirculating system Makeup Water Treatment System This option determines whether a makeup water treatment system is needed The choice Yes or No of a makeup water treatment system depends on site specific quality of makeup water for the cooling system Wet Cooling Tower Performance Inputs This screen is available for all plant types Inputs for performance of the Wet Cooling Tower technology are entered on the Performance input screen Each parameter is described briefly below Integrated Environmental Control Model User Manual Water Systems e 7 8 e Wate
17. 7 IECH Interface Fie Edit Yiew Go Window Help Configure Plant ae e aloje Sorbent Injection iol x Us Untitled ioi x Set Parameters Get Results s 0 0 502 CO2 By Prod Control Capture Mgmt Stack Mercury Removal Plant Costs General Facilities Capital 1 7452 03 Sorbent Recycle 0 0 ale nie Eng amp Home Office Fees 3 489e 03 Additional Ductwork 0 0 Project Contingency Cost 234e 03 Sorbent Disposal 0 0 Process Contingency Cost 1 745e 03 CEMS Upgrade 3 489e 02 Interest Charges AFUDC 2 246e 08 Zj tt Pulse Jet Fabric Filter 0 0 Royalty Fees 0 0 jajajaja Freproduction Startup Cost 77506 03 10 ll Inventory Working Capital 2 355e 04 12 13 14 15 Activated Carbon Inj Costs are in Constant 2005 dollars 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost Mercury Capital Cost result screen 186 e Mercury Integrated Environmental Control Model User Manual Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Direct Capital Costs The direct capital costs described here apply to the various mercury control equipment added to the power plant These controls may physically be part of other control technologies but hav
18. Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Integrated Environmental Control Model User Manual Fabric Filter e 221 Wet FGD The SO2 Control Technology Navigation contains screens that address post combustion air pollution technologies for Sulfur Dioxide The model includes options for a Wet FGD The screens are available if this SO control technology has been selected in Configure Plant for the Combustion Boiler plant type Wet FGD Configuration This screen is only available for the Combustion Boiler plant type Inputs for configuration of the Wet FGD SO control technology are entered on the Config input screen 7 IECM Interface Eile Edit View Window Help
19. Important Performance and Cost Factors Value Cost of CO2 Avoided Annual Operating Hours hours 6575 CO2 Emissions lbs kWh Annual CO2 Removed tons y1 2 550e 06 Cost of Electricity IMWh ASU Energy MW 77 40 Reference Plant Bis lt CO2 Emissions lbs kWh Flue Gas Fan Energy MW 0 2393 Cost of Electricity MWh 1 A 3 4 5 6 7 8 Flue Gas Cooling Energy MW 4 334 9 CO2 Purification Energy MW 6 983 Cost of CO2 Avoided ton 10 CO2 Compression Energy MW 41 51 Total Recycle Purification Energy MW 53 06 12 13 u 15 Fixed Charge Factor fraction 0 1480 Process Type FG Recycle amp Purification Costs are in Constant 2003 dollars 2 DCC Gas 4 Capital Cost 5 0 amp MCost 6 TotalCost 7 Misc The Misc result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Flue Gas Recycle portion of the CO2 Control technology Each result is described briefly below Important Performance and Cost Factors This screen displays information that is key to the model calculations The data is available else where in the model Net Plant Size MW This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties Annual Operating Hours hours This is the number of
20. Monte Carlo Monte Carlo is the simplest and best known sampling method It draws values at random from the uncertainty distribution of each input variable in the decision tree For a particular sampling run each input variable is randomly sampled once The random samples from each input result in one final output value This process is repeated m times and results in a final solution set This set can then be evaluated with standard statistical techniques to determine the mean precision and confidence 404 e Running a Probabilistic Analysis Integrated Environmental Control Model User Manual This method has the advantage of providing an easy method of determining the precision for a specific number of samples using standard statistical techniques However it suffers from requiring a large number of samples for a given precision It also has the drawback of substantial noise in the resulting distribution For these reasons Latin Hypercube sampling is preferred as the model default Latin Hypercube Latin Hypercube is a stratified sampling method that divides the sampling space into equally probable intervals or strata For each input variable the method samples each interval in a random order When the samples from each input variable are combined one resultant output is determined This process is repeated m times forming a final result of m output values These m output values contain the uncertainty of the output variable based on al
21. cee eesccesseecsseeceeeecseecseeceseeeesaeecsaeerceeeeeseesteeeesaes 340 Fixed Cost Components sssini ee i E N A T E N a ar 341 Sulfur Removal Total Cost Results ecceecesssccesseecceeecsneeesseecsseeeesaeecsaeeeceseeseseeseaeeesaes 341 Cost Component oasen atin Had ive al a Hae Ried 342 Sulfur Removal Hydrolyzer Syngas Results ceeeceeseccsscecssccecesecseecsseeeeseeeesaeesseeeesee 342 Major Syngas Components eeseceeseecsseeesesseeceeecseeesseecesaeessaeecssaeesesaeeneeeesaes 342 Sulfur Removal Selexol Sulfur System Syngas Results eeeeeeceeseeeeneceeeseeeneeeeseeeeeaes 343 Major Syngas Components ceeececescecesneeessseeceeecseeecsseecesseessaeecsaeesesaeeneeeesaes 343 Sulfur Removal Claus Plant Air Results 00 0 0 eeseeescecsseccesseceeeessseecsacesseeeeseeeesaaeessneeesee 344 Major Syngas Components eescccsseeceseeessneeceeessseeceseeeesseeesaeecseesesaesnaeeesaes 344 Sulfur Removal Claus Plant Treated Gas Results cee eesceesceceseeceeseceeecseecseeceeneeesaes 345 Major Syngas Components ceine iein a a taas 345 Sulfur Removal Beavon Stretford Plant Treated Gas Results ce eeseeeseeeeseeeeseeeneeeeeaee 346 Major Syngas Components seesccesseecesseeessseeceeecsseecsseeeeseeeesaeecsacesesaeeneeeesaes 346 Sulfur Removal Beavon Stretford Plant Flue Gas Results 000 0 eeseeeseesseeseseeeceseeeneeeesaes 347 Major Flue Gas Components miesi aina orra e E AAE a a Eees 347
22. 8 e le o h o 0 Heating Value Btu lb Carbon wt Hydrogen wt Oxygen wt Chlorine wt Sulfur wt Nitrogen wt Ash wt Moisture wt Process Type Coal Properties Y 1 Diagram Fuel Diagram result screen for coal Coal Flow Rate ton hr Configure Plant Air Preheater 166 7 Bituminous 1 326e 04 73 81 4 880 6 410 6 000e 02 2 130 1 420 7 240 5 050 c02 Capture Trace Element Flows Mercury Ib ht 3 799e 02 The Coal Diagram result screen displays fuel composition and flow rate information which is described briefly below Coal Flow Rate Coal flow rate into the boiler on a wet basis Waste products removed prior to the burners are not considered here Rank The rank of the coal based on the higher heating value This is primarily determined by the higher heating value and to a lesser degree by the sulfur and ash content Heating Value Higher heating value HHV is the thermal energy produced in Btu lb of fuel wet from completely burning the fuel to produce carbon dioxide and liquid water The latent heat of condensation is included in the value Carbon The carbon content of the coal by weight on an elemental and wet basis Hydrogen The hydrogen content of the coal by weight on an elemental H and wet basis Oxygen The oxygen content of the coal by weight on an elemental O and wet basis Chlorine The chlorine content of the coa
23. Each parameter is described briefly below Capital Cost Process Area Cooling Tower Structure This area deals with the cooling tower and installation The erected tower includes structure fans motors gear boxes fill drift eliminators etc Circulation Pumps This area deals with the circulating cooling water pumps Auxiliary Systems This area deals with a closed loop process that utilizes a higher quality water to remove heat from ancillary equipments and transfers that heat to the main circulating cooling water system Piping This area deals with the circuiting cooling water piping The piping system is equipped with butterfly isolation valves and all required expansion joints Makeup Water System This area deals with the capital equipments to provide makeup water for the cooling system Component Cooling Water System This area deals with the component cooling water system Foundation amp Structures This area deals with the circulating water system foundation and structures Wet Cooling Tower Capital Cost Inputs This screen is available for all plant types 10 e Water Systems Integrated Environmental Control Model User Manual 7 ECM Interface Eile Edit view Go Window Help Untitled Ea Configure Plant Set Parameters Get Results l F e o Title i Cale Min Max Default 0 2600 10 00 3000 1 2 3 General Facilities Capital j 0 0 50 00 10 00 4 Engineering amp Home Office Fees 0 0 50
24. Ele alelo Costs are in Constant 2005 dollars 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost In Furnace Controls Total Cost result screen Cost Component The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the In Furnace Controls NO Control technology These costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Note that all costs expressed in ton of NO removed assume tons of equivalent NO Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Integrated Environmental Control Model User Manual In Furnace Controls 153 Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The
25. Integrated Environmental Control Model User Manual Amine System 261 An auxiliary boiler may be added to the amine system to produced additional power and steam It is accessed by using the Process Type menu at the bottom of the input screen Use this menu to return to the amine system input screens If an auxiliary boiler is specified the following parameters are available Gas Boiler Efficiency This is the percentage of fuel input energy transferred to steam in the boiler The model default is based on standard algorithms described in the literature It takes into consideration the energy losses due to inefficient heat transfer across the preheater latent heat of evaporation incomplete combustion radiation losses and unaccounted losses Excess Air This is the excess theoretical air used for combustion in the auxiliary boiler Nitrogen Oxide Emission Rate This parameter establishes the level of NOx emissions from the boiler The default value reflects the AP 42 EPA emission factor which is a function of boiler firing method and the coal rank The value is given in pounds of equivalent NO2 per ton of coal Percent of NO as NO This parameter establishes the level of nitric oxide NO in the flue gas stream The remainder of the total NOx emissions is assumed to be nitrogen dioxide NO2 The default parameter reflects the AP 42 EPA emission factor which is dependent on the fuel type Steam Turbine Efficiency The steam
26. Process Contingency Cost Royalty Fees z 2 2 8 oleo Pre Production Costs Months of Fixed O amp M Months of Variable O amp M Misc Capital Cost Inventory Capital TCR Recovery Factor j 100 0 oo 1000 Process Type Air Separation z Costs are in Constant 2000 dollars 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Air Separation Capital Cost input screen Inputs for capital costs are entered on the Capital Cost input screen Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty
27. The value shown is determined without regard to particular mercury control methods It has a substantial effect on the amount of activated carbon needed to meet the required removal of mercury Cold Side ESP oxidized The cold side ESP typically removes some mercury without adding a specific mercury control technology This mercury is present in the ash and is removed with the collected ash When a mercury control technology is added the removal is enhanced The default value is set to meet the overall removal efficiency constraint with consideration given to the mercury removed by flue gas desulfurization and elemental mercury oxidized in a NO control technology The lower limit is set by the removal efficiency of ash alone as specified by Cold Side ESP total w o control specified above Integrated Environmental Control Model User Manual Mercury Carbon Cold Side ESP elemental Elemental mercury is assumed to be removed with the same efficiency as the removal of oxidized mercury specified above Wet FGD Wet FGD oxidized The wet lime limestone FGD typically removes all the oxidized mercury due to its high solubility in water Wet FGD elemental Elemental mercury is assumed to pass through the wet lime limestone FGD It is assumed that elemental mercury is present in the flue gas and is unreactive Spray Dryer Spray Dryer oxidized Oxidized mercury is assumed to pass through the lime spray dryer Although s
28. Total Total of the individual components listed above This item is highlighted in yellow Sulfur Removal Beavon Stretford Plant Treated Gas Results 346 e Sulfur Removal 7 IECM Interface J File Edit View Window Help Major Gas Componenis Hydrogen H2 Methane CH4 Ethane C2H6 Propane C3H8 Hydrogen Sulfide H25 Carbonyl Sulfide COS Ammonia NH3 9 Hydrochloric Acid HC 10 Carbon Dioxide CO2 11 Water Vapor H20 12 Nitrogen ND 13 Argon An zis 2 mlel le moeloo ele alain awn Process Type 3 Beavon Stretford Plant E 1 Treated Gas 2 Flue Gas Sulfur Removal Beavon Stretford Plant Treated Gas results screen Major Syngas Components Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H2 Total mass of hydrogen Methane CH Total mass of methane Ethane C2He Total mass of ethane Propane C3Hg Total mass of propane Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbonyl sulfide Ammonia NHs Total mass of ammonia Integrated Environmental Control Model User Manual Hydrochloric Acid HCI Total mass of hydrochloric acid Carbon Dioxide CO2 Total mass of carbon dioxide Water Vapor H20 Total mass of water vapor Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Oxygen O2 Total mass of oxygen Total Total of the individual components listed ab
29. Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Integrated Environmental Control Model User Manual Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Makeup Water System Results This screen is only available for pulverized coal power plants Major outputs are briefly described below 7 IECM Interface 6 2 ile Edit Yiew Go Window Help ie Untitled Configure Plant Set Parameters Get Results 502 Control le ojejo Boiler Makeup tons hr No cooling tower r Bot Ash Sluice tons h r C5 ESP Sluice ton
30. Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow 348 Sulfur Removal Integrated Environmental Control Model User Manual By Product Management The ByProduct Mgmt Technology Navigation Tab screens display and design the management of by products and waste disposal By Product Management Performance Inputs 7 IECM Interface 10l x File Edit View Window Help Bottom Ash Pond Energy Require f Fly Ash Disposal Power Requirem Flue Gas Waste Disposal Power R P E iF Zj i Process Type Waste Management z 1 Performance By Product Management Performance input screen General inputs regarding solid waste management are entered on the Performance input screen This screen is displayed for all plant configurations One or more of the following By Product Management options will be shown on the input screen depending upon the options selected in the Configure Plant program area Each of the possible parameters are described briefly below Bottom Ash Pond Energy Requirements The energy requirement is zero by default Any requirements are considered by the abatement technologies that dispose solids into the bottom ash pond Fly Ash Disposal Power Requirements The energy requirement is zero by default
31. Us Untitled Configure Plant Set Parameters Reagent Limestor Limestone Flue Gas Bypass Control No Bypa No Bypass zi amp P e oleo DADANE Process Type wet FGD z 1 Config 3 Additives 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Wet FGD Config Input screen no bypass Each parameter is described briefly below Reagent For Wet FGD systems the choice of reagent affects nearly all of the performance and economic parameters of the FGD Three choices are available Integrated Environmental Control Model User Manual Wet FGD e 223 224 e Wet FGD Limestone Limestone with Forced Oxidation A limestone slurry is used in an open spray tower with in situ oxidation to remove SO and form a gypsum sludge The main advantages as compared to conventional systems are easier dewatering more economical disposal of scrubber products and decreased scaling on tower walls Limestone with Additives Limestone with Dibasic Acid Additive Dibasic acid DBA is added to the Limestone to act as a buffer catalyst in the open spray tower The main advantages are increased SO removal and decreased liquid to gas ratio Lime Magnesium Enhanced Lime System A magnesium sulfite and lime slurry maglime is used to remove SO and form a precipitate high in calcium sulfite The high alkalinity of the maglime slurry allows very hi
32. aleo Blele alainlaleo in CO2 Sequestration Use MW 0 0 Net Plant Efficiency HHV 25 62 Net Electrical Output MW 331 8 Process Type overall Plant z 2 Plant Perf 4 Solids In Out 6 TotalCost f7 Cost Summary Combustion Overall Plant Plant Perf result screen The Plant Perf result screen displays performance results for the plant as a whole Heat rates and power in and out of the power plant are given Each result is described briefly below Performance Parameter Net Electrical Output This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties Primary Fuel Power Input This is the fuel energy input for the plant given on an hourly basis maximum capacity This rate is also referred to as the fuel power input Aux Fuel Power Input This is the fuel energy input for the auxiliary natural gas boiler if used with the Amine System This is additional fuel energy used by the plant given on an hourly basis This rate is also referred to as the auxiliary fuel power input Integrated Environmental Control Model User Manual Total Plant Power Input This is the total of all the fuel energy used by the plant given on an hourly basis maximum capacity This rate is also referred to as the total plant power input Gross Plant Heat Rate This is the heat rate of the gross cycle including th
33. pet et COE Wn Cold Side ESP Costs are in Constant 2005 dollars 2 Retrofit Cost 3 Capital Cost 4 0 amp M Cost Cold Side ESP O amp M Cost screen input O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Inputs for the operation and maintenance costs of the particulate control technology are entered on this screen Waste Disposal Cost This is the disposal cost for the particulate control system Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is defined as combustion boiler and an air preheater Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be develo
34. ssseeeseeeeeeereesererireerieresererereesreserereresereeseree 376 xii e Contents Integrated Environmental Control Model User Manual Power Block Retrofit Cost wets cet caeccsvccs a a hn Re cae ene a 376 Power Block Retrofit Cost Input Parameters 0 cc eeceeeeecssseeeesneeeeneeeseeeeseeeesaes 377 Power Block Capital Cost Inputs eee eesesesecssceecesecensecesseecsaeecsseecseeeeceneecsaeesseeseaeeesee 377 Power Block O amp M Cost Inputs ceeeecescssseecssececeeeessceeesaeecseecseecsseeeessaeecsaeesaeesseeeeea 379 Power Block Gas Turbine Diagram ceesceeescessseeccnseeesseessaeecsseecseecesaeecesaeecseeseneeesns 380 Air Entering COmpressor ccscccsscccsscecessececeeecsscecseecsseeeesseeesaeecesseesseeesseeeesaes 381 Syngas Entering Combustor sii sienne ae a E a a E ANEA 381 Heated Syngas Entering Combustor seeeseeeseesreesrrerieterrertseresereeereserereresereeseres 381 Flue Gas Exiting Gas Turbifesisininnini ntn ai ae aE 381 Power Blo k Steam Diagrani seisin eaa sas RE E E EE EE Gi 381 Flue Gas Exiting Steam Generator eeseeeseecesecesseeesaeecsseecseeseseeeeseeeesaaeeeees 382 Flue Gas Entering Steam Generator ees eesccesseeceseecesssecseecseeceseeeeseeeesneeeeees 382 Power Block Syngas Results sis scesicssec iana AE e EEEE E Gi 382 Major Syngas Component i sei rein e e aT RG 383 Power Block Flue Gas Results ssis scsec aseaissecsaseszeyast onde a EE T a E a G 383 Major
35. 66 Plant Outputs 333 20sati cesar Sect earci heal sels ovarian hile Bae 67 Overall IGCC Plant Gas Emissions Results ccccssssescccccccescseeeccccssceeesseecsccssseeensesseuees 67 Stack Gas Component sist sats cslicussceaheed Pet cheysheGheed gut coho deol Shas AEE ASEE EAEE 67 Overall IGCC Plant Total Cost Results ccccccccccccececccceccccceecccceeecceseusccsseecceesecssseeeeseees 68 Technology opite n E E A EE EEES 69 Overall IGCC Plant Cost Summary Results eee cecseceecceneeecesseeeceseeeeeeseeeeeseesaeees 70 Technology erini E ares A E AE E E ESSE 70 Fuel 73 Fuel Properties Coal Inputt srr nnns n R A 73 Selectin Gea Fuel eines vevedes staves Gd cave hove caus ses func devs cnet inns EETA EKTA SEEEN EEES EKES evi 76 M difying a Fielies Pos eee eoeta naen ee cals Sed ses levi thu EVEEN TE EE EE E O eaS 76 Integrated Environmental Control Model User Manual Savina Modified Fuel 3 0 0h vee baie eee eae eee alin ed 77 Deleting a Field ss a e e Ee EEEa mate ea eae eee AEE S 77 Ope Database 2 25 55 581 ih ihe See eee ah Ben eat ate aoe es 71 New Database ae e e sane E Ea E CEA OKE E santa E Eea eE EN ESS 77 Buel Mercury inputs ene hous choses Recetas ide a T cu eattsbe ona e E E a n 78 Concentration on a Dry Basis scceeseesscessseeecececsseeeeseeeesaeecsacesseeeessaeenseessaeers 78 Mercury Speciation i sceisseeissosds E e A E EE E RSA 79 Fuel Cost Input ion eaa a E ET E E a A Ea 79
36. Any requirements are considered by the abatement technologies that dispose of fly ash Integrated Environmental Control Model User Manual By Product Management e 349 Flue Gas Waste Disposal Power Requirements The energy requirement is zero by default Any requirements are considered by the abatement technologies that dispose of flue gas waste By Product Management Sequestration Input 7 IECM Interface Dj x Eile Edit View Window Help Configure Plant Emission Fuel Base Plant Constraint Title i i Max Default 1 Sequestration Power Requirement i y 25 00 0 0 ajel le mpole Fa Z E 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 By Product Management Sequestration input screen If the user has selected CO Capture in the Configure Plant program area this input screen will also be available Its parameter is described briefly below Sequestration Power Requirement The energy requirement is zero by default By Products Management Bottom Ash Pond Diagram The By Product Management Technology Navigation Tab screens displays the flow rates of solid and liquid substances collected which require management disposal or recovery There are three By Product Management areas Bottom Ash Pond Flue Gas Treatment and Fly Ash Disposal If CO2 Capture has been configured for the plant by the user then a Geological Reservoir is also
37. Configure Plant Set Parameters Get Results By Prod Mgmt Power Block NOx Control CO2 Capture NGCC CO Configuration e Post Combustion Controls CO2 Capture Amine System z t R Dele oo 1 Diagram 2 Plant Perf 5 Total Cost 6 Cost Summary Overall NGCC Plant Diagram input screen The Overall NGCC Plant Diagram appears in the Configure Plant Set Parameters and in the Get Results program area The screen displays the plant configuration settings on the left side of the page and a diagram of the configured plant on the right of the page No input parameters or results are displayed on this screen Integrated Environmental Control Model User Manual Overall NGCC Plant 43 Overall NGCC Plant Performance Inputs 44 e Overall NGCC Plant File Edit View Go Window Help Configure Plant Set Parameters Get Results tical Output MWg 516 5 100 0 Net Electrical Output W 506 100 0 MW output for reference only Ambient Air Temperature 130 0 77 00 Ambient Air Pressure psia 15 00 14 70 9 Ambient Air Humidity tb H20 lb dry air 1 800e 02 3 000e 02 1 800e 02 izis e le S me aeoo See Power Block tab for additional parameters Process Type overall Plant J 2 Perfomance OEM Cost Overall NGCC Plant Performance input screen The parameters available on this screen establish the plant availability electrical re
38. Cost of CO Avoided Cost of Electricity cap Cost of Electricity ref CO emissions ref CO emissions cap Integrated Environmental Control Model User Manual Selexol CO Capture IGCC systems use less energy intensive physical absorption processes to capture CO than post combustion chemical absorption processes required by the Combustion Boiler or Combustion Turbine plant types Physical absorption using Selexol solvent is currently the most effective technique for removing CO from IGCC fuel gases The CO capture using Selexol is described in the following section Selexol CO Capture Reference Plant Inputs This screen is only available for the IGCC plant type File Edit View Window Help j Configure Plant Set Parameters Get Results Overall Plant s a Power Block emoval C Title 2 Avoided Cost Calculation Reference Plant CO2 Emission Rate Cost of Electricity aje le lololo Ze oja aja wn alo N Process Type 2 Selexol CO2 Capture X 1 Reference Plant 3 CO2 Storage 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Selexol CO Capture Reference Plant input screen Reference Plant CO Emission Rate This is the emission rate for the reference power plant without CO capture Cost of Electricity This is the cost of electricity for the reference power plant without CO capture Integrated Environmental Control
39. K20 The percent by weight of potassium oxide in the ash TiOz The percent by weight of titanium dioxide in the ash MnO The percent by weight of manganese dioxide in the ash P205 The percent by weight of phosphorus pentoxide in the ash SO3 The percent by weight of sulfur trioxide in the ash The Current Fuel pane displays two check boxes that are grayed out when the model_default_fuels mdb database file is currently open If a personal fuel Integrated Environmental Control Model User Manual Fuel e 75 76 o Fuel database is opened these two check boxes become active The check boxes serve to allow the fuel to be available to multiple plant types or fuel types The current fuel must be saved to make the restrictions permanent Once saved all new sessions will use these filters to determine which fuels will be listed in the Fuel menu These check boxes are Plant Types This is a filtering agent that specifies whether or not this fuel is restricted to the current plant type If the box is not checked the fuel will only be available to new sessions with the same plant type as the current session If the box is checked the fuel will be available to all new sessions regardless of their plant type Fuel Types This is a filtering agent that specifies whether or not this fuel is restricted to a particular fuel type If the box is not checked the fuel will only be available to new sessions that use the same primary fuel type as
40. Overall IGCC Plant Mass In Out result screen Plant Inputs Coal Flow rate of coal used in the power plant Oil Flow rate of oil used in the power plant Natural Gas Flow rate of natural gas used in the power plant Petroleum Coke Total mass of petroleum coke used in the power plant Other Fuels Flow rate of other fuels used in the power plant Total Fuels This is the flow rate of fuel entering the power plant This result is highlighted in yellow Lime Limestone Total mass of this reagent used in the power plant on a wet basis Sorbent Total mass of sorbent used in the power plant Ammonia Total mass of ammonia used in the power plant Activated Carbon Flow rate of activated carbon injected in the power plant Other Chemicals Solvents amp Catalyst Flow rate of other chemicals solvents and catalysts used in the power plant Total Chemicals Flow rate of reagent entering the power plant This result is highlighted in yellow Oxidant Flow rate of oxidant entering the power plant This includes oxygen nitrogen and argon Process Water Flow rate of water used in the power plant Integrated Environmental Control Model User Manual Plant Outputs Slag Flow rate of slag from the power plant on a dry basis Ash Disposed Flow rate of ash from the power plant on a dry basis Other Solids Disposed Flow rate of scrubber and other treatment solid wastes from the power plant on a dry basis Particulate Emissi
41. Reactor Housing The reactor housing costs include carbon steel reactor vessel with six inches of mineral wool insulation vessel internals and supports steam soot blowers reactor crane and hoist installation labor foundations structures piping and electrical equipment The costs are 168 Hot Side SCR Integrated Environmental Control Model User Manual a function of the number of vessels including spares and the volume of catalyst required Catalyst costs are excluded Ammonia Injection The ammonia unloading storage and supply system includes a storage vessel with a seven day capacity an ammonia vaporizer mixer injection grid ductwork dampers and a truck unloading station The costs are a function of the ammonia injected Ducts The ductwork includes economizer bypass and outlet ducts SCR inlet and outlet ducts SCR and economizer control dampers air preheater inlet plenum various expansion joints in the ductwork and air preheater cross over ducting The costs are a function of the flue gas flow rate through the SCR Air Preheater Modifications Thicker and smoother material is used for the heat transfer surfaces in the preheater A larger motor is provided for the heat exchanger High pressure steam soot blowers and water wash spray nozzles are also added The costs are a function of the number of operating vessels and the heat transfer efficiency of the air preheater UA product ID Fan Differential The ID fans m
42. The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Integrated Environmental Control Model User Manual Selexol CO2 Capture 309 Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Transport and Storage Costs e CO Transportation Cost This is the cost of moving the CO i e pipeline truck to the place where it will be sequestered e CO Disposal Cost This is the cost of sequestering the CO Selexol CO Capture Diagram 310 e Selexol CO2 Capture This screen is only available for the IGCC plant type y IECM Interface File Edit View Go Window Help poies Untitled e Configure Plant Set Parameters Get Results z Power Block gra 8 amp Temperature Out CF Syngas Out tons hr e a e Temperature In F Syngas In tons hr g R To Storage CO2 Product tons h 469 7 CO2 Pressure psia 2000 Process Type AETAT X 1 Diagram 2 Syngas 3 Capital Cost 4 O amp M Cost 5 Total Cost Selexol CO Capture Diagram resu
43. This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Integrated Environmental Control Model User Manual Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of T
44. This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start Integrated Environmental Control Model User Manual Water Systems e 11 up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant in
45. Total of the individual components listed above This item is highlighted in yellow Amine System Capital Cost Results This screen is only available for the Combustion Boiler and Combustion Turbine plant types Integrated Environmental Control Model User Manual Amine System e 275 276 e Amine System 7 IECH Interface File Edit View Go Window Help s e Configure Plant Set Parameters Get Results ic S02 Control 8 aw MEA Scrubber Process Area Costs Sore MEA Scrubber Plant Costs M a 1 Flue Gas Blower 2 478 A General Facilities Capital CO2 Absorber Vessel 35 02 3 Eng amp Home Office Fees Heat Exchangers 2 545 4 Project Contingency Cost Circulation Pumps 5 243 5 Process Contingency Cost Sorbent Regenerator 19 20 6 Interest Charges AFUDC T 8 Zj tt Reboiler 11 72 Royalty Fees Steam Extractor T 1 188 Preproduction Startup Cost Sorbent Reclaimer 7 966 9 Inventory OW orking Capital Sorbent Pt ir 10 25 10 Drying and Compression Unit 26 84 11 Awxiliary Natural Gas Boiler 0 0 12 Auxiliary Steam Turbine 0 0 13 14 lalalaja a w n 15 Process Type Amine System Costs are in Constant 2005 dollars A 206M Con 6 Totalcon Amine System Capital Cost result screen The Capital Cost result screen displays tables for the capital costs Capital costs are typically expressed in either constant or current dollars for a specified year as sh
46. Total unit change can be used to determine the volume percent and weight percent of the components of the flue gas This is possible when viewing the Gas Summary result table for any control technology Cost Table The Cost Table option determines the units in which values are displayed on cost result screens The choices available are M Cap M yr O amp M and kW Cap mills kWh O amp M The default setting is M Cap M yr O amp M Cost Year The Cost Year option determines the year for which values are displayed on cost result screens You may choose any year between 1977 and 1998 The default setting is 1996 Inflation Control The Inflation Ctrl option determines the method by which inflation is calculated for cost result screens The choices available are Constant and Current The default setting is Constant 392 Units Integrated Environmental Control Model User Manual Working with Graphs Graph Chooser The table and diagram results displayed on the Get Results screens are all deterministic values that is uncertainties are not taken into consideration Probabilistic results with uncertainties taken into consideration can be displayed in graphical format as a supplement to every deterministic value shown The graph chooser window opens when any value displayed on a result screen is double clicked The figure below shows the initial graph window Graph Session Chooser xi Line 2D I Difference X Axis T
47. Transport amp Stora e nosine oa T EEE E E ali hires 305 Selexol CO Capture Retrofit Cost Inputs ccc eesceeeseeceseecceseessseecsacecseeeeseeeesaeeeeseeese 305 Capital Cost Process Area eoi is cosa sob vous cculeced saad beeen n cancun ceuteeet eubouent aia 306 Selexol CO Capture Capital Cost Inputs eee eesceceseceeseeeecsseesaeecsseecseeesseeeesaeeeeeeeenee 307 Selexol CO Capture O amp M Cost Inputs eee eeseeceesscsceecseceecesneeecessaeeesesaeesesesseeeees 308 Selexol CO Capture Didgram icc secisk n an e E cba nes Sie Rael 310 Selexol CO Capture Syngas Results eee ce ceesececceceseeceeseeecessseeeceseeeeeceesaeeessaeeeees 311 Major Syngas Components iacente a tonia 311 Selexol CO Capture Capital Cost Results cece eesceceseecesceecesseesneeceaeecsseeeeseeeesaeeeseeeesee 312 Selexol CO Capture O amp M Cost Results ee eeecceesseecesesseecesneeecesseeeeeesseeeeesesseeeees 314 Selexol CO Capture Total Cost Results 2 0 eee eeecceeesseceecscecenseeeceesseeeesseeeseeeeseeeres 315 x Contents Integrated Environmental Control Model User Manual Cost COMpPOne Nis aie Hele il E aE eee elias as abate E se ened eee 316 Selexol CO Capture Cost Factors Results 0 0 0 eee eeeesceceeceeseeceseeeseesaeeeeeseeesesseseeeees 316 Water Gas Shift Reactor 319 Water Gas Shift Reactor Performance Inputs eesceescecesseeeceseeeneecsseeceseeeesaeesseeeeseaes 319 Water Gas Shift Reactor Unit eee eeeeeeseccsseeccn
48. UCB Sulfur Total mass flow of other solids in the flue gas This includes unburned carbon or unburned sulfur from the boiler Water Total mass flow of condensed water associated with the solids stream This is more clearly represented in what is considered liquid streams See the Gas In Out screen for a summary of the evaporated water flow rate through the power plant Integrated Environmental Control Model User Manual Combustion Overall Plant Gas Emissions Hal File Edit View Go Window Help Gas Components at technology exit APH aaa APH ree Ee iT Post Comb unless neied n Bee b moles hr Ib moles hr h moles hr tb moles hr h moles hr 1 081e 05 1 081e 05 Oxygen 02 2 900e 04 i 2 900e 04 Water Vapor H20 3988 i 3988 Carbon Dioxide COZ 0 0 i 0 0 Carbon Monoxide CO 0 0 0 0 Hydrochloric Acid HCD 0 0 i 0 0 Sulfur Dioxide S02 0 0 i 0 0 Sulfuric Acid equivalent 503 0 0 i 0 0 9 Nitric Oxide NO 0 0 i 0 0 10 Nitrogen Dioxide NO2 0 0 i 0 0 11 Ammonia NH3 0 0 i 0 0 12 Argon An 1292 K 1292 As Tot atte oo aaae 14 z R alal le ollo 15 K Process Type overal Plant z 2 Plant Perf 3 Mass In Out 4 Solids In Out a WERE 6 TotalCost 7 Cost Summary Combustion Overall Plant Gas Emissions result screen The Gas In Out result screen displays the values for the flow of the gas components in the flue gas throughout t
49. baffles through which ash falls into the hoppers after rapping The major design parameters which can significantly impact the total system capital cost are gas flow volume which depends on the generating unit size SCA the collecting plate area per transformer rectifier T R set and the spacing between collector plates Particulate Removal Efficiency The calculated value determines the removal efficiency needed to comply with the specified particulate emission limit set earlier This efficiency then determines the mass of particulate matter removed in the collector Actual SO Removal Efficiency The default value is taken from the removal efficiency reported in the literature references are below This efficiency then determines the mass of SO removed from the flue gas in the collector For more information see also e www netl doe gov publications proceedings 98 98fg hardman pdf e www netl doe gov publications proceedings 98 98fg rubin pdf Collector Plate Spacing The collector plate spacing is typically 12 inches The spacing is used to determine the specific collection area Specific Collection Area The specific collection area SCA is the ratio of the total plate area and flue gas volume It sizes the ESP The value is calculated from the removal efficiency plate spacing and the drift velocity It is used to determine the capital cost and the total collection area required Plate Area per T R Set This is the total s
50. capital investment It is also the period over which an investment is recovered through book depreciation Real Bond Interest Rate This is a debt security associated with a loan or mortgage It is the most secure form of security but the lowest in its return Real Preferred Stock Return This equity security is the second most speculative type and pays the second highest rate of return The holder of the stock is a part owner of the company Real Common Stock Return This is the most speculative type of equity security sold by a utility and pays the highest relative return The holder of the stock is a part owner of the company Percent Debt This is the percent of the total capitalization that is associated with debt money This includes loans and mortgage bonds Percent Equity Preferred Stock This is the percent of the total capitalization that is associated with the sale of preferred stock Percent Equity Common Stock This value is the remainder of the capitalization calculated as 100 minus the percent debt minus the percent equity in preferred stock Federal Tax Rate This is the federal tax rate It is used to calculate the amount of taxes paid and deferred State Tax Rate This is the state tax rate It is used to calculate the amount of taxes paid and deferred Property Tax Rate The property tax rate or ad valorem is used to calculate the carrying charge Investment Tax Credit This is an immediate reduction in
51. column may be plate type or a packed one Most of the CO absorbers are packed columns using some kind of polymer based packing to provide large interfacial area Sorbent Concentration The solvent used for CO absorption is a mixture of monoethanolamine MEA with water MEA is a highly corrosive liquid especially in the presence of oxygen and carbon dioxide and hence needs to be diluted Today the commercially available MEA based technology supplied by Fluor Daniel uses 30 Integrated Environmental Control Model User Manual w w MEA solvent with the help of some corrosion inhibitors Other suppliers who do not use this inhibitor prefer to use lower MEA concentrations in the range of 15 20 by weight Lean CO Loading Ideally the solvent will be completely regenerated on application of heat in the regenerator section Actually even on applying heat not all the MEA molecules are freed from CO So the regenerated or lean solvent contains some left over CO2 The level of lean solvent CO loading mainly depends upon the initial CO loading in the solvent and the amount of regeneration heat supplied or alternatively the regeneration heat requirement depends on the allowable level of lean sorbent loading Nominal Sorbent Loss MEA is a reactive solvent In spite of dilution with water and use of inhibitors a small quantity of MEA is lost through various unwanted reactions mainly the polymerization reaction to form long chai
52. construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The percent of the water gas shift reactor TCR that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor Integrated Environmental Control Model User Manual Water Gas Shift Reactor e 327 Water Gas Shift Reactor O amp M Cost Results 328 e Water Gas Shift Reactor Fi
53. energy used for reheat plus the actual electrical output power required It is calculated as a function of the sulfur flow from the Claus plant Tailgas Treatment Note The number of trains for this area is the same as the number of trains for the Claus plant process area 332 e Sulfur Removal Integrated Environmental Control Model User Manual Sulfur Recovery Efficiency This is the recovery efficiency of the Beavon Stretford plant in generating elemental sulfur The remainder is oxidized to SO and sent to a stack Power Requirement This is the equivalent electrical output of thermal steam energy used for reheat plus the actual electrical output power required for all three technologies above It is calculated as a function of the sulfur flow rate from the Beavon Stretford plant Sulfur Removal Retrofit Cost Inputs 7 IECH Interface Fie Edit View Go Window Help 0 DA Untitled eS Configure Plant Set Parameters Get Results wi i O2 Capture Power Bloc Stack coze PowerBlock PET Stack 8 Title Units w Capital Cost Process Area COS Conversion System Hydrol retro new e Sulfur Removal System Selexol retro new Sulfur Recovery System Claus retro new El Tail Gas Treatment Beavon Stret retro new Ka gt R 3 Capital Cost 4 O amp M Cost Sulfur Removal Retrofit Cost input screen Capital Cost Process
54. for a fabric filter that has been paid off Gasifier O amp M Cost Inputs This screen is only available for the IGCC plant type 124 e Gasifier Integrated Environmental Control Model User Manual 7 ECM Interface File Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results CO2 Capture Power Block ee Title Units Max Son 30 00 Water Cost 1000 gal il 2 500 Electricity Price Base Plant Sawn 200 0 Number of Operating Jobs jobs shift 30 00 Number of Operating Shifts shifts day y 10 00 Operating Labor Rate hr j 100 0 Total Maintenance Cost TPC b 10 00 Maint Cost Allocated to Labor total 100 0 I Administrative amp Support Cost total labor i 100 0 izis t e mel e olo Costs are in Constant 2005 dollars 2 Syngas Out 3 Retrofit Cost 4 Capital Cost 5 O amp M Cost Gasifier O amp M Cost input screen Inputs for O amp M costs are entered on the Gasifier O amp M Cost input screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Slag Disposal Cost This is the solid disposal cost per ton Water Cost This is the cost of the water per 1000 gallons Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of
55. installation and may be set as low as 0 for a fabric filter that has been paid off Amine System O amp M Cost Inputs This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECH Interface ioj xi Fie Edit View Go Window Help my Untitled Configure Plant Set Parameters By Prod Base Plant Mercury Mgmt Title Units iton 0 0 1 500e 04 Inhibitor Cost of MEA 0 0 100 0 Activated Carbon Cost _ i ton Z 500 0 5000 Caustic NaOH Cost ton o0 2000 Water Cost 1000 gal o0 2500 Reclaimer Waste Disposal Cost ton 0 0 300 0 Electricity Price Base Plant M 0 0 200 0 Number of Operating Jobs jobs shift 0 0 10 00 Number of Operating Shifts shifts day 10 00 ul Operating Labor Rate hr 100 0 12 Total Maintenance Cost TPC 10 00 13 Maint Cost Allocated to Labor total il 100 0 14 Administrative amp Support Cost total labor i 100 0 15 16 CO2 Transport and Storage Costs 17 CO2 Transportation Cost ton 2 266 A 0 0 10 00 zj lt 2 ale B mlo 18 Process Type Amine System oa Cosis are in Constant 2005 dollars 1 Config 4 CO2 Storage 5 RetrofitCost 6 CapitalCost WAOU RLN Amine System O amp M Cost input screen Inputs for operation and maintenance are entered on the O amp M Cost input O amp M costs are typically expressed on an average annual basis and are provide
56. shown here for information only Net Plant Size This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties It is shown here for information only Ambient Air Temperature This is the inlet temperature of the ambient combustion air prior to entering the preheater The model presumes an annual average temperature Inlet air temperature affects the boiler energy balance and efficiency It provides a reference point for the calculation of pressure throughout the system Currently the model cannot have temperatures below 77 F Ambient Air Pressure This is the absolute pressure of the air inlet stream to the boiler The air pressure is used to convert flue gas molar flow rates to volume flow rates Ambient Air Humidity This is the water content of the inlet combustion air This value is used in calculating the total water vapor content of the flue gas stream The value is referred to as the specific humidity ratio expressed as a ratio of the water mass to the dry air mass 58 e Overall IGCC Plant Integrated Environmental Control Model User Manual Overall IGCC Plant Constraints Inputs The Constraints input parameters define the emission constraints as they apply to the gases emitted from the power plant Constraints for sulfur dioxide nitrogen dioxides carbon dioxide and mercury are not needed due to the cleaner emissions from IGCC plants 7 IECH
57. the auxiliary power requirements and the capital cost of the SCR technology A layer may be interpreted as either a full layer e g Integrated Environmental Control Model User Manual Hot Side SCR e 157 typically 1 meter deep or a half layer e g typically 0 5 meters deep to represent alternative SCR catalyst replacement schemes There is a limit of 8 total initial and reserve layers e Dummy Layers This is the number of dummy catalyst layers The value must be an integer A dummy layer corrects the flow distribution It is used to calculate the total pressure drop across the SCR and the auxiliary power requirements e Initial Layers This is the number of initial active catalyst layers The value must be an integer Three layers are installed initially It is used to calculate the total pressure drop across the SCR and the auxiliary power requirements e Reserve Layers This is the number of reserve or extra catalyst layers These are available for later catalyst additions The value must be an integer It is used to calculate the total pressure drop across the SCR and the auxiliary power requirements Catalyst Replacement Interval This parameter calculates the operating hour interval between catalyst replacements The interval is determined by the decision to replace all at once or each of them separately after each interval Currently the model is not set up to replace two half layers simultaneously Catalyst Space Velocity
58. the boiler must be modified to suit the new oxyfuel combustion system The cost for these modifications is estimated as a percentage of the cost of the boiler Flue Gas Recycle Fan The cost of the fan required for recycling part of the flue gas is scaled on the basis of the flow rate of the flue gas being recycled Flue Gas Recycle Ducts Additional ducting is necessary to recycle part of the flue gas in the oxyfuel combustion system The cost of this Integrated Environmental Control Model User Manual O2 CO2 Recycle e 289 ducting is assumed to be a function of the flow rate of recycled flue gas Oxygen Heater In addition to the air preheater that exists in a conventional PC plant the oxyfuel combustion system includes an additional heat exchanger called the oxygen heater for better heat integration The cost of this heat exchanger is scaled on the basis of the gross plant size Direct Contact Cooler The cost of the flue gas cooler is scaled on the basis of the flow rate of the flue gas CO Compression System The multi stage compression unit with inter stage cooling and drying yields the final CO product at the specified pressure about 2000 psig that contains only acceptable levels of moisture and other impurities e g N2 The size and cost of this unit will be a function of the CO product compression power O CO Recycle Capital Cost Inputs This screen is available for Combustion Boiler plant types File Edit V
59. 0 0 Sulfur Dioxide 02 oo 0 0 Sulfuric Acid equivalent 503 0 0 0 0 Nitric Oxide NO i 0 0 0 0 Nitrogen Dioxide NO2 i oo 0 0 Ammonia NH3 0 0 0 0 Argon Ar 0 0 1292 Major Air Componenis Air Preheater Flue Gas result screen Oxidant Gas Components The Oxidant result screen displays a table of quantities of air or recycled flue gas components entering and exiting the air preheater For each component entering and exiting in flue gas values are given in both moles and mass per hour For each component entering in atmospheric air values are given in moles per hour Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO3 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Integrated Environmental Control Model User Manual Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Integrated Environmental Control Model User Manual Air
60. 1 227e 06 7 441e 02 3 533e 03 Ash Removal 503 Removal Mercury Removal Dry Ash ton hi Sluice Water ton hr 0 0 o8e q Wet Ash ton hr Process Type Fabric Filter z 1 Diagram 2 Flue Gas 3CopitalCost 40 amp MCost 5 TotalCost Fabric Filter Diagram Each result is described briefly below Flue Gas Entering Filter Temperature In Temperature of the flue gas entering the particulate control technology This is determined by the flue gas outlet temperature of the module upstream of the air preheater e g the air preheater Flue Gas In Volumetric flow rate of the flue gas entering the particulate control technology based on the flue gas inlet temperature and atmospheric pressure Fly Ash In Total solids mass flow rate in the flue gas entering the air preheater This is determined by the solids exiting the module upstream of the particulate control technology e g the air preheater Mercury In Total mass of mercury entering the particulate control technology The value is a sum of all the forms of mercury elemental oxidized and particulate Flue Gas Exiting Filter Temperature Out Temperature of the flue gas exiting the particulate control technology The model currently does not alter this temperature through the particulate control technology Integrated Environmental Control Model User Manual Flue Gas Out Volumetric flow rate of the flue gas exiting the particu
61. 3 301 2811e 02 2811e 02 9 Hydrochloric Acid HCD 0 0 0 0 0 0 10 Carbon Dioxide CO2 2 302e 04 2 302e 04 506 5 11 Water Vapor H20 7483 7483 67 42 12 Nitrogen ND 363 6 363 6 5 092 13 Argon Ad 442 8 442 8 8 844 14 Oxygen 02 0 0 0 0 0 0 15 Process Type 3 Selexol Sulfur System Selexol Sulfur System Syngas results screen Major Syngas Components Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H2 Total mass of hydrogen Methane CH Total mass of methane Integrated Environmental Control Model User Manual Sulfur Removal e 343 Ethane C2He Total mass of ethane Propane C3Hg Total mass of propane Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbonyl sulfide Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of hydrochloric acid Carbon Dioxide CO2 Total mass of carbon dioxide Water Vapor H20 Total mass of water vapor Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Oxygen O2 Total mass of oxygen Total Total of the individual components listed above This item is highlighted in yellow Sulfur Removal Claus Plant Air Results 7 IECM Interface E 10J 344 e Sulfur Removal D alaj le lo P o i Blo File Edit View Window Help LI cx Set Parameters Get Results Configure Plant CO2 Capture Power Block Poe Stack A
62. 98 or better or Windows NT 4 0 or better operating system e Pentium Processor Integrated Environmental Control Model User Manual Introduction 3 e any SVGA or better display at a resolution of 800x600 or more 1 pixels e at least 40 Megabytes of free hard disk space e atleast 128 Megabytes of total memory Uncertainty Features The ability to characterize uncertainties explicitly is a feature unique to this model As many as one hundred input parameters can be assigned probability distributions When input parameters are uncertain an uncertainty distribution of results is returned Such result distributions give the likelihood of a particular value in contrast to conventional single value estimates The model can run using single deterministic values or uncertainty distributions The conventional deterministic form using single values for all input parameters and results may be used or probabilistic analyses may be run for instance to analyze advanced technology costs see Appendix A for more details Software Used in Development The underlying engineering models are written in Intel Visual Fortran Fortran runtime libraries are included with the IECM Interface software This language provides the flexibility to configure many various power plant designs while also providing the power to conduct probabilistic analyses All databases are in Microsoft Access format and may be viewed in Access as long as they
63. A aeaea a eea eae e eaa A e ea sees 407 Philosophy of Uncertainty Analysis cccscccecsesccceeesececeseeeeesneeeceseeeeeesnaeeceeseeeeeseneeeees 408 Types of Uncertain Quantities cececccecessecceeesneneeccseeeeessaeeeeesneecensaeeceecsaeeessenneeeeneeeeees 408 Encoding Uncertainties as Probability Distributions ccescceceeesececeeeneeeeeeteeeeeseneeeees 408 Statistical Technniques ccccsescceesssseeeceeeeeecseneeecesenececseseeeeescneeeesenaeeeesennteeeeeae 409 Judgments about Uncertainties 0 cececccceessecceeeseeeeeeesceeceesaceceesneeeceseaeaeeeesenaees 409 Designing an Elicitation Protocol ccccssscceeeenceeeeceeeeeseaceecesnneeeeesaeeeceeseeaeeecseeeeensaeeeees 410 A Non techinical Example vic sca niet As ietin intial etitindenaihetiada daca E EAE a 411 A Techincal Examples a devs readers Ea Ea EASON 411 Appendix B Technical Support 413 Reaching Technical SUpport eree a E E E ET RE 413 Carnegie Mellon University ccccecsescceesesececeeseeeecesneeeeeeeeeeceenneeeeceseeeeneeeeees 413 National Energy Technology Laboratory 0 ceescceeseeceseeeeseneeceeeceeesseeesseeeesaes 413 Glossary of Terms 415 Index 417 Integrated Environmental Control Model User Manual Disclaimer This report was prepared as an account of work sponsored by an agency of the United States Government Neither the United States Government nor any agency thereof nor any of their emplo
64. Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Effective TCR The TCR of the spray dryer that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor Gasifier O amp M Cost Results This screen is only available for the IGCC plant type File Edit View Go Window Help
65. Ammonia Parameters Ammonia Deposition on Fly Ash This is the percent of the ammonia slip that is absorbed onto the fly ash It is treated like a partition coefficient This is important for high dust systems Ammonia in High Conc Wash Water The ammonia that deposits in the air preheater is periodically removed by washing It is initially highly concentrated and requires denitrification pretreatment prior to regular treatment This is the average concentration in that stream Ammonia in Low Conc Wash Water The ammonia that deposits in the air preheater is periodically removed by washing The concentration is initially high but gradually decreases This is the average concentration of the low concentration stream Ammonia Removed from Wash Water The ammonia that deposits in the air preheater is periodically removed by washing This is the average amount of ammonia removed from the high and low concentrated streams Hot Side SCR Retrofit Cost This screen is only available for the Combustion Boiler plant type 160 Hot Side SCR Integrated Environmental Control Model User Manual 7 IECH Interface ioj xi Fie Edit View Go Window Help Configure Plant Set Parameters Get Results c02 Base Plant Mercury Capture Title Units Capital Cost Process Area Reactor Housing retro new Ammonia Injection retro new Ducts retro new Air Preheater Modifications retro new ID Fan Differential retro new Struc
66. CO2 Capture Power Block Post Combustion NOx Control Blo e e Emission Taxes Process Type overall Plant X Costs are in Constant 2005 dollars 2 Plant Perf 3 Mass In Out 5 Total Cost 6 Cost Summary Overall IGCC Plant Total Cost result screen The Total Cost result screen displays a table which totals the annual fixed variable operations maintenance and capital costs associated with the power plant as a whole Each technology row is described briefly below Integrated Environmental Control Model User Manual Technology Air Separation Unit This is the capital cost for the Air Separation process area of the plant Gasifier Area This is the capital cost for the equipment in the gasifier process area of the plant Particulate Control This is the capital cost for the equipment that performs particulate capture in the plant Sulfur Control This is the capital cost for the equipment that performs sulfur capture in the plant Mercury Control This is the capital cost for the mercury process area of the plant CO Capture This is the capital cost for the equipment that performs CO capture in the plant Power Block This is the capital cost for the power block process area of the plant Post Combustion NO Control This is the capital cost for the equipment that captures post combustion NO in the plant Subtotal This is the cost of the conventional and advanced abatement t
67. CO2 Storage Cost shon f 5452 A500 60 00 18 Process Type fe Selexol CO2 Capture gt Costs are in Constant 2005 dollars 1 Reference Plant 3 CO2 Storage 4 Retrofit Cost 5 Capital Cost 6 O amp M Cos Selexol CO Capture O amp M Cost input screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen The following inputs for operating and maintenance costs are available Bulk Reagent Storage Time This is the reagent stored at the plant Glycol Cost This is the cost in ton for glycol that is used by the Selexol CO capture system Waste Disposal Cost This is the cost of disposing the water that is used in the Selexol CO capture process Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is an air separation unit gasifier and the power block Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate
68. Consiant 2007 dollars 1 Config 3 Retrofit Cost 4 Capital Cost 5 0 Air Cooled Condenser O amp M Cost Input Screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each parameter is described briefly below Waste Disposal Cost This is the waste disposal cost for the wet tower Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is a combustion boiler and an air preheater Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total main
69. Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area Integrated Environmental Control Model User Manual Gasifier 123 by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout maj
70. Control Model User Manual Water Systems e 13 Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Wet Cooling Tower Diagram This screen is available for all plant type The Diagram result screen displays an icon for the Wet Cooling Tower selected and values for major flows in and out of it 7 IECM Interface File Edit view Go Window Help sds Untitled Configure Plant Set Parameters Get Results Drift Loss tons h 0 5548 e Evaporation tons ht 940 2 Makeup Water tons h Water In tons h 548e 4 Temperature In CF 90 00 Water Out tons hr 5 548e 4 Temperature Out F 70 00 Makeup Underflow Basin Sludge tons ht 4 278e 5 see separate diagram Blowdown tons hi 312 8 Process Type et Cooling Tower zi 1 Diagram A 3 O amp M Cost 4 Total Cost Wet Cooling Tower Diagram Each result is described briefly below Cooling Water Entering Wet Tower Water In The amount of recirculating cooling water entering the wet tower That depends on the plant size steam cycle heat rate and cooling water temperature drop range That is the sum of cooling water through the main steam cycle and amine based carbon capture system if applicable Temperature In The temperature of recircualting cooling water entering the wet tower Cooling Water Exiting Wet Tower Water Out The amount of recirculating c
71. Cost Air Cooled Condenser Config Input Screen The parameters are described briefly below Integrated Environmental Control Model User Manual Water Systems e 21 Condenser Type This menu controls the configuration of the condenser In practice there are two condenser types Single Row or Multiple Row There is only a Multiple Row condenser modeled in the current version Configuration This menu shows the geometry of the dry cooling system framework An air cooled condenser is comprised of fin tube bundles grouped together in parallel and arranged typically in an A frame configuration The A Frame configuration usually has an apex angle of 60 Air Cooled Condenser Performance Inputs This screen is only available for all plant types Inputs for performance of the Air Cooled Condenser technology are entered on the Performance input screen 7 IECM Interface File Edit View Go Window Help ER D eer Configure Plant g Set Parameters i Get Results Title i Value Cale Min Max Default Air Cooled Condenser Ambient Air Temp Dry Bulb Avg 77 00 15 00 100 0 77 00 Inlet Steam Temperature 126 1 100 0 160 0 Cale FenEfficiency MH 90 00 _ 0 100 0 2000 Condenser Plot Area per cell sqft 1186 538 2 2691 1186 Steam Cycle Turbine Back Pressure inches Hg 4 000 2000 8 000 4 000 Aur Heat Exch Load soo oo 10 00 cae 2A nn e amp wn Primary Steam Cycle
72. Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow 330 e Water Gas Shift Reactor Integrated Environmental Control Model User Manual Sulfur Removal SO emissions from IGCC systems are controlled by removing sulfur species from the syngas prior to combustion in the gas turbine The syngas is assumed to be scrubbed of particulates prior to entering the sulfur removal system and is further cooled to 101 F prior to entering a Selexol acid gas separation unit HS and COS are removed from the syngas in the Selexol unit and sent to a Claus plant and a Beavon Stretford tail gas treatment unit for sulfur recovery The sulfur recovered can be sold as a by product and credited to the sulfur removal technology area Sulfur Removal Performance Inputs x File Edit view Window Help o Configure Plant By Prod Overall Plant Separation TO Mgmt Hydrolyzer or Shift Reactor COS to H25 Conversion Efficiency Sulfur Removal Unit COS Removal Efficiency s il 100 0 calc CO2 Removal Efficiency i 98 00 calc Max Syngas Capacity per Train tb mole hr i 3 000e 04 2 500e 04 Number of Operating Absorbers integer Menu calc Power Requirement MWe 4 K 6 000 calc Claus Plant Max Sulfur Capacity per Train tofhr 1 000e 04 ii 1 500e 0411 000e 04 Number of Operating Absorbers integer 2 Menu calc Power Requirement MWe
73. Cost 76 18 3 4 Annualized Capital Cost 20 15 t alel o e e o Process Type Amine System Costs are in Constant 2005 dollars 4 CapitalCost 7 5 OGM 6 Tocos Amine System Total Cost result screen The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Amine System CO Control technology Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Integrated Environmental Control Model User Manual Amine System 281 Total Levelized Annual Cost The total annual cost is the sum of the total
74. Costs Saa Combustion NOx Plant Costs Combustion NOx Capital Requirement SNCR Capital Requirement zis t me aeoo laaan eal cd H Process Type n Furnace Controls Costs are in Constant 2005 dollars 2 Flue Gas 2 Capital Cost 4 0 amp M Cost 5 Total Cost In Furnace Controls Capital Cost result screen The Capital Cost result screen displays tables for the direct and indirect capital costs related to the In Furnace Controls NO control technology Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Total Capital Costs Combustion NOx Capital Requirement The total capital costs including retrofit costs for the LNB OFA and gas reburn technologies are included here A zero is displayed when none of these technologies are installed SNCR Capital Requirement The total capital costs including retrofit costs for the SNCR technology is included here A zero is displayed when an SNCR is not installed Total Capital Requirement Sum of the above Effective TCR The TCR of the retrofit NO controls that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor for the hot side SCR Integrated Environmental Control Model User Manual In Furnace Controls 151 In Furnace Controls O amp M Cost Results 152 e In Furnace Contr
75. Dioxide S02 The user may enter a cost to the plant of emitting sulfur dioxide in dollars per ton Nitrogen Oxide equiv NO3 The user may enter a cost to the plant of emitting nitrogen oxide in dollars per ton Carbon Dioxide CO2 The user may enter a cost to the plant of emitting carbon dioxide in dollars per ton Integrated Environmental Control Model User Manual Overall IGCC Plant 63 Overall IGCC Plant Performance Results y IECH Interface 64 e Overall IGCC Plant File Edit View Go Window Help 2 Untitled ol x Configure Plant Set Parameters Get Results CO2 Capture Power Block Performance Parameter Value Net Electrical Output MW 442 4 Total Plant Power Input MBtwfhr 4940 Gross Plant Heat Rate HHV Btu kWh 9166 Net Plant Heat Rate HHV Btu kWh 1 117e 04 Plant Energy Requirements Total Generator Output MW Air Compressor Use MW Turbine Shaft Losses MW Gross Plant Output MWg Misc Power Block Use MW Air Separation Unit Use MW Gasifier Use MW Sulfur Capture Use MW Claus Plant Use MW Beavon Stretford Use MW Wrater Gas Shift Reactor Use MW Selexol CO2 Capture Use MW Net Electrical Output MW t mlel aleo Annual Operating Hours hours 6575 Annual Power Generation BkWh yr 2 909 e ped cal cal eed jo m Net Plant Efficiency HHY 30 56 3 Overan Plant z 2 Plant Perf 3 Mass In
76. Fixed Cost Comiponents ii iin eener nee E O A E a Eaa Tea 110 Boiler Total Cost Res ltsi msnen ie A ena e tn aid 110 Cost Componenf kaeni ei ee a e EEA ovens EET aE 111 Auxiliary Boiler 113 Auxiliary Boiler Diagrams i ccciccccicievescesicvesdeanccascans E e EA TE Y 113 Auxiliary Boiler Natural Gas Results ccceseeesceceseeeessneceseecsseecsseecseecesaeeessaeecneessaeeeene 114 Natural Gas Components 2 scsvsceccevscsascusscanssvetecassveccoussvcconssaveseessued cdevebessvesantesees 115 Auxiliary Boiler Flue Gas Results cceeseeescecsscecesecececeeesaeeesaeesseecsseeseseaeessaessaeessaeeesee 116 Integrated Environmental Control Model User Manual Contents v vi e Contents Major Flue Gas Components ceseccesseessseecceeecsceceseeeesseessaeecsaeesceaeeneeeesaes 116 Auxiliary Boiler Costs Results 0 eeeeseseesseecesseeceeecesceeesaeecsseecsseecsseaecseeesaeessaeesseeenee 117 Gasifier 119 Gasifier Performance Inputs esceeeeccesseecssececsseceseecescecssaeecsseecseeceesaecnaeeesaeessaeeseneesees 119 AGES Wo ig cr ete er aeea e ae kes ET 119 Raw Gas Cleanup Area oee enone an eseon er see aane oaa Nerep nes ara eae NaS ESE ieee ene 120 Gasifier Syngas TNPutS r e meprise geen a eaaa eera e Ree aaeeea aeea Eepe Eae Eas AEE EAE SE 120 Raw Syngas Composition cescsescccsseecssseeceeeecseecsseecsseeeesseeesseeseseeeeseesseeeesaes 121 Gasifier Retrofit Cost Inputs eceeeeesss
77. Flue Gas Component sccceseccesseessseeceeeecsseeesseecesaeecsaeecsaeeecesaeeeeeesaes 384 Power Block Capital Cost Results urieni annie eina a e E EE Ei 384 Power Block Process Area Costs c ccessccsssessseecesceecesseesneecsaeesseecseeeesaeeeseneeeses 385 Power Block Plant Costs ss 2hcsicnicunsiisiaiedeveiviar ats navi a E NaN 385 Power Block O amp M Cost Results eecceesessseccsseeecesseensecesseecsaeecseecseeeecsaeessaeesseeseaeeesee 386 Variable Cost COMPOMENL eeeescceeseeceseeceeeeeseecsseecsseeessaeessaeerceeeseeesneeeesaes 387 Fixed Cost Component s 0cicateunieeniindsleeiossnateei N A A T a a a 387 Power Block Total Cost Results ceeceeesessseeesscecceeeceseeessaeecsaeecseecsseeecesaeecsaeesaeessneeenea 388 Cost Component sa n R E hate vais ete lata ei 388 Units 391 Units Inputs nasenne nl Qiao id ibe anie dla an dus daar aeaa eee 391 Unit System wicca kek ode eat Lae sel ee ina 391 Units R sullts 0 ccc eylaiiduciin deny diene dest heise di eda Sarean 391 Result Types csssicta itech a idee heats 392 Unit Systeitisscschac sites ata oie tee ee ete ik 392 Time Period sjs cc0 dc dilniak bee id aids Lee ea a 392 Performance Tableau aea eoa ie aaien 392 Cost Tables ee ae aie eddie eke Diageo e Sa 392 COSt Year serae A e O ae et 392 Inflation Controleren eta r aa a er aa a e ian 392 Working with Graphs 393 Graph Chooser i a E aE E E Re a ea NS 393 Graph TYPE s cai TE E ein E be
78. Help 7 s02 coz By Prod i Control Capture Mgmt stack aj Units amp retro new A Ductwork retro new Fly Ash Handling retro new Differential ID Fan ji retro new Zis Let 1 Config PROM 4 Capital Cost 5 O amp M Cost Fabric Filter Retrofit Cost input screen Capital Cost Process Area Particulate Collector This is the cost for the collecting equipment based on actual vendor prices Included in the cost are the mechanical equipment and labor particulate removal system alternate cleaning system gas conditioning system structural supports electrical and instrumentation Ductwork This is the cost of all the mechanical electrical and supports of the ductwork to and from the collector Fly Ash Handling This is the cost of all the mechanical conveyors storage and electrical portions of the ash handling system The costs are based on actual vendor prices Differential ID Fan This area includes the additional cost of the ID fan and the motor due to the pressure loss that results from the particulate Integrated Environmental Control Model User Manual collectors Also included are the erection piping electrical and foundation costs Fabric Filter Capital Cost Inputs This screen is only available for the Combustion Boiler plant type y IECH Interface Fie Edit View Go Window Help Us Untitled Configu
79. Integrated Environmental Control Model User Manual Installing the Model Installation Options Normal installation is described in Getting Started This section addresses installation from a network drive or the worldwide web This section also describes advanced features of the installation program and the files installed Local and Network Installation The Setup program can be run from a local hard drive or a network server Installing from a hard drive eases the burden of sharing one IECM compact disk CD between multiple users Installing from a network server simplifies the process of installing the entire package on a series of personal computers connected to the network However both methods require some familiarity with creating and finding folders and sub directories on a network hard drive NOTE You may also install the interface to a network server All files will be loaded to the server except the shortcut in the start menu of the local personal computer The interface will run from the server and all sessions will be saved to the network drive meaning that others with access to the network drive may change or delete them Installation to a network server is not currently supported Installing the IECM from a Local Hard Drive To install from a local hard drive copy the SETUP EXE installer program from the IECM compact disk CD disk into one sub directory or folder on your personal hard drive 1 On the personal comput
80. Interface Fie Edit View Go Window Help Ei Untitled Configure Plant Set Parameters Get Results Air By Prod Mgmt Particulate Emission Rate 1b MBtu 1 000e 03 Process Type overall Plant 3 Constraints 5 O amp M Cost Overall IGCC Plant Emission Constraints input screen The emission constraints determine the removal efficiencies of control systems that capture particulates The level of capture is set to comply with the specified emission constraints As discussed later however user specified values for control technology performance may cause the plant to over comply or under comply with the emission constraints specified in this screen Each parameter is described briefly below Particulate Emission Constraint The emission constraint of the total suspended particulates is a function of the fuel type and is used to determine the removal efficiency of particulate control systems if used Overall IGCC Plant Financing Inputs Inputs for the financing costs of the base plant itself are entered on the Financing input screen Integrated Environmental Control Model User Manual Overall IGCC Plant 59 60 e Overall IGCC Plant 7 IECH Interface File Edit View Go Window Help US Untitled Configure Plant Set Parameters Get Results By Prod Separation Mgmt Or specify all the following Inflation Rate Plant or Project Book Life Real B
81. Manual In Furnace Controls 143 7 IECH Interface ioj xi File Edit View Go Window Help Configure Plant Set Parameters Get Results c02 Base Plant Mercury Combustion NOx Controls Maimun NOz Removal Eifciency SNCR NOx Control Maximum NOx Removal Efficiency 38 00 Urea Concentration Injected 20 00 SNCR Power Requirement 1 000e 02 CeRAAKH amp wn Sls e le mle la mlo bt pmt pet p Opet pe et AANA WN 18 Process Type Jin Furnace Controls gt 1 Config 2 Performance 3 Capital Cost 4 O amp M Cost In Furnace Controls Performance input screen Inputs for the performance of the In Furnace Controls NO control technology are entered on the on the Performance input screen Combustion NOx Controls These inputs will display if any combustion technology is used in the option selected in the In Furnace Controls pull down menu This includes the LNB LNB OFA Gas Reburn and the LNB SNCR options Combustion NO Controls Actual NOx Removal Efficiency This is the NO removal efficiency of the LNB LNB OFA and Gas Reburn options and the LNB removal portion of the LNB SNCR option The percent reduction of NO is calculated by comparing the actual NO emission to the uncontrolled NO emission The removal is a function of the In Furnace Control type selected in the pull down menu the boiler type and the maximum remova
82. NGCC Plant 47 48 e Overall NGCC Plant File Edit View Go Window Help Configure Plant Set Parameters Get Results By Prod Power Block NOx Control CO2 Capture Mgmt Unc Value Min Max Default Internal COE for Comp Allocations Base Play Menu Menu 5e Plant ui Internal Electricity Price MWh 53 01 0 0 200 0 calc Natural Gas Cost imscf i 5 346 Water Cost 1000 gal 0 8316 0 0 10 00 oo 2500 Limestone Cost ton 19 64 Lime Cost ton 72 01 Ammonia Cost ton 248 2 Urea Cost ton 412 4 MEA Cost iton 1293 12 Activated Carbon Cost ton Bz 13 Caustic NaOH Cost iton 624 7 14 15 Operating Labor Rate hr 24 82 0 0 100 0 16 17 18 Process Type Overall Plant z Costs are in Constant 2005 dollars 0 0 30 00 40 00 90 00 100 0 400 0 200 0 400 0 0 0 1 500e 04 500 0 5000 0 0 2000 CRA AH amp wn zs t S mle le moo SRRRRRK RN Overall NGCC Plant O amp M Cost input screen Internal COE for Comp Allocations This is a pop up selection menu that determines the method for determining electricity costs within the power plant The selection of this pop up menu determines the actual internal electricity price on the next line The options are e Base Plant uncontrolled e User Specified e Total Plant COE Internal Electricity Price This is the price of elect
83. NaOH Cost iton 624 7 14 15 Operating Labor Rate hr 24 82 1 100 0 16 17 18 Process Type Overall Plant z Costs are in Constant 2005 dollars oo 2000 Overall IGCC Plant O amp M Cost input screen Internal COE for Comp Allocations This is a pop up selection menu that determines the method for determining electricity costs within the power plant The selection of this pop up menu determines the actual internal electricity price on the next line The options are e Base Plant uncontrolled e User Specified e Total Plant COE Internal Electricity Price This is the price of electricity and is calculated as a function of the utility cost of the base plant The base plant for the IGCC model is assumed to be a coal pile air separation unit gasifier power block and disposal sites This value is calculated and provided for reference purposes only unless User Specified is selected in the pop up in the previous line As Delivered Coal Cost This is the cost of the coal as delivered Natural Gas Cost This is the cost of natural gas in dollars per thousand standard cubic feet Water Cost This is the cost of water in dollars per thousand gallons Limestone Cost This is the cost of limestone in dollars per ton Lime Cost This is the cost of lime in dollars per ton Ammonia Cost This is the cost of ammonia in dollars per ton Urea Cost This is the cost of natural gas in
84. Nitric Oxide NO 35 11 35 11 05268 0 5268 Nitrogen Dioxide NO2 1 848 1 848 4 251e 02 4 251e 02 Ammonia NH3 2 713 2713 2 310e 02 2 310e 02_ Argon A oo oo oo 0 0 Major Flue Gas Components Process Type Jactivated Carbon Inj Y 2 Flue Gas Mercury Flue Gas result screen Integrated Environmental Control Model User Manual Mercury 185 Major Flue Gas Components Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO3 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Mercury Capital Cost Results This screen is only available for the Combustion Boiler plant type The Capital Cost result screen displays tables for the direct and indirect capital costs related to the water and carbon injection systems both part of the overall mercury control option
85. OFA and Gas Reburn options and the LNB removal portion of the LNB SNCR option This combines the base capital cost with the retrofit cost factor This parameter is not shown when one of these options is not selected SNCR Boiler Modifications This specifies the total capital cost for the SNCR boiler NO removal equipment alone This parameter is not shown when one of the SNCR options is not selected TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for in furnace controls that has been paid off In Furnace Controls O amp M Cost This screen is only available for the Combustion Boiler plant type 146 e In Furnace Controls Integrated Environmental Control Model User Manual File Edit View Go Window Help 5 eS Configure Plant Set Parameters Get Results TSP s02 co2 By Prod Base Plant Mercury Control Control Capture Mgmt Stack 8 Title ue 1 Variable O amp M Costs 2 UreaCost 3 Ammonia Cost e 4 Bll Electricity Price Base Plant ro 6 7 Fixed O amp M Cost gt Fixed O amp M C 8 Combustion Modifications 9 SNCR Boiler Modifications R 1 en mF Process Type fin Furnace Controls gt Costs are in Constant 2005 dollars 1 Config 3 Capital Cost 4 O amp M Cost In Furnace Controls O amp M Cost input sc
86. Once Through Water Systems Results cece eseseceseseeeceeeseeseeeeeaeceeeecsessseeecaeeseeeesaseeeeaes 5 Wet Cooling Tower Configuration cies ecceseesseeeeeeeseceessecseesessecesesesseeesesesaseaeesesaseessaeees 6 Wet Cooling Tower Performance Inputs 00 0 0 eeeesecsseeecsceecesecseeeceseesceessaeseeessaeeeaeeaeeaeeaes 7 Wet Cooling Tower Retrofit Cost Inputs eee eseseceeeseceeeeesseeeeseaeeeseesseseesseseseesaeeaeeaes 9 Wet Cooling Tower Capital Cost Inputs ce ec eesseesesceeeceecsecreeseeseeeeeseaeeessaeesceesseeeeeaee 10 Wet Cooling Tower O amp M Cost Inputs eee ecesessereeseeseesecseeeeseesseeessaeeeseesseseesaeseeeeeaeel 12 Wet Cooling Tower Diagram vec iad ia lat arin me ia Nai hes 14 Cooling Water Entering Wet Tower cccccesseeeeessecesesecseceesaeeeceeessceeseeseeseesaeees 14 Cooling Water Exiting Wet Tower ce cesseeeeeeseceeesecseeseeseesceeeaeeeseasseeesaeens 14 Wet Tower Performance cecececeesecescseeseeeeeseceeeeeseeeceeesaeeesesesaeeessaeeeseessaeeeeeees 15 Wet Cooling Tower Cooling Water Diagram oo ceeceesecnseeeseeeceseesceessaeesseeneeeeaee 15 Wet Cooling Tower Capital Cost Results oo cece ccesseesesceneceessecnsesesseeeseseescnessaseesaeeseeeeaee 16 Wet Cooling Tower O amp M Cost Results 0 eee ccececeeecessseeneeseeseceesesseeeeeseescnessaeeessesseeeeaeed 18 Variable Cost Component cece eeeseeeceeesseeesesesseeseseeseceessaeescecsaesesesseceeesaeens 19 Fixed Cost Components sce knee as ee
87. Out 5 TotalCost 6 Cost Summary Overall IGCC Plant Performance result screen The Plant Perf result screen displays performance results for the plant as a whole Heat rates and power in and out of the power plant are given Each result is described briefly below Performance Parameter Net Electrical Output This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties Total Plant Power Input This is the total of all the fuel energy used by the plant given on an hourly basis maximum capacity This rate is also referred to as the total plant power input Gross Plant Heat Rate HHV This is the gross heat rate of the entire plant Net Plant Heat Rate HHV This is the net heat rate of the entire plant including aux power produced which includes the effect of plant equipment and pollution control equipment Annual Operating Hours This is the number of hours per year that the plant is in operation If a plant runs 24 hours per day seven days per week with no outages the calculation is 24 hours 365 days or 8 760 hours year Annual Power Generation This is the net annual power production of the plant The capacity factor and all power credits or penalties are used in determining its value Net Plant Efficiency HHV This is the net efficiency of the entire plant Integrated Environmental Control Model User Manual Plant Power
88. Post Combustion Controls coco aaa zis llt 2 ilei le olo Configure Plant Combustion Turbine input screen The figure above shows the base configuration of the Combustion Turbine or NGCC plant Only post combustion controls can be configured by the user The following sections describe each popup menu on the configuration screen Pre configuration settings can be selected using the Configuration menu at the top of the screen No Devices is the default Post Combustion Controls CO Capture The default is None The following options are available Integrated Environmental Control Model User Manual e None No CO capture is used e Amine System An MEA scrubber is the only method currently available in the IECM for capturing CO e CO Adsorption This method of CO capture is grayed out in the menu and is planned for a future release of the model e O Transport Membrane This method of CO capture is grayed out in the menu and is planned for a future release of the model e Cryogenics This method of CO capture is grayed out in the menu and is planned for a future release of the model Configuring the IGCC The following configuration options are available when the IGCC is selected as the plant type from the New Session pull down menu 7 IEC Interface File Edit View Go Window Help 0D aj amp B 3 US Untitled Configure Plant Gasification Options Gasifier GE Oxygen blown X G
89. Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a
90. Removal Efficiency z e le aleo Nitrogen Oxide Emission Rate Ib MBtu Percent of NOx as NO Cone of Carbon in Collected Ash Percent of Burned Carbon as CO Process Type Base Plant AMECEA 2 RetrofitCost 4 Capital Cost 5 O amp M Cost Base Plant Furn Factors input screen Each parameter is described briefly below Percent Ash Entering Flue Gas Stream The default values for this parameter are a function of the fuel and boiler types and are based on the AP 42 EPA emission factors Ash not entering the flue gas stream is assumed to be removed as bottom ash This is also referred to as the overhead ash fraction Sulfur Retained in Flyash This parameter gives the percent of total sulfur input to the boiler that is retained in the flyash stream of a coal fired power plant The default values are a function of the selected boiler type and the coal rank as specified by the AP 42 EPA compilation of emission factors Percent of SO as SOs This parameter quantifies the sulfur species in the flue gas stream Sulfur not converted to SO is assumed to be converted to SO3 The default value is based on emission factors derived by Southern Company and are a function of the selected coal Preheater SO Removal Efficiency Sulfuric acid H SO is created downstream of the boiler by the reaction of SO with H20 A percent of the sulfuric acid is conde
91. SCR Diagram This screen is only available for the Combustion Boiler plant type 7 IECM Interface Eile Edit View Window Help Temperature In deg F Flue Gas In acfm Fly Ash In ton hr Mercury In lb hr Ammonia Injection ton hr Preheater 700 0 2 086e 06 9 726 3 633e 02 8 269e 02 Set Parameters 502 Control co2 TSP Mercu Control Capture Temperature Out deg F Flue Gas Out acfm By Prod Mgmt Get Results Stack 700 0 2 093e 06 9 726 3 533e 02 4 985 Steam for Injection ton hr 1 662 Steam for Soot tom hr 0 1652 Initial Catalyst Layers Reserve Catalyst Layers Dummy Catalyst Layers Dry Solids ton hi 0 0 Active Catalyst Layers Fly Ash Out ton hr Mercury Out lb hr i Ammonia Slip ton hr 4 NOx Removal TSP Removal Layers Replaced Yearly Process Type E M Pz Fie Gas 3 Capital Cost 4 OEM Cost __5 Total Cost J 1 Diagram Hot Side SCR Diagram result screen The Diagram result screen displays an icon for the Hot Side SCR NO technology selected and values for major flows in and out of it Reagent Ammonia Injection The total mass flow rate of ammonia injected into the SCR This is a function of the NO concentration in the flue gas and the ammonia stoichiometric performance input value Steam for Injection The total mass flow rate of steam into the SCR This is the amount of steam added to the SCR to vaporize an
92. SNCR Power This is the power used for the pumps to move reagents and water in the SNCR Total Variable Costs This is the sum of the entire variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Integrated Environmental Control Model User Manual Combustion NOx Costs This is the fixed O amp M costs associated with the LNB OFA and gas reburn systems SNCR Boiler Costs This is the fixed O amp M costs associated with the SNCR system Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow In Furnace Controls Total Cost Results This screen is only available for the Combustion Boiler plant type File Edit View Go Window Help Configure Plant Set Parameters Get Results TSP 02 coz By Prod Mercury Control Control Capture Mgmt eidh Percent Total 1 jAnnual Fixed Cost 3 829 2 Annual Variable Cost 3 440 1 572 728 9 58 40 3 TotalAnnulO amp MCost 366s 167s 7767 en 4 Annualized Capital Cost 2225 1 017 471 5 37 78 t
93. Startup Cost 0 8782 Inventory Working Capital 0 6633 t mlel aleo AA na wn DaDa WH 15 Effet TCR O O O sa Costs are in Constant 2005 dollars 3 Capital Cost 4 O amp M Cost 3 Total Cost Spray Dryer Capital Cost result screen The Capital Cost result screen displays tables for the direct and indirect capital costs Capital costs are typically expressed in either constant or current dollars for a Integrated Environmental Control Model User Manual Spray Dryer 253 254 e Spray Dryer specified year as shown on the bottom of the screen Each result is described briefly below Each process area direct capital cost is a reduced form model based on regression analysis of data collected from several reports and analyses of particulate control technology units They are described in general below The primary factors in the model that effect the capital costs of the scrubbers are the flue gas flow rate through the scrubber the composition of the flue gas the reagent stoichiometry and the reagent flow rate Reagent Feed System This area includes all equipment for storage handling and preparation of raw materials reagents and additives used SO Removal System This area deals with the cost of equipment for SO scrubbing such as absorption tower recirculation pumps and other equipment Flue Gas System This area treats the cost of the duct work
94. The base capital costs excluding retrofit using gross KW specify the total base capital costs not considering any retrofit factors No detailed information about Integrated Environmental Control Model User Manual In Furnace Controls 145 direct or indirect costs is given The costs are given as a total in units of dollars per gross kilowatt Combustion Modifications This is the base capital cost of the LNB LNB OFA and Gas Reburn options and the LNB removal portion of the LNB SNCR option This parameter is not shown when one of these options is not selected SNCR Boiler Modifications This specifies the total base capital cost for the SNCR boiler NO removal equipment alone This parameter is not shown when one of the SNCR options is not selected Retrofit Capital Cost Factors Retrofit cost factors allow you to differentiate between the base cost of purchasing the capital equipment and the actual cost incurred These factors vary from unit to unit Combustion Modifications This is the retrofit cost factor for the LNB LNB OFA and Gas Reburn options and the LNB removal portion of the LNB SNCR option This parameter is not shown when one of these options is not selected SNCR Boiler Modifications This is the retrofit cost factor for the SNCR option alone This parameter is not shown when one of the SNCR options is not selected Total Capital Costs Combustion Modifications This is the total capital cost of the LNB LNB
95. This process area PFC is a function of the solvent flow rate the capture CO flow rate and the inlet temperature Power Recovery Turbines The pressure energy in the CO rich solvent is recovered with one or two hydro turbines This process area PFC is a function of the turbine horsepower and the turbine outlet pressure Slump Tanks H CO and CH entrained or absorbed in the solvent is released in the slump tank and recycled back to the absorber Because extra Selexol is used in the absorber only a small amount of CO is released in the slump tank This process area PFC is a function of the solvent flow rate Recycle Compressors The lean solvent is compressed and cooled in preparation for recycling back into the absorbers This process area PFC is a function of the compressor horse power Flash Tanks Most of the CO absorbed by the solvent is recovered through flashing The captured CO is then ready for transport and sequestration To reduce the compression power three flashing tanks with different pressures are used There is no heat demand for solvent Integrated Environmental Control Model User Manual regeneration because solvent recovery is possible through flashing This process area PFC is a function of the solvent flow rate Selexol Pumps The lean solvent fed back into the absorber via pumps This process area PFC is a function of the pump horse power Refrigeration The solvent must be cooled down to the absorber opera
96. Type Jair Cooled Condenser Costs are in Constant 2007 dollars Air Cooled Condenser O amp M Cost Result Screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Disposal Total cost to dispose the collected cleaning wastes Electricity Cost of power consumption of the scrubber This is a function of the gross plant capacity and the cooling system energy penalty performance input parameter Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Integrated Environmental Control Model User Manual Water Systems e 31 Maintenance Labor The maintenance labor
97. a flue gas This flue gas is emitted to the atmosphere via a secondary stack Each component is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO3 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SOs Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Integrated Environmental Control Model User Manual Auxiliary Boiler Costs Results This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECM Interface File Edit Yiew Go Window Help US Untitled Configure Plant Set Parameters Auxiliary boiler costs are located on the Amine System cost screens Use the Process Type menu below z e me O P o o DaDa WH Amine System Total Cost result screen The Costs result screen displays a note pointing the user to the amine system cost screens Because the auxiliary boiler is a sub system of the am
98. a pilot plant and lower factors to full size or commercial systems Integrated Environmental Control Model User Manual Base Plant 101 Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to O amp M costs over a specified period of time months Fixed Operating Cost Time period of fixed operating costs operating and maintenance labor administrative and support labor and maintenance materials used for plant startup Variable Operating Cost Time period of variable operating costs at full capacity chemicals water and other consumables and waste disposal changes used for plant startup Full capacity estimates of the variable operating costs will assume operations at 100 load Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The a
99. aie de Palas h seeds one E dT Sng Se eT Sos 251 Fl Gas Entering Dryer s2 0 530e esi e ea N a ae 251 Flue Gas Exiting Dryerise ican ise e A i a 251 Spray Dryer Performance sreca t E E S E E Se 252 Collected Solids nesine a e a e a eee 252 Spray Dryer Blue Gas Results ci cerdo eer apis EE E EE E R KE 252 Major Flue Gas Components sccsscccssseessseeccseecssceceseecesseeesaeecsaeessesaeeneeeesaes 253 Spray Dryer Capital Cost Results 00 0 ceseescecsscecesscecseecscecseecssaeeesaeecsaeeeesseeseeesaeeesaes 253 Spray Dryer O amp M ReSults scexssiieesisiesteibe die e Selenite Beis GAN eR GBs 255 Variable Cost Components ceeeceeseeceseeesssceceeecsseeceseecesaeeesaeecssneesesaeeeeeesaes 255 Fixed Cost Components csin ea e aae aea ee es 256 Spray Dryer Total Cost Res lts creca a A r Ta 256 Cost COMpPOMe ner 3 vs eesevesrevsecessevacnubstedevesseve caus svessevssuedceesssevbevs E EEE ESE EN EESE 257 Amine System 259 Amine System Configuration cceeccessseessseeeceseceseeceseeessaeecsaeecsaeecessaecaeeesseessaeeseneeseee 259 Referenc Plant c 2c rsitic heii ited died tine voids wine yop evans 261 Auxiliary Boiler Configuration eeeceessessseecssseeceeeceseeeesaeecsaeecsseecseaecnaeeesaeessaeesseeeens 261 Amine System Performance Inputs c ceesccesscecsseceeeseeesseessaeecsseecsseeessaeeessaeesseessseeeens 262 Amine System Capture Inputs eis osc 0i sc csnis cosh cud en NEEE ieici eh cage
100. and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable Integrated Environmental Control Model User Manual Air Separation 87 O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to co
101. and Combustion Turbine plant types when an amine scrubber is configured It is a sub system inside the amine scrubber when the auxiliary boiler option is added Integrated Environmental Control Model User Manual Auxiliary Boiler e 113 7 IECM Interface File Edit Yiew Go Window Help Us Untitled Configure Plant Set Parameters CO2 db MBtu Steam Supply MBtu hz Equiv 302 b MBtu Electricity MW Equiv NO2 ib MBtu Flue Gas Out tons h ai a Air In tons hr Blo t amp ale lololo Natural Gas In acfim 2 109e 06 Process Te TAT L Diagram 3 Flue Gas Auxiliary Boiler Diagram Each result is described briefly below Air and Fuel Air In The mass flow rate of fresh air is provided This is the stoichiometric amount of air and excess air as specified on the CO Capture input screen Natural Gas In This is the flow rate of natural gas necessary to provide the heat necessary to provide regeneration heat to the MEA regenerator Steam and Power Generation Steam Supply This is the total steam energy required by the CO regenerator The steam is supplied to the MEA regenerator Electricity Low pressure steam generated by the auxiliary boiler may be used to generate electricity in a steam turbine This electricity supplements that produced by the base plant Flue Gas Exiting Aux Boiler System COz This is the flow rate of emission dioxide from the auxiliary boiler It is emitted from a s
102. and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Integrated Environmental Control Model User Manual Fabric Filter 211 Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of
103. and labor flange to flange for the equipment and labor cost for installation of the entire collection system Ductwork This area includes the material and labor for the ductwork needed to distribute flue gas to the inlet flange and from the outlet flange to a common duct leading to the suction side of the ID fan Fly Ash Handling The complete fly ash handling cost includes the conveyor system and ash storage silos Differential ID Fan The complete cost of the ID fan and motor due to the pressure loss that results from particulate collectors Cold Side ESP Capital Cost Inputs This screen is only available for the Combustion Boiler plant type Inputs for the capital costs of particulate control technology are entered on the Capital Cost input screen Integrated Environmental Control Model User Manual Cold Side ESP e 195 196 Cold Side ESP Fo ole a ee En Configure Plant Set Parameters Get Results 502 c02 By Prod Base miesti Control Capture Mgmt Stack Title Min Max 10 00 General Facilities Capital i 50 00 Engineering amp Home Office Fees P fl 60 00 Project Contingency Cost y 100 0 Process Contingency Cost 4 i 100 0 Royalty Fees s y 10 00 _ CeAANKH amp wn Pre Production Costs Months of Fixed O amp M 1 000 i 12 00 Months of Variable O amp M BBE E 1 00 00 1200 Misc Capital Cost zs t mle moo a o 10 00 Inv
104. and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Integrated Environmental Control Model User Manual Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Hot Side SCR e 173 Mercury Mercury Control is a Technology Navigation Tab in the Set Parameters and in the Get Results program area These screens define and display results for the performance and costs directly associated with the removal of mercury from each technology in the power plant Pre combustion and post combustion control technologies are all considered Special consideration is given to flue gas conditioning used to enhance mercury removal Water and activated carbon injection are currently considered as conditioning agents Mercury Removal Efficiency Inputs This screen is only available for the Combustion Boiler plant type Inputs for the removal of the speciated mercury fro
105. and performance of emission control systems costs for the base plant are also needed to properly account for pre combustion control options that increase the cost of fuel and affect the characteristics or performance of the base plant Base plant costs are also needed to calculate the internal cost of electricity which determines pollution control energy costs Each process area direct capital cost is a reduced form model based on regression analysis of data collected from several reports and analyses They are described in general below The primary factors in the model that effect the capital cost of the base plant are the plant size the coal rank and the geographic location of the plant Steam Generator This area accounts for the steam cycle equipment and pumps Turbine Island This area accounts for the turbine island and associated pumps Coal Handling This area accounts for the mechanical collection and transport equipment of coal in the plant Integrated Environmental Control Model User Manual Base Plant 107 108 Base Plant Ash Handling This area accounts for the mechanical collection and transport of ash in the plant Water Treatment This area accounts for the pumps tanks and transport equipment used for water treatment Auxiliaries Any miscellaneous auxiliary equipment is treated in this process area Process Facilities Capital The process facilities capital is the total constructed cost of all on site p
106. and through the bags to remove dust cake while the bags are filtering flue gas Wire support cages are used to prevent bag collapse during filtration and ash is collected outside of the bags SO Control The default option is None The following choices available are None for no post combustion SO control Wet FGD for a Wet Flue Gas Desulfurization technology Multiple reagent options are available under the SO2 Control tab in the Set Parameters section of the interface Lime Spray Dryer for a dry scrubber using lime as a reagent The interfact places this technology before the particulate control technology in the plant design and diagrams Mercury The default option is None Other options are only available if a particulate control is configured The options provided are None for no mercury control Carbon Injection Although some mercury removal is accomplished naturally in a power plant It is believed that some mercury is captured or trapped in ash and is removed with bottom ash and fly ash Carbon injection is provided as a technology to achieve higher removals by injecting fine particles of activated carbon into the flue gas after the air preheater Carbon Water Injection Because the removal increases with lower flue gas temperatures water injection is added to the carbon injection as a second technology option CO Capture The default option is None The following choices available are None for no CO cap
107. annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Amine System Cost Factors Results 282 e Amine System This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECH Interface File Edit View Go Window Help Configure Plant Set Parameters Get Results 02 SVN By Prod Control ie apt ure Mgmt Stack Important Performance and Cost Factors Costof CO2 Avoided Net Electrical Output MW 331 8 Capture Plant Annual Operating Hours hours 6575 CO2 Emissions lbs k Wh Annual CO2 Removed tons yz 2 720e 06 Cost of Electricity GMIWh Annual 02 Removed tons yz 905 9 Annual S03 Removed tons yr 171 2 Reference Plant Annual NO2 Removed tons yr 103 7 CO2 Emissions lbs kWh Annual HCl Removed tons yr 64 83 Cost of Electricity G MWh Flue Gas Fan Use MW 11 68 Sorbent Pump Use MW 0 8939 Cost of CO2 Avoided ton CO2 Compression Use MW 44 26 10 Aux Power Produced MW 0 0 Sorbent Regeneration Equiv Energy MW 64 40 Zi elt 2 mek e moe zaleje mla n a w n Fixed Charge Factor fraction 0 1480 Costs are in Constant 2005 dollars Process Type Amine System Tea a a Amine System Cost Factors result screen Important Performance and Cost Factors This screen displays information that is key to the model calculations The data is available else where
108. are given in both moles and mass per hour For each component entering in atmospheric air values are given in moles per hour Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen 02 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Integrated Environmental Control Model User Manual Air Preheater 137 Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO2 Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Air Preheater Oxidant Results 138 e Air Preheater This screen is only available for the Combustion Boiler plant type File Edit Yiew Go Window Help Set Parameters Get Results TSP 02 CO2 By Prod Control Control Capture Mgmt Air wee M ry oie Control Y OxidantIn RecycleIn Oxidant Out b moles hr b moles hx h moles hr 1os1e 05 o0 1081e 05 Oxygen 02 2 900e 04 0 0 2 900e 04 Water Vapor H20 3988 0 0 3988 Carbon Dioxide C02 0 0 0 0 0 0 Carbon Monoxide CO 0 0 0 0 Hydrochloric Acid HCD i 0 0
109. are in Constant 2005 dollars Integrated Environmental Control Model User Manual Sulfur Removal e 335 Sulfur Removal O amp M Cost input screen Inputs for O amp M costs are entered on the Sulfur Removal O amp M Cost input screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Selexol Solvent Cost This is the unit cost of Selexol Claus Plant Catalyst Cost This is the unit cost of catalyst used in the Claus plant Beavon Stretford Catalyst Cost This is the unit cost of catalyst used in the Beavon Stretford plant Sulfur Byproduct Credit This is the unit price of sulfur sold on the market Sulfur Disposal Cost This is the unit cost of any disposal wastes generated by the sulfur recovery processes Sulfur Sold on Market This is the fraction of the collected sulfur that is sold on the market Any remaining sulfur is assumed to be utilized at no cost 1 e neither disposed nor sold Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is defined as the air separation unit the gasifier and the power block Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total
110. are not changed This format is a software industry standard and facilitates sharing and updating of information To simplify the use of the model a Graphical User Interface GUI has been added The interface eliminates the need to master the underlying commands normally required for model operation The interface is written in Microsoft Visual C a standard software development tool for the Windows environment Visual C runtime libraries are included with the IECM Model software and do not need to be licensed separately Wise for Windows Installer was used to generate full installer programs This product was chosen based on its flexibility and its support of Visual Basic runtime libraries and Microsoft Data Access Components MDAC The Visual Basic runtime libraries provide the support needed to run the database file compactor program provided with the IECM MDAC provides the software support needed to link Microsoft Access data files to the IECM interface program Wise for Windows Installer provides the VB and MDAC installation as an option rather than forcing the user to download it from Microsoft and install it prior to installing the IECM Smaller screen resolution results in the interface screens being scaled smaller The taskbar part of the Windows operating system reduces the useable resolution of the screen if it is always visible This may force the IECM interface to be scaled down slightly To avoid this situation select t
111. areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens The following are the Capital Cost Process Areas for the Amine System Direct Contact Cooler A direct contact cooler is typically used in plant configurations that do not include a wet FGD A direct contact cooler is a large vessel where the incoming hot flue gas is placed in contact with cooling water The cost is a function of the gas flow rate and temperature of the flue gas Flue Gas Blower The flue gas enters the bottom of the absorber column and flows upward countercurrent to the sorbent flow Blowers are required to overcome the substantial pressure drop as it passes through a very tall absorber column The cost is a function of the volumetric flow rate of the flue gas CO Absorber Vessel The capital cost of the absorber will go down with higher MEA concentration and higher CO loading level of the solvent and lower CO content in the lean solven
112. basis not on a mercury compound basis The default value is a function of the coal rank 78 e Fuel Integrated Environmental Control Model User Manual Mercury in Oil elemental This input parameter specifies the mass concentration of total mercury in the oil The mercury concentration should be given on an elemental basis not on a mercury compound basis Mercury in Natural Gas elemental This input parameter specifies the mass concentration of total mercury in the natural gas The mercury concentration should be given on an elemental basis not on a mercury compound basis Mercury Speciation Once the fuel is combusted the mercury can be identified in primarily two chemical states elemental Hg and oxidized Hg Although mercury can alternatively be reported as particulate or gas phase the IECM assumes Mercury is reported on an elemental and oxidized basis Elemental This is the percent of total mercury that is in an elemental state Hg after combustion Elemental mercury is typically unreactive and passes through a power plant The default value is a function of the coal rank Oxidized This is the percent of total mercury that is in an oxidized state Hg after combustion Oxidized mercury is very reactive and typically forms mercury compounds The default value is a function of the coal rank Particulate This parameter is not currently used in the IECM It s value is set to force the sum of the speciation ty
113. below Capital Cost The total capital requirement TCR This is the money that is placed capitalized on the books of the utility on the service date The total cost includes the total plant investment plus capitalized plant 70 e Overall IGCC Plant Integrated Environmental Control Model User Manual startup Escalation and allowance for funds used during construction AFUDC are also included The capital cost is given on both a total and an annualized basis Revenue Required Amount of money that must be collected from customers to compensate a utility for all expenditures in capital goods and services The revenue requirement is equal to the carrying charges plus expenses The revenue required is given on both an annualized and a net power output basis Integrated Environmental Control Model User Manual Overall IGCC Plant 71 Fuel The screens associated with the Fuel Technology Navigation Tab display and define the composition and cost of the fuels used in the plant The IECM supports the use of various fuels ranging from coals of various rank fuel oil of various weight and natural gas of various places of origin Default properties of fuels are provided but user specified properties can also be easily substituted The combustion model currently supports the use of pulverized coal in the furnace with natural gas available as a reburn option to the in furnace NOx controls and an optional natural gas auxiliary boiler The coal
114. bottom dump railroad car unloading hopper vibrating feeders conveyors belt scale magnetic separator sampling system deal coal storage stacker reclaimer as well as some type of dust suppression system Slurry preparation trains typically have one to five operating trains with one spare train The typical train consists of vibrating feeders conveyors belt scale rod mills storage tanks and positive displacement pimps to feed the gasifiers All of the equipment for both the coal handling and the slurry feed are commercially available A regression model was developed for the direct cost of coal handling and slurry preparation using the data collected for possible independent variables affecting direct capital cost Coal feed rate to the gasifier on as received basis is the most common and easily available independent variable The direct cost model for the coal handling is based upon the overall flow to the plant rather than on a per train basis Gasifier Area The GE gasification section of an IGCC plant contains gasifier gas cooling slag handling and ash handling sections For IGCC plants of 400 MW to 1100 MW typically 2 to 4 operating gasification trains are used along with one spare train The mass flow of coal to the gasifier is assumed to be between 3000 and 3500 tons day per train as_received Low Temperature Gas Cooling The low temperature gas cooling section includes a series of three shell and tube exchangers The numb
115. by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the spray dryer that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor Selexol CO Capture O amp M Cost Results This screen is only available for the IGCC plant type Eile Edit View Go Window Help 0 e Configure Plant Set Parameters Get Results z Power Block B Stack a b Variable Cost Component Fixed Cost Component OEM tiei M yr Disposal Maintenance Labor 1 456 Electricity Maintenance Material 2 184 CO2 Transport i Admin amp Support Labor 0 6176 ral Ei Zis Let Process Type 2 Selexol CO2 Capture Costs are in Constant 2005 dollars 2 Syngas 3 Capital Cost 4 O amp M Cost 5 Total Cost Selexol CO Capture O amp M Cost results screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Variable Cost Component Glycol Selexol is a commercially available physical solvent that is a mixture of dimethyl ether and polyethylene glycol This is the annual cost of the makeup solvent Disposal This is the ann
116. by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the wet cooling tower that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor for the wet cooling tower Wet Cooling Tower O amp M Cost Results This screen is available for all plant types The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the Wet Cooling Tower technology 18 e Water Systems Integrated Environmental Control Model User Manual 7 ECM Interface Eile Edit Yiew Go Window Help is Untitled Configure Plant f Set Parameters Get Results le ojelo o O amp M Cost O amp M Cost Myr Sr 1 Disposal J 0 0 1 Operating Labor 0 3429 2 Electricity 2 436 2 Maintenance Labor 0 3067 3 Water 2 034 3 Maintenance Material 0 4600 4 Admin amp Support Labor 0 1949 Variable Cost Component Fixed Cost Component e al R Process Type Wet Cooling Tower Costs are in Constant 2007 dollars LL Digen 2 oco A Wet Cooling Tower O amp M Cost Result Screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a
117. can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Spray Dryer Diagram This screen is only available for the Combustion Boiler plant type le Edit View Window Help iT Us Untitled Configure Plant Set Parameters Get Results CO2 By Prod TSP Control Capture Mgmt Temperature deg F 153 1 Dry Reagent tons hr 6 313 Temperature In deg F 300 0 Temperature deg F alel le o P 9 0 E Z Flue Gas In acfm Fly Ash In ton hi Mercury In lb hr 1 579e 06 12 92 3 533e 02 f Temperature Out deg F Flue Gas Out acfm Solids Out ton hr Mercury Out Ib hr 175 0 1 395e 06 26 82 3 533e 02 ola Ash Removal 502 Removal 503 Removal Mercury Removal Dry Solids ton hr Process Type Spray Dryer 7 F Capital Cost 7 408MCot 7 3 TolalCost J 0 0 1 Diagram Spray Dryer Diagram 250 e Spray Dryer Integrated Environmental Control Model User Manual The Diagram result screen displays an icon for the Lime Spray Dryer SO control technology selected and values for major flows in and out of it Each result is described briefly below Reagent Dry Reagent The total
118. choose the mode of analysis for the entire IECM economics The cost basis is reported on every input and result screen associated with costs throughout the interface Discount Rate Before Taxes This is also known as the cost of money It is the return required by investors in order to attract investment capital It is equal to the weighted sum of the return on debt and equity It is the time values of money on the discount rate used in present worth arithmetic One may specify a Fixed Charge Factor and Discount Rate or fill in the following inputs and the model will calculate them Fixed Charge Factor FCF The fixed charge factor is one of the most important parameters in the IECM It determines the revenue required to finance the power plant based on the capital expenditures Put another way it is a levelized factor which accounts for the revenue per Integrated Environmental Control Model User Manual dollar of total plant cost that must be collected from customers in order to pay the carrying charges on that capital investment One may specify a fixed charge factor or fill in the following inputs and the model will calculate the FCF based on them Inflation Rate This is the rise in price levels caused by an increase in the available currency and credit without a proportionate increase in available goods or services It does not include real escalation Plant or Project Book Life This is the years of service expected from a
119. costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Fabric Filter Total Cost Results This screen is only available for the Combustion Boiler plant type The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Particulate Control technology The result categories are the same for both the Cold Side ESP and the Fabric Filter File Edit View Go Window Help Configure Plant Set Parameters Get Results 502 CO2 By Prod T 5 Control Control Capture Mgmt Stack ton solids removed Annual Fixed Cost 16 05 11 33 Annual Variable Cost 21 90 16 45 Cost Component Percent Total wmn Annualized Capital Cost 103 8 73 22 zis t e me le ooo ed ed el eal alle Fabric Filter Costs are in Constant 2005 dollars 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost Fabric Filter Total Cost result screen Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs 220 e Fabric Filter Integrated Environmental Control Model User Manual
120. data are available for operating plants In other cases especially where data are limited expert technical judgments may be necessary to develop appropriate distribution functions for model parameters The emphasis of the discussion below is on the situations where statistical analysis alone may be insufficient Judgments about Uncertainties In making judgments about a probability distribution for a quantity there are a number of approaches heuristics that people use which psychologists have observed Some of these can lead to biases in the probability estimate Three of the most common are briefly summarized Availability The probability experts assign to a particular possible outcome may be linked to the ease availability with which they can recall past instances of the outcome For example if tests have yielded high sorbent utilization it may be easier to imagine obtaining a high sorbent utilization in the future than obtaining lower utilization Thus one tends to expect experts to be biased toward outcomes they have recently observed or can easily imagine as opposed to other possible outcomes that have not been observed in tests Representativeness has also been termed the law of small numbers People may tend to assume that the behavior they observe in a small set of data must be representative of the behavior of the system which may not be completely characterized until substantially more data are collected Thus one s
121. dependent on the minimum and maximum removal efficiencies of the SCR and the emission constraint for NO The model assumes a minimum removal of 50 The actual removal is set to match the constraint if feasible It is possible that the SCR may under or over comply with the emission constraint This input is highlighted in blue Maximum NOx Removal Efficiency This parameter specifies the maximum efficiency possible for the absorber on an annual average basis The value is used as a limit in calculating the actual NO removal efficiency for compliance Particulate Removal Efficiency The ash in the high dust gas entering the SCR collects on the catalyst layers and causes fouling Ash removal is not a design goal rather it is a reality which is taken into consideration by this parameter Number of SCR Trains This is the total number of SCR equipment trains It is used primarily to calculate the capital costs The value must be an integer Number of Spare SCR Trains This is the total number of spare SCR equipment trains It is used primarily to calculate capital costs The value must be an integer Number of Catalyst Layers The total number of catalyst layers is a sum of the dummy initial and spares used All catalyst layer types are of equal dimensions geometry and catalyst formulation You specify each value the value must be an integer The catalyst layer types and quantities are combined with pressure drop information to determine
122. different technology options to be evaluated systematically at the level of an individual plant or facility The model takes into account not only avoided carbon emissions but also the impacts on multi pollutant emissions plant level resource requirements costs capital operating and maintenance and net plant efficiency In addition uncertainties and technological risks also can be explicitly characterized The modeling framework is designed to support a variety of technology assessment and strategic planning activities by DOE and other organizations The model currently includes four types of fossil fuel power plants a pulverized coal PC plant a natural gas fired combined cycle NGCC plant a coal based integrated gasification combined cycle IGCC plant and an oxyfuel combustion plant Each plant can be modeled with or without CO2 capture and storage The IECM cs can thus be employed to quantify the costs and emission reduction benefits of CCS for a particular system or to identify the most cost effective option for a given application This model also can be used to quantify the benefits of technology R amp D and to identify advanced technology options having the highest potential payoffs A Graphical User Interface GUI facilitates the configuration of the technologies entry of data and retrieval of results System Requirements The current model requires the following configuration e Intel based computer running Windows
123. dollars per ton MEA Cost This is the cost of MEA in dollars per ton Activated Carbon Cost This is the cost of activated carbon in dollars per ton Integrated Environmental Control Model User Manual Caustic NaOH Cost This is the cost of caustic NaOH gas in dollars per ton Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Overall IGCC Plant Stack Emis Taxes Inputs This screen allows users to specify emission taxes or credits as part of the overall plant cost economics Taxes or credits are typically provided in either constant or current dollars for a specified year as shown on the bottom of the screen 7 IECH Interface Fie Edit View Go Window Help iol x 0 US Untitled Configure Plant By Prod Mgmt Title Sulfur Dioxide S02 Nitrogen Oxide equiv NOJ Carbon Dioxide CO2 zj el gt ale B mlo Process Type Overall Plant Costs are in Constant 2005 dollars Overall IGCC Plant Emis Taxes input screen The Emis Taxes input screen allows the user to enter the taxes on emissions in dollars per ton The final costs determined from these inputs are available under the stack tab in the results section of the IECM The costs are added to the overall plant cost not a particular technology Tax on Emissions Sulfur
124. ductwork needed to distribute flue gas to the inlet flange and from the outlet flange to a common duct leading to the suction side of the ID fan Fly Ash Handling The complete fly ash handling cost includes the conveyor system and ash storage silos Differential The complete cost of the ID fan and motor due to the pressure loss that results from particulate collectors Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Total Capital Costs Process Facilities Capital see definition above Integrated Environmental Control Model User Manual Fabric Filter e 217 General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency
125. e ees Raton a a a EE 234 Fl e Gas Exitin FGD eii n a t aana e Ress eae 234 FGD Performancea ae A se enh e oe e aae aaa E REE 234 Collected Solids ieni innn a a E E Aa 235 Wet FGD Flue Gas Resullt cccsissiscscsscusssevecascsssetbeaasastasboveatasaoyeedanseoueseaes dbadeadsotedustontaauatoetas 235 Major Flue Gas Componedt iesiri eiea a a EE S 235 Wet FGD Bypass ResultSet tne tiena i EATE Ea iT et 236 Major Flue Gas Component iiien it aaa a a a E S 236 Wet FGD Capital Cost R s ltSrirnii aeie i eaaa EA EAA REEERE E 237 Wet FGD O amp M Cost Results iriiritia iE E i nints 239 Variable Cost Components eienn aee E aT AES 239 Fixed Gost Components isisa eE E A ERa EEES 240 Wet FGD Total Cost Results ii sscicsscusssevecascsssatastasastassaveatasdoveedanseuegasdasyea sas aenedustentadnazeesas 240 Cost Component ssi scsiissstesestsckasias coho ssheenadgaseenetassonsasasseassdsudsdeasisaeasasvadeevasist sense 241 Spray Dryer 243 Spray Dryer Configurations a aii wl aie Akins OE TEE a eh esl KEAS dea 243 Spray Dryer Performance Input inas artere ra este cies aa EE OEE E EE ES EA 244 Spray Dryer Retrofit Cost sc err a Mute Mek O a EE O S EEEa 246 Spray Dryer Capital Cost Inputs eraen ert enrere ard rE eaa Ra EE OS RE EECA EEEE EE 247 Spray O amp M Cost INpUtS iasi ss ssesecyepdssatccsdsesbesetisisesedasseesedenstes saute rP EEE r ES ENEE 249 Spray Dryer DIET reii AERE EE aetna eh ai albins Geese 250 ReaGentei seis des Rit eG tee abe
126. eee ek eee eee Mates 19 Wet Cooling Tower Total Cost Results ice ceeceecesscesesecssesesseeseesecseeeeesescnessaeeessesseeneeaees 20 COSt COMPON EN sf 4 24 a E E A dona denser E E RE 21 Air Cooled Condenser Configuration 0 ccccecceeeseeseesesseeeceseeceecseceeaesseeesesssaeeessasseeneeasens 21 Air Cooled Condenser Performance Inputs 000 0 ccc eececesseeeeesceeceeesecneeeecaeeeceeessceesseceeesaeeas 22 Air Cooled Condenser Retrofit Cost Inputs cece eseeseesesseeeeeeeeeeeeseeessesseeseesesaeeeseaees 23 Air Cooled Condenser Capital Cost Inputs cece ecesseeeceseeecescseeseesessessessecseeeeeseseeesaeens 24 Air Cooled Condenser O amp M Cost Input 0 eceeseeeecseeseeeeseeeeceeeseeesceessaeeseesseeneeesaeens 26 Air Cooled Condenser Diagram sessscsscessecsscenenecsscenenecssesnensessesnenscssesnensenseesnsensvae sas 28 Air Cooled Condenser Capital Cost Results 00 cecseeesecseeeesseeeseeeacessseeseesesseeeesesseeessaens 29 Air Cooled Condenser O amp M Cost Results cccecesesseeeesesseeeesseesceeeseesceessaesseeessecneseesaeens 30 Variable Cost Component cee ceesseeeceseseeeeeeeseeeseeeseceessaeseceessaesseeesaecneeesaeens 31 Fixed Cost Components s ccen tat teindte len cia sen ne elle 31 Air Cooled Condenser Total Cost Results cc ccecsesseeeeceeseeeeeseesceeesaesceecsaeeeesessaeesenesaaees 32 COS COMPONeNt ee EER EAE E AEE EIRE EREE EET EE DEEE 32 Makeup Water System Results 0 cecescecseeseesecseeeecseesce
127. effect on the cooling system size when air cooled condensers are loaded Aux Heat Exch Load This parameter specifies additional heat load on the auxiliary condenser and is expressed as a percentage of the load on the primary condenser Air Cooled Condenser Power Requirement This parameter specifies the power needed to operate the big fans in the dry cooling system It is also referred to as an energy penalty to the base plant The electricity required for these big fans is estimated using the air cooled condenser performance model and is expressed as a percentage of the gross plant capacity That is a function of the initial temperature difference between inlet steam and air and ambient pressure Air Cooled Condenser Retrofit Cost Inputs This screen is only available for all plant types Inputs for capital costs of modifications to process areas to implement the Air Cooled Condenser are entered on the Retrofit Cost input screen for the Air Cooled Condenser system The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct
128. equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Integrated Environmental Control Model User Manual Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow CO Transport System Gas Results This screen is only available for the IGCC plant type Gl x Eile Edit View Go Window Help ME Configure Plant Set Parameters Get Results By Prod Mgmt Power Block Stack Hydrogen H2 Methane CH9 Ethane C2H6 Propane C3H8 Hydrogen Sulfide H25 Carbonyl Sulfide COS Ammonia NH3 Hydrochloric Acid HCD Carbon Dioxide COZ 2 134e 04 2 134e 04 Blo S amp a P le ole g 11 Water Vapor 20 o0 0 0 Nitrogen ND T 00 0 0 Argon At 0 0 0 0 Oxygen 02 0 0 0 0 CO Transport System Gas result screen Major Gas Components Each result is described briefly below Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H Total mass of hydrogen Methane CH Total mass of methane Ethane C2He Total mass of ethane Propane C3Hsg Total mass of propane Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbon dioxide Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of
129. factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area Integrated Environmental Control Model User Manual Selexol CO2 Capture 307 by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This
130. factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Integrated Environmental Control Model User Manual Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc C
131. fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Integrated Environmental Control Model User Manual Selexol CO2 Capture 313 Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables
132. flow rate determine the power used by the fan Recycle Fan Efficiency This is the efficiency of the fan converting electrical power input into mechanical work output Flue Gas Recycle Power Requirement This is the percentage of the total gross power of the plant required to recycle the flue gas Flue Gas Purification Unit Is Flue Gas Purification Present The user may add a flue gas purification system CO Capture Efficiency This is the percentage of the CO which the system is able to capture CO Product Purity This is the percentage of the product that is carbon dioxide CO Unit Purification Energy This is the energy required for one unit to purify the CO product per ton purified CO Purification Energy This is the total energy required to purify the CO product O 2 CO Recycle CO Storage Inputs This screen is available for Combustion Boiler plant types 7 IECH Interface ioj xi File Edit View Go Window Help D Untitled Riggs Configure Plant Set Parameters Get Results NOx TSP CO2 By Prod Have Plant Control Ca e Mgmt Units CO2 Compression CO2 Product Pressure psig kWhton CO2 MWg CO2 Compressor Efficiency Unit CO2 Compression Energy Total CO2 Compression Energy T CO2 Transport amp Storage Enhanced Oil Recovery EOR Enhanced Coal Bed Methane E Geological Reservoir Geologic 12 Ocean Ocean zs t ao el e alelo
133. hard drive Once it is finished the installer program will automatically proceed to install the IECM software If you receive an error message while running the install program restart your computer and run the installation program again If it still returns an error message contact Technical Support Once the installer program is completed it will be deleted from the temporary location on your hard drive Integrated Environmental Control Model User Manual Installing the Model e 15 Files Added by Install This section provides a full list and short description of the files installed by the IECM installer software The software is divided into three categories Help Files The following help files are installed by default in the C PROGRAM FILES IECM_CS directory by the installation program Tecmint cnt IECM Getting Started online help contents file Tecmint hlp IECM Getting Started online help file Program Files All applications and their support files specific to the IECM software itself are considered program files These can be installed into any directory during installation The folder can be changed from the default location suggested during installation GSPROP 32 DLL Graphics Server for Windows 6 15 support file GSW32 EXE Graphics Server for Windows 6 15 program file GSWAG32 DLL Graphics Server for Windows 6 15 support file GSWDLL32 DLL Graphics Server for Window
134. hours per year that the plant is in operation If a plant runs 24 hours per day seven days per week with no outages the calculation is 24 hours 365 days or 8 760 hours year Annual CO Removed ton yr This is the amount of CO removed from the flue gas by the CO capture system per year ASU Power MW Flue Gas Fan Power MW The flue gas has to be compressed in a flue gas blower so that it can overcome the pressure drop in the absorber tower This is the electrical power required by the blower CO Purification Power MW CO Compression Power MW This is the electrical power required to compress the CO product stream to the designated pressure Compression of CO to high pressures requires considerable power and is a principle contributor to the overall energy penalty of a CO capture unit in a power plant Integrated Environmental Control Model User Manual O2 CO2 Recycle 301 302 O2 CO2 Recycle Fixed Charge Factor fraction The fixed charge factor is one of the most important parameters in the IECM It determines the revenue required to finance the power plant based on the capital expenditures Put another way it is a levelized factor which accounts for the revenue per dollar of total plant cost that must be collected from customers in order to pay the carrying charges on that capital investment Cost of CO Avoided Many analysts like to express the cost of an environmental control system in terms of the c
135. ieiet OaE aaoi ia 24 Solids Ma agement sronto da inet e ea a a a E EASE asian 24 Combustion Overall Plant 27 Integrated Environmental Control Model User Manual Contents iii iv e Contents Combustion Overall Plant Diagram ees eeeceesscecsseeccnseeesscecscecsseecesaeeesaeeceseesneeesneeeesaes 27 Combustion Overall Plant Performance Inputs cc eescesseeceseecesseeceecseesseeeesaeeesneesenee 28 Combustion Overall Plant Constraints Inputs escceeeseesseecesseeceeeceseeeesseecsaeecseessseaeerses 29 Combustion Overall Plant Financing Inputs ee eeeeesceeseeeceseceseeceseeeesseecsaeecseeeeseaeeeses 30 Combustion Overall Plant O amp M Inputs ce eeeeceeeseecssneeccsseesneecsscecesaeessaeecsaeeecesaeessaeeraes 32 Combustion Overall Plant Emis Taxes Inputs ceeseesseeceseeceeeeceseeeesseecsaeecseeeneeeeaes 33 Combustion Overall Plant Performance Results ccccccccccccesseseescecesseeesesescccssseeeeeesssceees 34 Performance Parameter cccccessessccccccceeeccccsccccseeeesseeccccssseeessscssseeuseseseesscessseees 34 Plant Power Requitemetits lt csicsisccssecesgeasasusosetuges geaneaysceenaduadooneagses EEE EE teas 35 Combustion Overall Plant Mass In Out c cccccccesseseseccceesseessseeccccssseeseseecccsesesesceseuees 36 Combustion Overall Plant Solids Emissions cccsssececcccccceecccccseccsseeeseseecccssseennecessuees 37 Combustion
136. in either constant or current dollars for a specified year as shown on the bottom of the screen Integrated Environmental Control Model User Manual Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant for the IGCC Model is an air separation unit gasifier and the power block Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Air Separation Diagram Eile Edit View Go Window Help Configure Plant
137. in dollars per thousand gallons Limestone Cost This is the cost of limestone in dollars per ton Lime Cost This is the cost of lime in dollars per ton Ammonia Cost This is the cost of ammonia in dollars per ton Urea Cost This is the cost of natural gas in dollars per ton MEA Cost This is the cost of MEA in dollars per ton Activated Carbon Cost This is the cost of activated carbon in dollars per ton Caustic NaOH Cost This is the cost of caustic NaOH gas in dollars per ton Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Combustion Overall Plant Emis Taxes Inputs This screen allows users to specify emission taxes or credits as part of the overall plant cost economics Taxes or credits are typically provided in either constant or current dollars for a specified year as shown on the bottom of the screen File Edit View Go Window Help Configure Plant Set Parameters Get Results NOx TSP 502 coz By Prod Base Plant Control Control Control Capture Mgmt Title Sulfur Dioxide 302 Nitrogen Oxide equiv NO2 Carbon Dioxide CO2 zs t mlel o e e o Overall Plant Costs are in Constant 2005 dollars Emission Constraint Emission Taxes input screen The Emis Taxes input screen allows the user to enter the taxes on emiss
138. income taxes equal to a percentage of the installed cost of a new capital investment It is zero by default It is used to set the initial balance and the book depreciation Overall IGCC Plant O amp M Cost Inputs This screen combines the variable O amp M unit costs from all the model components and places them in one spot These values will also appear in the technology input screens where they are actually used Values changed on this screen will reflect exactly the same change everywhere else they appear O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Integrated Environmental Control Model User Manual Overall IGCC Plant 61 62 e Overall IGCC Plant 7 IECH Interface ioj xi zs t S mle moo File Edt View Go Window Help Configure Plant Set Parameters Get Results Max Default 1 Base Play Menu e Plant u 2 intemal Electricity Price MWh 56 21 A 200 0 calc 3 4 Natural Gas Cost fimsef 5 346 x oo 1000 5 Water Cost 1000 gal 0 8316 oo 2600 6 7 Limestone Cost ton 19 64 vw 0 0 30 00 8 Lime Cost ton 72 01 w 40 00 90 00 9 Ammonia Cost iton 248 2 x 100 0 400 0 10 Urea Cost ton 412 4 w 200 0 400 0 Il MEA Cost Son 12933 00 1 500e 04 WlActivatedCabonCost Sion 1322 500 0 5000 cA 13 Caustic
139. integer 0 a Menu 0 zi a R ae e oeo Unit ASU Power Requirement kWh ton CO2 550 0 Total ASU Power Requirement MWg g 40 00 Process Type Air Separation 1 Performance 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Air Separation Performance input screen Oxidant Composition Oxygen O2 This is the percent of oxygen that is in the oxidant that is produced by the air separation unit The value is fixed for the IGCC plant type Argon Ar This is the percent of argon that is in the oxidant that is produced by the air separation unit Nitrogen Nz This is the percent of nitrogen that is in the oxidant that is produced by the air separation unit Integrated Environmental Control Model User Manual Air Separation 85 Final Oxidant Pressure The final oxidant stream from the ASU can be provided at a high pressure The default value is determined by the plant type being used Maximum Train Capacity The maximum production rate of oxidant is specified here It is used to determine the number of operating trains required Number of Operating Trains This is the total number of operating trains It is used primarily to calculate capital costs The value must be an integer Number of Spare Trains This is the total number of spare trains It is used primarily to calculate capital costs The value must be an integer Unit ASU Power Requirement The main air co
140. interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the cold side ESP that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor for the cold side ESP Cold Side ESP O amp M Cost Results This screen is only available for the Combustion Boiler plant type The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved
141. is determined by the TCR Recovery Factor O 2 CO Recycle O amp M Cost Results 298 e O2 CO2 Recycle This screen is available for Combustion Boiler plant types 7 IECH Interface File Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results 502 Control Variable Cost Component Fixed Cost Component ale e orlo Misc Chemicals Wastewater Treatment CO2 Transport CO2 Storage Electricity Operating Labor Maintenance Labor M aintenance Material Admin amp Support Labor ounan mamia nne Zj tt ea a joie Costs are in Constant 2005 dollars Process Type FG Recycle amp Purification 2 DCC Gas 2 Purif Gas 4 CapitalCost a EEMOCAU LLAW 6 Total Cost O gt CO Recycle Flue Gas O amp M cost result screen The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the CO2 Capture technology O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Integrated Environmental Control Model User Manual Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are
142. is highlighted in yellow Sulfur Removal Plant Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the o
143. kal aie 18 Process Type Jin Furnace Controls gt 1 Config 3 Capital Cost 4 O amp M Cost In Furnace Controls Config input screen In Furnace Controls This pull down menu chooses what type of in furnace NO controls are used These technologies reduce NO between the primary fuel injection into the furnace and the economizer These can be used in the combinations given in addition to the SCR The low NO burner options are not displayed when a cyclone boiler is configured The full list of choices is LNB Low NO burners are a combustion NO control These burners replace the upper coal nozzle of the standard two nozzle cell burner with a secondary air port The lower burner coal nozzle is enlarged to the same fuel input capacity as the two standard coal nozzles The LNB operates on the principle of staged combustion to reduce NO emissions Approximately 70 of the total air primary secondary and excess air is supplied through or around the coal feed nozzle The remainder of the air is directed to the upper port of each cell to complete the combustion process The fuel bound nitrogen compounds are converted to nitrogen gas and the reduced flame temperature minimizes the formation of thermal NO The net effect of this technology is greater than 50 reduction in NO formation with no boiler pressure part changes and no impact on boiler operation or performance Low NO burners are not a
144. new power plant This value is 100 for a new installation and may be set as low as 0 for a wet FGD that has been paid off Wet FGD O amp M Cost Inputs This screen is only available for the Combustion Boiler plant type Integrated Environmental Control Model User Manual Wet FGD e 231 232 e Wet FGD File Edit View Go Window Help Us Untitled ot x Configure Plant Set Parameters Get Results CO2 By Prod Capture Mgmt Stack Base Plant Mercury Title Bulk Reagent Storage Time Limestone Cost Lime Cost _ Stacking Cost Waste Disposal Cost ton Electricity Price Base Plant MWh CeAAH amp w N zs t S mle moo Number of Operating Jobs jobs shift Number of Operating Shifts shifts day 12 Operating Labor Rate hr 13 14 Total Maintenance Cost HTPC 15 Maint Cost Allocated to Labor total 16 Administrative amp Support Cost total labor 17 18 Process Type wet FGD z Costs are in Constant 2005 dollars 1 Config 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost t 4 Wet FGD O amp M Cost input screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each parameter is described briefly below Bulk Reagent Storage Time This is the num
145. number of operating absorber vessels The calculated value is determined by comparing the total flow rate of syngas through the Selexol process and the maximum syngas capacity per train The value must be an integer Number of Spare Absorbers This is the total number of spare absorber vessels It is used primarily to calculate capital costs The value must be an integer Power Requirement This is the electricity used by the Selexol CO2 Capture System for internal use It is expressed as a percent of the gross plant capacity Selexol CO Capture CO Storage Inputs This screen is only available for the IGCC plant type 304 e Selexol CO2 Capture Integrated Environmental Control Model User Manual lolx Eile Edit View Go Window Help Configure Plant Set Parameters Get Results i S By Prod Mgmt Power Block Stack CO2 Product Stream Number of Compressors integer Product Pressure psig CO2 Compressor Efficiency Transport amp Storage Storage Method Geologicy Geologic Enhanced Oil Recovery EOR T Enhanced Coal Bed Methane B Geological Reservoir Geologic Ocean Ocean i Ao izis izle l2 alsi baled io Process Type fe Selexol CO2 Capture X 1 Reference Plant 3 CO2 se 5 Capital Cost 6 O amp M Cost Selexol CO Capture CO Storage input screen CO Product Stream The concentrated CO product stream obtained from CO captu
146. of MBtu This value cannot be edited It is based on the value given in units of mscf Natural Gas Cost This is also provided in units of MBtu This value cannot be edited Fuel Aux Gas Properties Input 80 o Fuel The natural gas composition and density can be entered on the natural gas properties screen The screen below is shown when accessed from the Combustion Turbine plant type It is also available for combustion plant configurations that include CO Capture with an Auxiliary Natural Gas Boiler or In Furnace NO Integrated Environmental Control Model User Manual Control with Gas Reburn and is accessed by selecting 4 Aux Gas from the Fuel Screen of the Set Parameters Tab y IECM Interface joj xj File Edt View Go Window Help Set Parameters Mero NOx TSP 02 sdercusy Control Control Control Units Unc Value Higher Heating Value Btu lb 2 317e 04 2 500e 04 Natural Gas Composition Methane CH4 vol 83 40 100 0 Ethane C2H6 vol A i 100 0 Propane C3H8 vol A p 100 0 Carbon Dioxide COD vol j A 100 0 Oxygen 02 vol A 100 0 Nitrogen N2 vol a 100 0 Hydrogen Sulfide H25 vol K 100 0 e a a 3 e R Natural Gas Density lbfcu ft 4 849e02 i 1000 Fuel Auxiliary Natural Gas input screen The Natural Gas input screen displays and allows the user to update the fuel prop
147. of water injected into the flue gas If the approach is above the actual temperature the temperature is dropped to be the approach above the dew point The dew point is a function of the SO and H O content in the flue gas and the pressure of the flue gas Sorbent Injection Rate The flue gas temperature the mercury removal efficiency in the particulate device the coal rank and the mercury removal efficiency without control determines the injection rate of activated carbon into the flue gas Mercury removal due to the ash removed in a cold side ESP or fabric filter in the absence of enhanced mercury control methods is specified in the input screen The default value is most sensitive to the flue gas temperature and the mercury removal efficiency without control Carbon Injection Power Requirement The power required for the water and carbon injection system is a function of carbon injection rate the water injection rate and the flue gas flow rate This assumes the addition of a fan in the flue gas to balance the pressure drop The default value is calculated as the ratio of the actual energy consumption by the gross electrical output of the power plant Integrated Environmental Control Model User Manual Mercury Retrofit Cost Inputs This screen is only available for the Combustion Boiler plant type Inputs for the capital costs of modifications to process areas of the activated carbon and water injection system are entered on the Retro
148. per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Integrated Environmental Control Model User Manual Fabric Filter e 213 Fabric Filter Diagram 214 e Fabric Filter This screen is only available for the Combustion Boiler plant type The Diagram result screen displays an icon for the Fabric Filter particulate control technology selected and values for major flows in and out of it Eile Edit View Window Help Temperature In deg F Flue Gas In acfm Fly Ash In ton hr Mercury In lb hr 175 0 1 392e 06 26 44 3 533e 02 R Temperature Out deg F Flue Gas Out acfim Fly Ash Out ton hr Mercury Out lb hr D e Get Results amp Air 502 CO2 By Prod Control Capture Mgmt 8 db B 175 0
149. properties can be modified The natural gas properties will be made available in the future At present a common Pennsylvania natural gas is assumed NGCC The natural gas combined cycle NGCC plant configurations all assume natural gas for fuel The properties can be specified by the user The integrated gasification combined cycle IGCC plant configurations assume coal gasification to produce a synthetic fuel gas The coal properties must be chosen from a predetermined set of coals Fuel Properties Coal Input The selection of the particular coal model default cleaned saved externally or user specified and its ultimate and ash properties are selected and editable on the Properties input screen Integrated Environmental Control Model User Manual Fuel e 73 74 o Fuel zix File Edit view Window Help B untitled 5 x zls lale le lorlo Current Fuel r Fuel Databases Configure Plant Set Parameters Get Results Name Fuel Appalachian Low Sulfur gt Rank Bituminous Rank Bituminous urce Default Source model_default_fuels mdb c progra 1 iectr Composition wt as received and I Show All Plant Types Higher Heating Value Btw Tot 100 0 J Show All Fuel Types Open x Database Property Value Save For AIl Property Value Heating Value 10900 I Plant Types Heating Value 1 308e 04 New Carbon 61 2 EEE Carbon 71 74 Database Hydrogen 4 2 Hydrogen 4 620 Oxyge
150. rate into the boiler on a wet basis Waste products removed prior to the burners are not considered here Mercury In This is the mass flow rate of total mercury entering the boiler The mass reflects the molecular weight of elemental mercury Air Entering Boiler Temperature Heated air temperature measured at the burners This is generally determined by the combustion air temperature exiting the air preheater 148 e In Furnace Controls Heated Air Volumetric flow rate of the air at the burners based on the air temperature at the burners and atmospheric pressure Integrated Environmental Control Model User Manual Flue Gas Exiting Convective Zone This the area of the furnace between the combustion zone and the SNCR if present Changes in the flue gas after combustion due to in furnace combustion NO controls are reflected here Temperature Temperature of the flue gas exiting the convective zone Flue Gas Volumetric flow rate of the flue gas exiting the convective zone based on the temperature exiting the convective zone and atmospheric pressure Fly Ash Total solids mass flow rate in the flue gas exiting the convective zone This includes ash unburned carbon and unburned sulfur Mercury Total mass of mercury in the flue gas exiting the convective zone The value is a sum of all the forms of mercury elemental oxidized and particulate Flue Gas Exiting the Economizer Temperature Out Temperature of the flue gas
151. retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens Each parameter is described briefly below Although the user cannot set the capital cost directly the descriptions below include the key parameters used to determine the capital cost itself The input parameters on this screen adjust this capital cost as calculated in the IECM Capital Cost Process Area Spray Cooling Water This capital cost area represents the materials and equipment necessary to inject water into the flue gas duct for the Integrated Environmental Control Model User Manual Mercury 179 purpose of cooling the flue gas to a prerequisite temperature Equipment includes water storage tanks pumps transport piping injection grid with nozzles and a control system The direct capital cost is a function of the water flow rate Sorbent Injection This capital cost area represents the materials and equipment necessary to deliver the activated carbon into the flue gas Equipment includes silo pneumatic loading system storage silos hoppers blowers transport piping and a control system The direct capital co
152. right of way for the pipeline This cost not only includes compensating landowners for signing easement agreements but landowners may be also be paid for loss of certain uses of the land during and after construction loss of any other resources and any damage to property Booster Pump Cost This is the total capital cost of a booster pump Miscellaneous Cost This includes the costs of surveying engineering supervision contingencies telecommunications equipment freight taxes allowances for funds used during construction AUFDC administration and overheads and regulatory filing fees Integrated Environmental Control Model User Manual CO Transport System Capital Cost Inputs This screen is available for all of the plant types the Combustion Boiler the Combustion Turbine and IGCC File Edit View Go Window Help Configure Plant Set Parameters Get Results z e amp S B S 0 2500 10 00 General F acilities Capital L n 50 00 Engineering amp Home Office Fees B oo 60 00 Project Contingency Cost p 100 0 e Process Contingency Cost 4 y 100 0 gt Royalty Fees A K 10 00 Pre Production Costs Months of Fixed O amp M Months of Variable O amp M Misc Capital Cost Inventory Capital TCR Recovery Factor Process Type C02 Transport ha 1 Config 3 Retrofit Cost 4 Capital Cost 5 0 amp M Cost CO Tran
153. sabe aaa 264 ADSOLDER i is citties Sess sock sulcus E A E E 264 RegeneratOt soiecs codacd esbiSta ae aoee E nE E A EEE EEES EAE AEE EE E E ASEE 265 Amine System Storage INpuls annsan erin ea en ea aea a eE E a aa Ea 266 CO Product Steamin e a cheeses Man O 266 CO Transport amp Storage iiei inerea o Een 267 Amine System Retrofit Cost Inputs seseseseseeesseessesresesressressressressrererersrerserersrereesreesresse 267 Capital Cost Process Area rasnon a e ve i ee 268 Amine System Capital Cost Inputs 0 cee anene a E a 269 Amine System O amp M Cost Inputs 3 ieni indies aoe hae Ai eles 271 Integrated Environmental Control Model User Manual Contents e ix CO2 Transport and Storage Costs 00 eeseeeseeceseeeeceeesseecsacesseeceseesesaeeeseeeenee 272 Amine System Dia gran oc eane eke veh cess eer sake aut ste ETa chested aa eaa n eaa aa 273 Reagent corde cigs roe eek canis eSorsceaes este lensaoets a adh ste netey oats A obs 273 Flue Gas Entering Amine System eee eesceeseeceseeeeceeesseecsaeecsseecsneeeesaeeeseneeeeee 273 Flue Gas Exiting Amine System ceceeesceseseeceseecenseeesseecsaeecsaeesseeeesaeeessneeeees 274 Amine System Performance cscceescccesseesssececesceceecescecesaeeesaeecsaeeceesaeeneeeesaes 274 Collected Solids sevusds ash eesiasiieds A E E E RE 274 Amine System Flue Gas Results yseaesseeaesieghaes ba e EE ne eueesedepounnedustenses 274 Major Flue Gas Components
154. saturation temperature increases the evaporation time decreases thereby decreasing removal efficiency Temperature Rise Across ID Fan An induced draft ID fan is assumed to be located upstream of the FGD system The fan raises the temperature of the flue gas due to dissipation of electro mechanical energy Gas Temperature Exiting Scrubber A thermodynamic equation is used to calculate this equilibrium flue gas temperature exiting the scrubber The gas is assumed to be saturated with water at the exiting temperature and pressure The value determines the water evaporated in the scrubber Integrated Environmental Control Model User Manual Spray Dryer e 245 Oxidation of CaSO3 to CaSO4 This parameter determines the mixture of the two chemical species in the solid waste stream Slurry Recycle Ratio An atomized spray of a mixture of lime slurry and recycled solids is brought into contact with the hot flue gas This parameter specifies the amount of solid waste recycled and lime slurry used It is calculated from the sulfur content of the coal Spray Dryer Power Requirement This is the equivalent electrical output of thermal steam energy used for reheat plus the actual electrical output power required for pumps and booster fans Spray Dryer Retrofit Cost 246 e Spray Dryer This screen is only available for the Combustion Boiler plant type Inputs for capital costs of modifications to process areas to implement the SO control tec
155. scrubbing General Support Area The cost associated with the equipment required to support FGD system operation such as makeup water and instrument air are treated here Miscellaneous Equipment Any miscellaneous equipment is treated in this process area Wet FGD Capital Cost Inputs This screen is only available for the Combustion Boiler plant type Integrated Environmental Control Model User Manual Wet FGD e 229 230 Wet FGD 7 IECH Interface ioj xi zs t mle moo File Edt View Go Window Help Us Untitled ot x Configure Plant Set Parameters Get Results Base Plant Mercury Title 10 00 General Facilities Capital i 50 00 Engineering amp Home Office Fees Hl 60 00 Project Contingency Cost 100 0 Process Contingency Cost fl 100 0 Royalty Fees i 10 00 _ CeAAH amp wn Pre Production Costs Months of Fixed O amp M Months of Variable O amp M 12 Misc Capital Cost 13 14 Inventory Capital 15 16 17 18 TCR Recovery Factor Process Type wet FGD z 1 Config mance 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Wet FGD Capital Cost input screen Each parameter is described briefly below Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC Bypass Duct Cost Adder The bypass capital
156. specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Disposal Total cost to dispose the collected tower waste solids and wastewater Electricity Cost of power consumption of the scrubber This is a function of the gross plant capacity and the cooling system energy penalty performance input parameter Water This is the annual cost of the water used by the cooling system Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight Integrated Environmental Control Model User Manual Water Systems e 19 hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenan
157. subject to inflation Misc Chemicals A small quantity of chemicals is used in this process including chemicals desiccant and lubricants The aggregate cost of these chemicals is estimated based on the flow rate of CO captured Wastewater Treatment The user may enter a cost for treating the moisture condensed from the flue gas CO Transport The CO captured at the power plant site has to be carried to the appropriate storage disposal site Transport of CO to a storage site is assumed to be via pipeline This is the annual cost of maintaining those pipelines CO Storage Once the CO is captured it needs to be securely stored sequestered This cost is based upon the storage option chosen on the O CO Recycle Flue Gas CO storage input screen Electricity The cost of electricity consumed by the Flue Gas Recycle System Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determ
158. supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the hot side SCR that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor for the hot side SCR Hot Side SCR O amp M Cost Results 170 Hot Side SCR This screen is only available for the Combustion Boiler plant type 7 IECM Interface O x File Edit View Go Window Help Configure Plant Set Parameters Get Results NOx TSP 502 co2 By Prod Preheater Mefraraye Mercury Control Control Capture Mgmt Stack O amp M Cost O amp M Cost Variable Cost Co nt Fixed Cost Co t oan Msa acta Msye 1 683 Ammonia 0 5587 Steam 0 3551 Water 1 720e 03 Electricity 0 7356 Operating Labor 0 1386 Maintenance Labor 0 1593 Maintenance Material 0 2390 Admin amp Support Labor 8 938e 02 ne Aw aw Celli ar a j zaleen zs t Se aloo ealan awin Process Type Hot Side SCR z 2 Flue Gas 3 Capital Cost 4 0 amp M Cost 3 Total Cost Costs are in Constant 2005 dollars Integrated Environmental Contro
159. tend to be conservative in their estimates e the person may want to suppress uncertainty that they actually believe is present in order to appear knowledgeable or authoritative and e the expert has taken a strong stand in the past and does not want to appear to contradict himself by producing a distribution that lends credence to alternative views Designing an Elicitation Protocol Studies of uncertainty judgment show that the most frequent problem encountered is overconfidence Knowledge of how people make judgments about probability distributions can be used to design a procedure for eliciting these judgments The appropriate procedure depends on the background of the expert and the quantity for which the judgment is being elicited For example if you have some prior knowledge about the shape of the distribution for the quantity then it may be appropriate to ask you to think about extreme values of the distribution and then to draw the distribution yourself On the other hand if you have little statistical background it may be more appropriate to ask you a series of questions For example you might be asked the probability of obtaining a value less than or equal to some value x and then the question is repeated for a few other values of x Your judgment can then be graphed by an elicitor who would review the results of the elicitation with you to see if you are comfortable with your answers To overcome the typical problem of overcon
160. the Combustion Boiler plant type The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Cold Side ESP TSP Control technology File Edit View Go Window Help Configure Plant Set Parameters Get Results 02 CO2 By Prod Control Capture Mgmt Stack ton solids Cost Component MWh d Percent Total Annual Fixed Cost 0 3431 11 90 15 06 Annual Variable Cost 1 114 0 5092 17 67 22 35 3 TotalAnmulOeMCot 1885 oss23 2957 s40 Annualized Capital Cost 3 121 1 427 49 50 62 60 wh t Ele alelo ed ell ea alle pt pet pet pt pt pet na Ne Process Type cota Side ESP z Costs are in Constant 2005 dollars 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost Cold Side ESP Total Cost result screen Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Integrated Environmental Control Model User Manual Cold Side ESP e 205 Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent che
161. the IECM interface click the Help icon inside the IECM folder on the Start menu This opens the help file to the table of contents If you are running the IECM interface do any one of the following e Press the F1 key The IECM supports context sensitive help and will open the help file to the topic associated with the item or screen you are viewing e Pull down the Help menu at the top of the IECM window Select Help Topics This opens the help file to the table of contents e Click the Context Sensitive Help icon on the toolbar on the left side of the IECM window The IECM supports context sensitive help and will open the help file to the topic associated with the item or screen you are viewing e Click the Help Topics icon on the toolbar on the left side of the IECM window This opens the help file to the table of contents If this method does not work try one of the other options above Integrated Environmental Control Model User Manual User Documentation and Help e 9 The IECM Help File Contents window will display Help Topics IECM User_hip lt Introduction User Documentation and Help Installing the Model Advanced Configure Plant Combustion Overall Plant Overall NGCC Plant Overall IGCC Plant Fuel ir Separation Base Plant Auzsiliary Boiler Gasifier Air Preheater In Furnace Controls Hot Side SCR The IECM Help File Topics Window 10 e User Documentation and Help
162. the bumps on the pipe wall for commercial pipes this is usually a very small number Note that perfectly smooth pipes would have a roughness of zero CO Transport System Financing Inputs This screen is available for all plant types 356 e CO2 Transport System lolx Edit View Go Window Help Eile zie S amp mle O H e o Configure Plant Inflation Rate 18 Process Type C02 Transport 2 Financing 2 RetrofitCost 4 Capital Cost 5 O amp M Cost CO Transport System Financing input screen Integrated Environmental Control Model User Manual Pipeline Region This is the region of the U S where the project will be built central mid west northeast southeast or western These regions are based on the EIA natural gas pipeline regions Year Costs Reported This is the year in which all costs are given or displayed both in the input screens and the results A cost index is used by the IECM to scale all costs to the cost year specified by this parameter Discount Rate Before Taxes This is also known as the cost of money Discount rate before taxes is equal to the sum or return on debt plus return on equity and is the time value of money used in before tax present worth arithmetic i e levelization Fixed Charge Factor FCF This parameter also known as the capital recovery factor is used to find the uniform annual amount needed to rep
163. the gas scrubbing unit and because blowdown from the gas scrubbing unit is the larger of the flow streams entering the process condensate treatment section it is expected that process condensate treatment cost will depend primarily on the scrubber blowdown flow rate Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow GE Gasifier Plant Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC
164. through heat exchangers added after each reactor This process area accounts for the heat exchangers used Steam generated in the heat exchangers is sent to the steam cycle Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Integrated Environmental Control Model User Manual Water Gas Shift Reactor Plant Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during
165. to avoid accumulation of these salts in the sorbent stream and to recover some of this lost MEA sorbent a part of the sorbent stream is periodically distilled in this vessel Addition of caustic helps in freeing of some of the MEA The recovered MEA is taken back to the sorbent stream while the bottom sludge reclaimer waste is sent for proper disposal Sorbent Processing The regenerated sorbent has to be further cooled down even after passing through the rich lean cross heat exchanger using a cooler so that the sorbent temperature is brought back to acceptable level about 40 deg C Also in order to make up for the sorbent losses a small quantity of fresh MEA sorbent has to be added to the sorbent stream So the sorbent processing area primarily consists of sorbent cooler MEA storage tank and a mixer It also consists of an activated carbon bed filter that adsorbs impurities degradation products of MEA from the sorbent stream Drying and Compression Unit The CO product may have to be carried to very long distances via pipelines Hence it is desirable that it does not contain any moisture in order to avoid corrosion in the pipelines Also it has to be compressed to very high pressures so that it gets liquefied and can overcome the pressure losses during the pipeline transport The multi stage compression unit with inter stage cooling and drying yields a final CO product at the specified pressure about 2000 psig that contains moistu
166. to convert electrical power input into mechanical power output Percent Water in Reclaimer Waste This is the amount of water typically present in the reclaimer waste Amine System Storage Inputs 266 e Amine System This screen is only available for the Combustion Boiler and Combustion Turbine plant types y IECM Interface File Edit View Go Window Help my Untitled e Configure Plant Set Parameters Get Results T peA cS TSP Con ontrol Capture S Title Units Fi CO2 Product Stream CO2 Product Pressure psig eB CO2 Compressor Efficiency E CO2 Unit Compression Energy kWh ton CO2 En CO2 Transport amp Storage gt g Enhanced Oil Recovery BOR R Enhanced Coal Bed Methane B Geological Reservoir Geologic Ocean Ocean F 5 Retrofit Cost 6 Capital Cost 7 O amp M Cost Amine System Storage input screen This screen characterizes the compression and storage location for the product CO A separate pipeline model is provided to specify inputs for that sub system The pipeline model is accessed from the Process Type menu at the bottom of the screen CO Product Stream The concentrated CO product stream obtained from sorbent regeneration is compressed and dried using a multi stage compressor with inter stage cooling Integrated Environmental Control Model User Manual Product Pressure The CO product may
167. to process areas to implement the Particulate control technology are entered on the Retrofit Cost input screen The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment Integrated Environmental Control Model User Manual Fabric Filter e 209 210 e Fabric Filter installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens File Edit View Go Window
168. total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Hot Side SCR Total Cost Results 172 e Hot Side SCR This screen is only available for the Combustion Boiler plant type File Edit View Go Window Help Configure Plant Set Parameters Get Results TSP 02 CO2 By Prod Mercury Control Control Capture Mgmt piaci Percent Total 7 447 Annual Variable Cost 39 64 vne a Annualized Capital Cost 52 91 S TotaiLeveized AnaualCost e41 sese 1393 100 zs t mlel alelo e ed el aa Hot Side SCR Costs are in Constant 2005 dollars 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost Hot Side SCR Total Cost result screen The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Hot Side SCR NO Control technology Note that all costs expressed in ton of NO removed assume tons of equivalent NO Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating
169. turbine efficiency may be considered the power generation efficiency when converting heat of the low pressure LP steam into usable electricity The efficiency is much lower due to the low quality of the steam being converted This is only visible when steam and power are specified Amine System Performance Inputs 262 e Amine System This screen is only available for the Combustion Boiler and Combustion Turbine plant types Integrated Environmental Control Model User Manual 7 IECM Interface File Edit View Window Help Bf untitled AmE Config Plant Set Parameters TSP 502 z R e e le oleo Maximum Train CO2 Capacity tom hr Number of Operating Absorbers integer Number of Spare Absorbers integer Max CO2 Compressor Capacity ton hr No of Operating CO2 Compressors integer No of Spare CO2 Compressors integer Amine Scrubber Power Requirement MWg Process Type Amine System z b 1Conis APRENEM 2 Capture 4 CO2Storage 5 RetrofitCost 6 CapitalCost 1 O amp M Cost A Amine System Performance input screen The amine based absorption system for CO removal is a wet scrubbing operation This process removes other acid gases and particulate matter in addition to CO from the flue gas These are listed below along with additional performance parameters CO Removal Efficiency Most studies report the CO capture efficiency of the amine based syst
170. typically used in a single train The staging process reduces the power of CO compression later Selexol Pumps The CO lean solvent is pumped back to the absorber operating pressure by a Selexol circulation pump Refrigeration CO lean solvent must be cooled to the absorber operating temperature before being returned to the absorber vessel A refrigeration unit is used to reduce the temperature of the solvent CO Compressors CO released from the first two flash tanks is compressed to the flashing pressure of the first flash tank The two CO streams are then combined and sent to the final product compressors Integrated Environmental Control Model User Manual Final Product Compressors The product CO must be separated from the water vapor dried and compressed to liquid form in order to transport it over long distances The multi stage compression unit with inter stage cooling and drying yields a final CO product at the nominal pressure of 2000 psig This area is a function of the CO flow rate Heat Exchangers This process area considers miscellaneous heat exchangers used in the overall process Selexol CO Capture Capital Cost Inputs This screen is only available for the IGCC plant type 7 IECH Interface Fie Edit View Go Window Help US Untitled eS Configure Plant Set Parameters Get Results i By Prod Mgmt aj Min Max 4 10 00 e General Facilities Capital 50 00 Eng
171. used by the PC plant The choices also include the following which are grayed out and may be available in the future e Coal e Oil e Natural Gas e Other NO Control From this configuration screen you may choose e None e In Furnace Controls Controls include an assortment of options which combine low NO burners LNB with overfire air OFA selective non catalytic reduction SNCR and natural gas reburn These options are selected from a pull down menu in the Set Parameters menu Post Combustion Controls These configuration options determine the presence and type of post combustion emissions controls NO Control The default option is None The choices available are e None for no post combustion NO control e Hot Side SCR for a Hot Side Selective Catalytic Reduction technology Although an SCR technology can be positioned at various points along the flue gas train the IECM considers only the hot side high dust configuration Hot Side SCR may be together with In Furnace Controls Particulates The default option is None The None setting is not available when the Mercury technology option is either Carbon Injection or Carbon Water Injection This assures the removal of the carbon being injected immediately downstream of the air preheater Multiple fabric filter types are provided Fabric filter types are based on the bag cleaning techniques used Various bag cleaning techniques influence other process paramet
172. wet tower and back to the condenser The tower mainly relies on the latent heat of water evaporation to transfer waste heat to the atmosphere Air Cooled Condenser The air cooled condenser utilizes the sensible heating of atmospheric air passed across finned tube heat exchangers to reject heat Once Through Water Systems Results This screen is available for all plant types when the once through cooling system is loaded Integrated Environmental Control Model User Manual Water Systems e 5 7 IECM Interface File Edit View Go Window Help sa Untitled Configure Plant e o P e o ti Cooling Water tons hr 2 999e 4 Process Type TTC 1 Diagram l 1 g Once Through Cooling Water Result Screen Cooling Water This variable presents the amount of cooling water through the primary steam cycle plus auxiliary cooling Wet Cooling Tower Configuration This screen is available for all plant types Inputs for configuration of the Wet Cooling Tower are entered on the Config input screen 6 e Water Systems Integrated Environmental Control Model User Manual 7 IECM Interface 6 1 1 DER File Edit View Go Window Help Ve Untitled Configure Plant Set Parameters j Get Results Mgmt Une Value Cale Mi Default 1 Configuration Menus 2 Ai Flow Draft Control Type Forced E Forced a le lollo o 3 Slip Stream Treatment System No No 4 Makeup Water Treatment System No No
173. with the Cold Side ESP TSP particulate control technology Integrated Environmental Control Model User Manual Cold Side ESP 203 204 e Cold Side ESP 7 IECH Interface ioj xi File Edit View Go Window Help Configure Plant Set Parameters Get Results 02 CO2 By Prod Control Capture Mgmt Stack Variable Cost Component Fixed Cost Component Ms Solid Waste Disposal Operating Labor 0 2922 Electricity Maintenance Labor 0 1459 Maintenance Material 0 1809 Admin amp Support Labor 0 1315 ae ealo lig _ tt oaoa wn 9 Cold Side ESP z Costs are in Constant 2005 dollars F CapitalCost E 5 Total Cost Cold Side ESP O amp M Cost result screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Component Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Solid Waste Disposal Total cost to dispose the collected fly ash This does not consider by product ash sold in commerce Power Cost of power consumption of the particulate control technology This is a function of the flue gas flow rate ash removal efficiency and the ty
174. year as shown on the bottom of the screen Each result is described briefly below Direct Capital Costs Each process area direct capital cost is a reduced form model based on regression analysis of data collected from several reports and analyses of particulate control technology units They are described in general below The primary factors in the model that effect the capital costs of the scrubbers are the flue gas flow rate through the scrubber the composition of the flue gas the reagent stoichiometry and the reagent flow rate Reagent Feed System This area includes all equipment for storage handling and preparation of raw materials reagents and additives used SO Removal System This area deals with the cost of equipment for SO scrubbing such as absorption tower recirculation pumps and other equipment Integrated Environmental Control Model User Manual Wet FGD e 237 Flue Gas System This area treats the cost of the duct work and fans required for flue gas distribution to SO system plus gas reheat equipment Solids Handling System This area includes the cost of the equipment for fixation treatment and transportation of all sludge dry solids materials produced by scrubbing General Support Area The cost associated with the equipment required to support FGD system operation such as makeup water and instrument air are treated here Miscellaneous Equipment Any miscellaneous equipment is treated in this process are
175. 0 00 Project Contingency Cost 5 100 0 Process Contingency Cost i 100 0 Royalty Fees 4 10 00 CO2 Capture Power Block Stack Pre Production Costs Months of Fixed O amp M Months of Variable O amp M Misc Capital Cost zis lt a me le aeoo Inventory Capital TCR Recovery Factor Sulfur Capture System 2 Retrofit Cost 3 Capital Cost 4 0 amp M Cost Sulfur Removal Capital Cost input screen Inputs for capital costs are entered on the Capital Cost input screen Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost
176. 0 3017 Sulfuric Acid equivalent 503 K 0 0 0 0 Nitric Oxide NO 1 786e 02 2 679e 04 3 186e 02 Nitrogen Dioxide NO2 9 399e 04 3 yi 2 162e 05 Ammonia NH3 0 0 i 0 0 Argon Ar 0 0 0 0 z 2 e olmo 1 cil Process Type Stack v Stack Flue Gas result screen Major Flue Gas Components Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO3 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass ofargon Total Total of the individual components listed above This item is highlighted in yellow Integrated Environmental Control Model User Manual Stack 371 Stack Emission Taxes Results LC File Edit View Window Help Nitrogen Oxide equiv NO2 Carbon Dioxide CO2 Costs are in Constant 2000 dollars Stack Emis Taxes result screen The Stack Emis Taxes results screen shows the cost of to the plant for emissions The Taxe
177. 00 10 00 5 Project Contingency Cost 0 0 100 0 15 00 6 Process Contingency Cost i 0 0 100 0 00 7 Royalty Fees i i 5 l oo 10 00 0 5000 a da e a n A Miil 9 Pre Production Costs 10 Months of Fixed O amp M l i i o 120 11 Months of Variable O amp M j 12 00 12 Misc Capital Cost i 10 00 13 14 Inventory Capital 10 00 B E s a 100 0 0 0 200 0 Costs are in Constant 2007 dollars Wet Cooling Tower Capital Cost Input Screen Each parameter is described briefly below Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost
178. 02 7 167e 03 i 17 47 Annualized Capital Cost 8 167e 03 3 733e 03 il 9 099 Zis elt 2 mle le aeoe Activated Carbon Inj Costs are in Constant 2005 dollars LCi Cosi AOMC EEE Mercury Total Cost result screen Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Mercury 191 Cold Side ESP The TSP Control Technology Navigation screens define and disp
179. 100 0 Total Maintenance Cost TPC 4 10 00 Maint Cost Allocated to Labor total 40 1 A 100 0 Administrative amp Support Cost total labor if i 100 0 CRA AH amp w N Zis elt 2 ale e moe _ CO2 Transport and Storage Costs 13 CO2 Transportation Cost ton mile 0 0 0 1000 14 15 16 a7 N y 18 Process Type Fe Recycle amp Purification gt Costs are in Constant 2005 dollars 1 Config 3 CO2 Storage 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost O2 CO gt Recycle Flue Gas O amp M cost input screen Inputs for operation and maintenance are entered on the O amp M Cost input O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each parameter is described briefly below Misc Chemicals Cost This is the annual cost of chemicals that are used in the Flue Gas Recycle area of the plant The cost is reported in dollars per ton of CO2 captured Wastewater Treatment Cost This is the annual cost of treating the wastewater that is used in the Flue Gas Recycle area of the plant The cost is reported in dollars per ton Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is a combustion boiler and an air preheater
180. 2 SteamCycle 4 RetrofitCost 5 CapitalCost 6 O amp M Cost Power Block O amp M Cost input screen Inputs for operating and maintenance costs are entered on the O amp M Cost input screen O amp M costs are typically expressed on an average annual basis and are Integrated Environmental Control Model User Manual Power Block 379 provided in either constant or current dollars for a specified year as shown on the bottom of the screen Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is the power block This is provided for reference purposes only Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost al
181. 2722e 02 2 722e 02 9 Hydrochloric Acid HC 0 0 0 0 0 0 0 0 10 Carbon Dioxide COD 2 243e 04 2243 4937 4937 11 Water Vapor H20 6639 6639 59 82 59 82 12 Nitrogen ND 3525 3525 4 937 4 937 13 Argon At 417 3 417 3 8 336 8 336 14 Oxygen 02 oo o0 oo oo asha ate ane erg 100 Process Type fe Selexol CO2 Capture X smes METTEN RT zis a P le loeloe Selexol CO Capture Gas Flow result screen Major Syngas Components Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H2 Total mass of hydrogen Methane CH4 Total mass of methane Ethane C2H6 Total mass of ethane Propane C3Hsg Total mass of propane Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbonyl sulfide Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of hydrochloric acid Carbon Dioxide CO2 Total mass of carbon dioxide Water Vapor H20 Total mass of water vapor Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Oxygen O2 Total mass of oxygen Total Total of the individual components listed above This item is highlighted in yellow Integrated Environmental Control Model User Manual Selexol CO2 Capture 311 Selexol CO Capture Capital Cost Results 312 e Selexol CO2 Capture This screen is only available for the IGCC plant type 7 IECH Interface File Edit Vi
182. 3 5 643 0 1029 Sulfur Dioxide S02 214 2 213 0 6 862 Sulfuric Acid equivalent S03 1 728 2935 6 916e 02 Nitric Oxide NO 21 98 10 99 0 3298 Nitrogen Dioxide NOD 1157 0 5783 2 661e 02 11 Ammonia NH3 2595 0 7392 2 210e 02 Argon Ay 0 0 oo o0 alel le olplo o ha i Z Process Type Hot Side SCR hd 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost Hot Side SCR Flue Gas result screen Major Flue Gas Components The Flue Gas result screen for the Hot Side SCR displays a table of quantities of flue gas components entering and exiting the SCR For each component quantities are given in both moles and mass per hour Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Integrated Environmental Control Model User Manual Hot Side SCR e 167 Sulfur Dioxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is high
183. 3 Toulon WH Overall NGCC Plant Cost Summary results screen Integrated Environmental Control Model User Manual Overall NGCC Plant e 55 56 e Overall NGCC Plant The Cost Summary result screen displays costs associated with the power plant as a whole Each technology row is described briefly below Technology CO Capture This is the capital cost for the equipment that captures CO in the plant Power Block This is the capital cost for the power block process area of the plant Post Combustion NO Control This is the capital cost for the equipment that captures post combustion NO in the plant Subtotal This is the cost of the conventional and advanced abatement technology modules alone This is the total abatement cost The subtotal is highlighted in yellow Emission Taxes This is the sum of the user assessed taxes on the plant emissions of SO NO and CO Total This is the sum of all of the above capital costs for all of the process areas in the plant Each cost category column is described briefly below Capital Cost The total capital requirement TCR This is the money that is placed capitalized on the books of the utility on the service date The total cost includes the total plant investment plus capitalized plant startup Escalation and allowance for funds used during construction AFUDC are also included The capital cost is given on both a total and an annualized basis Revenue Required Amoun
184. 361 Froni Pl t i siei sath Sesshate seelaanwnctvatta cgelecehcednethaceedecendscnctoneget caubes cktbas Seadeaseudbeacess 361 To COs Transport Systems cccischsccectia ccelocsbeanseaen ectecebs cchsbeh siebcaeberskecesdenebawbaedtetess 361 VO SOLA SE ve ood es ione reer n e E EEEE E AE coud ccbdus EEEE 362 CO Transport System Flue Gas Results eseeseeseeseeeesesssserresrreserrersereersereererreesrssrreeseet 362 Major Flue Gas Components scceesccssseessseeceeeecseecsseeeesaeessaeecsaeesceaeeneeeesaes 362 CO Transport System Gas Results eee eesscceesssneeeesseeesesseeeceesseeecesseaeeesesaesessaeeeees 363 Major Gas Coriponents sss 2 2 sa cae out degarededuns ctvedesoresuatpasetstetese adanpetedeveteeteuseasnty 363 CO Transport System Capital Cost Results cee eeeeseseccsseeeceseceseeeesaeecsaeecseessseeeeseaeers 364 CO Transport Process Area Costs eecceesscecceessceeeecesseeceseseceesseeecessaeeesenenaaees 364 CO Transport Plant COStss srecno te ese anpare r etesevsecdepstudeseslouupbedepesuecedsntsedess 365 CO Transport System O amp M Cost Results ieee cceeseeeecceeeeecesseeeceesseeecessaeeesesesaaees 366 Variable Cost Components eeecceeseeceseeesssceceeecsseecsseecesaeessaeecssneesesaeeneeeesaes 366 Fix d Cost Components or eisegi e eae naes eeen pones aeeie eano tap iesean eats 366 CO Transport System Total Cost Results ssesesseeseeeesseseeeeererserrersereerseree
185. 7 302e02 i 6 000 calc Tailgas Treatment 17 Power Requirement MWe 0 2221 A 0 0 6 000 calc 18 Process Type Sulfur Capture System E 1 Performance 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Sulfur Removal Performance input screen The acid gas removal system employs the Selexol process for selective removal of hydrogen sulfide H2S and carbonyl sulfide COS Usually COS is present in much smaller quantities than HS In this unit most of the H S is removed by absorption in the Selexol solvent with a typical removal efficiency of 95 to 98 percent Typically only about one third of COS in the syngas will be absorbed A hydrolyzer is used to convert the captured COS to H3S in preparation for the stripping of H2S from the Selexol solvent along with sour gas from the process water treatment unit This Integrated Environmental Control Model User Manual Sulfur Removal 331 concentrated gas stream is then sent to the Claus sulfur plant for recovery of elemental sulfur Hydrolyzer or Shift Reactor COS to H2S Conversion Efficiency This is the efficiency with which carbonyl sulfide is converted to hydrogen sulfide Sulfur Removal Unit H2S Removal Efficiency This is the removal efficiency of HS from the inlet syngas stream The H3S is removed by an absorption process that is very effective at capture of HS COS Removal Efficiency This is the removal efficiency of COS The absorp
186. 88 O3 CO Recycle Capital Cost Inputs ee eeeeesceceseecesnecsseecsseeseeecsseeesaeeeseaeessereneeeeee 290 O CO Recycle O amp M Cost Inputs eee e E E EEE i 291 O5 CO gt Recycle Diagram 2 s 2 cents edie ee ee ee ae Ea 293 OCO Recycle DCC Gas Results 2 0 0 eeessssnnccceececeesssenecececeeeesssneeeeeeeeeeseeeseseeeeseees 294 O CO Recycle Purification Gas Results cccccceeescceceesseeceeeeeeeeeeneeeeeesneeeeeseeeeeeenennees 295 O5 CO Recycle Capital Cost Results 0 0 ee eee ceesceesseecessneecsseeseeceeeseseeessaeeessaeessereneeeeea 296 O CO Recycle O amp M Cost Results eeeessncececeeeceeeseneeeeeeceeeesssneeeeceeeeeceeeeesseeeeeeees 298 O CO Recycle Total Cost Results ee eeeessseceecceeceeessnneeeeeceeesesssnceeeeeeeeceeeseeeeeeeeeeeees 299 O CO Recycle Miscellaneous Results cccsccceesseeceeeeeeeceeeeeeeeeseeeeceseeeeeeseneeeessenees 300 Selexol CO Capture 303 Selexol CO Capture Reference Plant Inputs eee eeececeseecessneeceeesseeceseeesseeeesaeessaeeeenee 303 Reference Plant 5 2 saves onvatinaiei adie aan olde ele Ri aie 303 Selexol CO Capture Performance Inputs 0 0 0 0 eessesesecceseeccsseessseecscecsseeesseeeesaeeeeseeeees 304 Carbon Dioxide Removal Unit 0 eee eeseceseecesseeeneeeesseecsaeecsseessseeeeseaeesseeese 304 Selexol CO Capture CO Storage Inputs eee ceeeseeceseeseesesaeeecesseeeesesseeeeesesseeeees 304 COs Product Stream 33 drna E E N N E E N 305
187. A Non technical Example To illustrate the process of defining a subjective probability distribution let s turn to a simple example of eating lunch in a cafeteria How long does it take from the time you enter the cafeteria to the time you pay the cashier Assume that you enter at 12 05 p m on a weekday and that you purchase your entire meal at the cafeteria The answer you give may depend on your recent experiences in the cafeteria Think about the shortest possible time that it could take suppose nobody else is getting lunch or the longest possible time everyone shows up at the same time What is the probability that it will take 2 minutes or less 45 minutes or less Is the probability that it takes 10 minutes or less greater than 50 percent etc After asking yourself a number of questions such as these it should be possible to draw a distribution for your judgment regarding the time require to obtain and purchase lunch at the cafeteria Such a distribution might take the form of a fractile distribution giving the probabilities of different waiting times to purchase lunch For example your evaluation may conclude that there is only a 1 percent 1 in 100 chance it will take one minute or less a 60 percent chance of 1 to 10 minutes a 25 percent likelihood of 10 to 15 minutes and a 14 percent chance of up to 25 minutes These probability intervals can be drawn as a histogram and translated into a fractile distribution for a probabilistic anal
188. Area COS Conversion System Hydrolyzer The Hydrolyzer helps to separate the carbon from the sulfur by converting carbonyl sulfide to hydrogen sulfide Sulfur Removal System Selexol H2S in the syngas is removed through counter current contact with Selexol solvent The cost of the Selexol section includes the acid gas absorber syngas knock out drum syngas heat exchanger flash drum lean solvent cooler mechanical refrigeration unit lean rich solvent heat exchanger solvent regenerator regenerator air cooled overhead condenser acid gas knock out drum regenerator reboiler and pumps and expanders associated with the Selexol process Sulfur Recovery System Claus The Claus plant contains a two stage sulfur furnace sulfur condensers and catalysts Tail Gas Treatment Beavon Stretford The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs Integrated Environmental Control Model User Manual Sulfur Removal e 333 All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Sulfur Removal Capital Cost Inputs 334 e Sulfur Removal 7 IECH Interface ioj xi Fie Edit View Go Window Help Configure Plant Set Parameters Get Results By Prod Mgmt Title Min Max 10 00 General Facilities Capital o 50 00 Engineering amp Home Office Fees y 6
189. Area Reagent Feed System retro new 502 Removal System retro new Flue Gas System retro new Solids Handling System retro new General Support Area retro new Miscellaneous Equipment retro new _ SAA ne wr zs t S mle le moo Process Type Spray Dryer z 1 Config ORA 4 Capital Cost 5 0 amp MCost Spray Dryer Retrofit Cost input screen Each parameter is described briefly below Reagent Feed System This area includes all equipment for storage handling and preparation of raw materials reagents and additives used SO Removal System This area deals with the cost of equipment for SO scrubbing such as absorption tower recirculation pumps and other equipment Flue Gas System This area treats the cost of the duct work and fans required for flue gas distribution to SO system plus gas reheat equipment Solids Handling System This area includes the cost of the equipment for fixation treatment and transportation of all sludge dry solids materials produced by scrubbing General Support Area The cost associated with the equipment required to support FGD system operation such as makeup water and instrument air are treated here Miscellaneous Equipment Any miscellaneous equipment is treated in this process area Spray Dryer Capital Cost Inputs This screen is only available for the Combustion Boiler plan
190. CapitalCost 5 OM Cost Fabric Filter Configuration input screen Fabric Filter Type Fabric filters consist of a large number of long tubular filter bags arranged in parallel flow paths As the ash laden flue gas passes through these filters much of the particulate matter is removed Ash accumulated on the bags is removed periodically by various methods of cleaning Choose the cleaning method in the Config input screen The available methods are e Reverse Gas RG e Reverse Gas with Sonic RG S Integrated Environmental Control Model User Manual Fabric Filter e 207 e Shake and Deflate Sh D e Pulse jet PJ Fabric Filter Performance Inputs 208 e Fabric Filter This screen is only available for the Combustion Boiler plant type zaxi File Edit View Window Help Ef untitled oli f 215 Configure Plant Set Parameters Get Results Emission 502 CO2 By Prod Base Plant Constraint 7 Control Capture Mgmt Solids Loading Out grains scf 1 500e 02 1 500e 02 alel le O P 9 0 Number of Baghouse Units number z cale Number of Compartments per Unit number 14 00 Number of Bags per Compartment number calc Bag Length feet calc Bag Diameter feet oo 1 000 Bag Life J years ral i cale Z FS P a 220 a e mawn o Air to Cloth Ratio acfin sq ft calc Total Pressure Drop Across Fabri in H20 gauge A calc Percent Water in Fabric Filter Disc A
191. Coal Costs n oneei a s TAAT E ATEEN E TE EE TEN 80 Aux Natural Gas Costs iesiri ioiii ii iTe aT ai Tia ini 80 Fuel Aux Gas Properties Inputis ss2 5 2ii aseaissessaausgegentente onde iA A R sienedasaensaces 80 Natural Gas Composition i2 5 csis cesicceasienasieeastages teassanscesagaaszenveadsesiag aaasenesestewneaed 81 Fuel Coal Diagrami seeni aea e i NE EA R T E 82 Fuel Natural Gas Dia grain o i sestscsssesyecievesiszes sine tenagauaveszaauedeaseaiesssousde Risgweeanadusdevieagsoeanaeen 83 Air Separation 85 Air Separation Performance TAPUS seelaa eanes aneor eaa era ea aa Ea eaS aE rea Er E Gii 85 Air Separation Retrofit Cost INPUTS ee erinadi ert ae as eia reete ea rrei rE EEEa KEE SETEK 86 Air Separation Capital Cost Inputs e e seis sceedesd eephesstcsthaatlepbeasscbadaadl apd aE oia p EE a Si 87 Air Separation O amp M Cost NPU Sa eaa aras aa esaa rarere r Sa Earra Paaren OE AAKE EERE ENT R NOT eoii 88 Air S paration Dia Stains aT a a E aaa Eaa a aa e aa EAO E a Ea SENE Ei 89 Air Separation Gas Flow Result oeae aris a eeraa rran a esaiar a Eea sadaatdacteeapeadsuabeasbesheveees 90 Air Separation Capital Cost Results s secserecssecsessseensotesoresssnsvensenescenessoneseneosssersoees 91 Air Separation O amp M Cost Results e s a ea aa aa aeo a aara Taa Ea aa lacboss bbe asses ROETES 93 Air Separation Total Cost Results soere ceesessssesssceceeseceneeeesacecsseecsseeceseeeessaeecseceseeseseeeeses 94 Base Plant 95 Base Pla
192. Combined SOxNOx Control CO2 Capture Blo S a P le omelo Base Plant Emission Taxes 12 13 14 15 Process Type Overall Plant z Costs are in Constant 2003 dollars 2 Plant Perf 3 Mass In Out 4 Solids In Out Pelee 7 Cost Summary Combustion Overall Plant Total Cost result screen The Total Cost result screen displays a table which totals the annual fixed variable operations maintenance and capital costs associated with the power plant as a whole The costs summarized on this screen are expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each technology row is described briefly below Combustion NO Control The total cost of the In Furnace NO controls used Post Combustion NO Control The total cost of all the Post Combustion NO removal modules used Mercury Control The total cost of all the mercury control modules used TSP Control The total cost of all the conventional particulate removal modules used SO Control The total cost of all the SO conventional removal modules used Combined SO NO The total cost of all the combined SO NO advanced removal modules used Subtotal This is the cost of the conventional and advanced abatement technology modules alone This is the total abatement cost The subtotal is highlighted in yellow Base Plant T
193. Configure Plant Set Parameters Get Results S02 co2 By Prod a gosci j Mie Control Capture Mgmt Stacie 8 Title ue 1 Fabric Filter Bag Cost 2 Waste Disposal Cost 3 Electricity Price Base Plant MWh a y 4 5 Number of Operating Jobs jobs shift ro 6 Number of Operating Shifts shifts day gt 7 Operating Labor Rate fhr 8 9 Total Maintenance Cost 96TPC R 10 Maint Cost Allocated to Labor total _ Administrative amp Support Cost total labor aiian ietan a a aaa i E aaa bt pmt t pet pet et AA ns wn mF 18 i Process Type Fabric Filter Costs are in Constant 2005 dollars 1 Config 3 RetrofitCost 4 Capital Cost 5 0 amp M Cost Fabric Filter O amp M Cost input screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Fabric Filter Bag Cost This is the cost of a fabric filter bag as used for the fabric filter technology Waste Disposal Cost This is the disposal cost for the particulate control system Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is a combustion boiler and an air preheater Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant
194. Control Model User Manual Spray Dryer e 255 Reagent Annual cost of lime or limestone injected into the scrubber on a wet basis This is a function of the SO concentration in the flue gas and the reagent stoichiometric performance input value Steam Annual cost of steam used for direct or reheat use in the scrubber This is a function of the steam heat rate reheat energy requirement and gross plant capacity Solid Waste Disposal Total cost to dispose the collected flue gas waste solids This does not consider by product gypsum sold in commerce Power Cost of power consumption of the scrubber This is a function of the gross plant capacity and the scrubber energy penalty performance input parameter Water Cost of water for reagent sluice in the scrubber This is a function of the liquid to gas ratio performance input parameter for the wet FGD The cost is a function of the flue gas flow rate and the slurry recycle ratio performance input parameter for the spray dryer Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight ho
195. Efficiency HHV 7768 Tapane bao Inn Raw Gas 3 Quench Pressure Out psia 5720 e Syngas Out tons h 426 3 El Syngas Out acfim 2 630e 05 g K Temperature In CF Coal In tons hr Water In tons hr Oxidant In tons hi Discharge Sluice Water tons hr 0 0 T ee Wet Slag tons hr Process Type GE 1 Diagram 3 Syngas 4 Capital Cost 5 O amp M Cost 6 Total Cost Gasifier Diagram result screen The Gasifier Diagram result screen displays an icon for the Gasifier Unit and values for major flows in and out of it Each result is described briefly below in flow Cold Gas Efficiency This is the ratio of the heat contents calculated at room temperature of the syngas fuel output and the coal fuel input The higher heating value is used here Temperature In This is the temperature of the oxidant stream into the gasifier Coal In This is the mass flow of coal into the gasifier on a wet basis Water In This is additional mass flow of water added to the coal Wet coal already contains some water Oxidant In This is the mass flow of oxidant into the gasifier Sluice Water Slag collected can be removed from the gasifier and disposed by sluicing the slag with water Temperature Out This is the syngas temperature exiting the raw gas quench Pressure Out This is the approximate pressure of the syngas exiting the raw gas quench Syngas Out This is the mass flow rate of syngas exiting the
196. Environmental Control Model User Manual 7 IECM Interface E Eile Edit View Window Help Gom Configure Plant Set Parameters Get Results TF 502 coz By Prod Control Control Capture Mgmt Stack A Flue Gas In Flue Gas Out Flue Gas In Flue Gas Out EL IEE ES b moles hx h moles hr tow kr ton hr 1 266e 05 1 266e 05 1773 1773 Oxygen 02 9372 3372 1499 149 9 Water Vapor H20 2 369e 04 1 776e 04 213 4 160 1 Carbon Dioxide COZ 2 050e 04 2 050e 04 4511 451 1 Carbon Monoxide CO 0 0 0 0 0 0 0 0 Hydrochloric Acid HCD 5 643 5 643 01029 0 1029 Sulfur Dioxide 802 41 24 41 24 1 324 1 321 Sulfuric Acid equivalent 03 8 639e 02 6 479e 02 3 458e 03 2 594e 03 Nitric Oxide NO 36 11 3511 0 5268 0 5268 Nitrogen Dioxide NO2 1 848 1 848 4 251e 02 4 251e 02 Ammonia NH3 2 713 2 713 2 310e 02 2 310e 02 12 Argon At 0 0 0 0 0 0 0 0 13 Tod 180005 1743e 05 2589 2538 z R ele le alelo 14 15 Process Type Cold Side ESP 7 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost Cold Side ESP Flue Gas results screen Each result is described briefly below Major Flue Gas Components Nitrogen N2 Total mass of nitrogen Oxygen 02 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydr
197. F based on them Inflation Rate This is the rise in price levels caused by an increase in the available currency and credit without a proportionate increase in available goods or services It does not include real escalation Plant or Project Book Life This is the years of service expected from a capital investment It is also the period over which an investment is recovered through book depreciation Real Bond Interest Rate This is a debt security associated with a loan or mortgage It is the most secure form of security but the lowest in its return Real Preferred Stock Return This equity security is the second most speculative type and pays the second highest rate of return The holder of the stock is a part owner of the company Real Common Stock Return This is the most speculative type of equity security sold by a utility and pays the highest relative return The holder of the stock is a part owner of the company Percent Debt This is the percent of the total capitalization that is associated with debt money This includes loans and mortgage bonds Percent Equity Preferred Stock This is the percent of the total capitalization that is associated with the sale of preferred stock Percent Equity Common Stock This value is the remainder of the capitalization calculated as 100 minus the percent debt minus the percent equity in preferred stock Federal Tax Rate This is the federal tax rate It is used to calculate the a
198. Forced Draft Fans Cooling System Miscellaneous Process Type Base Plant 1 Performance 3 Retrofit Cost 4 Capital Cost 5 O amp M Cost Base Plant Performance input screen The first six inputs are highlighted in blue Each parameter is described briefly below Gross Electrical Output This is the gross output of the generator in megawatts MW The value does not include auxiliary power Integrated Environmental Control Model User Manual Base Plant e 95 96 e Base Plant requirements The model uses this information to calculate key mass flow rates Unit Type This is the type of steam turbine system being used The possible selections are Sub Critical Super Critical and Ultra Supercritical This selection determines the steam cycle heat rate default value Steam Cycle Heat Rate This is the gross amount of energy in steam needed to produce a kilowatt hour kWh of electricity at the generator This variable does not consider auxiliary power requirements This heat rate plus the boiler efficiency is used to figure out the overall plant performance 1 e the gross cycle heat rate Boiler Firing Type Combination boilers are most often represented by three types wall tangential and cyclone The wall category is the most general and represents variations such as opposed top cell and others The solution of boiler type affects the boiler efficiency and furnace emissi
199. Go Window Help Us Untitled ot x Configure Plant Set Parameters _ Construction Time General Facilities Capital Engineering amp Home Office Fees Project Contingency Cost Process Contingency Cost Royalty Fees CeRAAH amp wn Pre Production Costs Months of Fixed O amp M Months of Variable O amp M 12 Misc Capital Cost 13 14 Inventory Capital 15 16 17 zs t S mle moo S S 18 TCR Recovery Factor Process Type Power Block z 1 Gas Turbine 2 SteamCycle 4 Retrofit Cost Wap Meena 6 O amp M Cost Power Block Capital Cost input screen Inputs for capital costs are entered on the Capital Cost input screen Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other cost
200. I Number of Operating Jobs jobs shift 0 1750 x Number of Operating Shifts shifts day 4 750 Operating Labor Rate hr 24 82 Total Maintenance Cost TPC Maint Cost Allocated to Labor total Administrative amp Support Cost total labor 1 500202 40 00 25 00 Zi elt 2 ale e ole loo Activated Carbon Inj Costs are in Constant 2005 dollars 1 Removal Eff 2 Carbon Inj 3 Retrofit Cost 4 Capital Cost 5 O amp M Cost Mercury O amp M input screen Inputs for the operation and maintenance costs of the mercury control technology are entered on the O amp M cost input screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Activated Carbon Cost w shipping This is the cost for the activated carbon including the cost of shipping Disposal Cost This is the disposal cost for the particulate control system It is assumed that the ash is not hazardous therefore can be disposed with the collected fly ash Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is a combustion boiler and an air preheater Number of Operating Jobs This is the total number of operating jobs that are required to operate the plan
201. I calc Fabric Filter Power Requirement iz MWg J i oo cal Process Type Fabric Filter E PRL 2 ReirofitCost 4 Capital Cost 5 O amp M Cost Fabric Filter Performance input screen The baghouse system is very efficient in removing particulate matter from the flue gas It s model design is simple requiring few parameters to characterize its effects on the overall performance of the plant For properly designed fabric filters the size of the system is independent of the removal efficiency Although the performance is determined by very few parameters there are several design parameters necessary to determine the cost These factors are also determined in this section The major design parameters that can significantly impact the total system cost of the fabric filter are gas flow volume which depends on the generating unit size A C ratio the flange to flange pressure drop in the baghouse and the bag life Particulate Removal Efficiency The calculated removal is set to comply with the particulate emission limit set earlier The mass removed is then determined If you select a spray dryer the particulate removal efficiency applies to the combined mass of flyash and sulfur laden wastes This input is highlighted in blue Actual SO Removal Efficiency The default value is taken from the removal efficiency reported in the literature references are below This efficiency then determines the
202. IECM User Manual DE AC26 04NT41917 November 2009 N TL Integrated Environmental Control Model User Manual Disclaimer This report was prepared as an account of work sponsored by an agency of the United States Government Neither the United States Government nor any agency thereof nor any of their employees makes any warranty express or implied or assumes any legal liability or responsibility for the accuracy completeness or usefulness of any information apparatus product or process disclosed or represents that its use would not infringe privately owned rights Reference therein to any specific commercial product process or service by trade name trademark manufacturer or otherwise does not necessarily constitute or imply its endorsement recommendation or favoring by the United States Government or any agency thereof The views and opinions of authors expressed therein do not necessarily state or reflect those of the United States Government or any agency thereof Integrated Environmental Control Model User Manual IECM User Manual DE AC26 04NT41917 This document contains a new User Manual developed for the new Water Systems modules of the IECM The previous User Manual for the remainder of the IECM follows the new Water Systems User Manual Integrated Environmental Control Model User Manual Water Systems Water Systems 4 Cooling System Configuration seeen arr aee rr a ane aE AE EAEE E ETA EE ERRER 5
203. MEA the carbamate formed is stable and it takes large amount of energy to dissociate It also consists of a flash separator where CO is separated from most of the moisture and evaporated sorbent to give a fairly rich CO stream Regeneration Heat Requirement This is the total amount of heat energy required in the reboiler for sorbent regeneration Steam Heat Content The regeneration heat is provided in the form of LP steam extracted from the steam turbine in case of coal fired power plants and combined cycle gas plants through the reboiler a heat exchanger In case of simple cycle natural gas fired power plants a Integrated Environmental Control Model User Manual Amine System e 265 heat recovery unit maybe required This is the enthalpy or heat content of the steam used for solvent regeneration Heat to Energy Efficiency This is the efficiency of converting low pressure steam to electricity The value reflects the loss of electricity to the base plant when the LP steam is used for regenerator heat Solvent Pumping Head The solvent has to flow through the absorber column generally through packed media countercurrent to the flue gas flowing upwards So some pressure loss is encountered in the absorber column and sufficient solvent head has to be provided to overcome these pressure losses Solvent circulation pumps are used to provide the pressure head Pump Efficiency This is the efficiency of the solvent circulation pumps
204. MWh The IECM framework calculates the cost of electricity COE for the overall capture plant by dividing the total annualized plant cost yr by the net electricity generated kWh hr Reference Plant Integrated Environmental Control Model User Manual Selexol CO2 Capture 317 e CO2 Emissions lbs kWh This is the amount of CO vented to the air for every kilowatt hour of electricity produced in the power plant with no CO capture e Cost of Electricity MWh The IECM framework calculates the cost of electricity COE for the overall reference plant by dividing the total annualized plant cost yr by the net electricity generated kWh hr Cost of CO Avoided ton This is the economic indicator widely used in the field calculated as the difference between the cost of electricity in the capture plant and the reference plant divided by the difference between the CO emissions in the reference plant and the capture plant Cost of CO2 Avoided Cost of Electricity cap Cost of Electricity ref CO2 emissions ref CO2 emissions cap 318 e Selexol CO2 Capture Integrated Environmental Control Model User Manual Water Gas Shift Reactor Water Gas Shift Reactor Performance Inputs x File Edit View Go Window Help Water Gas Shift Reactor CO to CO2 Conversion Efficiency y 100 0 calc COS to H25 Conversion Efficiency 98 50 100 0 98 50 Steam Added mol H2O0 mal CO 0 9900 i 100 0 calc Maximum T
205. Model User Manual Selexol CO2 Capture 303 Selexol CO Capture Performance Inputs This screen is only available for the IGCC plant type 7 ECM Interface File Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results 2 By Prod Separation Mgmt Min Max Default Carbon Dioxide Removal Unit CO2 Removal Efficiency 95 00 50 00 98 00 calc H25 Removal Efficiency 94 00 0 0 100 0 94 00 Number of Operating Absorbers integer 2 Menu Menu calc 0 H Menu Menu 0 Max Syngas Capacity per Train Tb mole hr 3 200e 04 0 0 3 500e 043 200e 04 Number of Spare Absorbers integer _ 4 1 MWg 7446 oo 1500 calc Process Type fe Selexol C02 Capture 1 Reference Plant 2 Performance 3 CO2 Storage 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Selexol CO Capture Performance input screen Carbon Dioxide Removal Unit CO Removal Efficiency CO removal is specified by the user and is used to determine the solvent makeup flow capital cost and operating and maintenance costs H2S Removal Efficiency H2S is naturally removed with CO This parameter specifies the amount it is captured Max Syngas Capacity per Train Each train contains one absorber vessel that has a maximum flow rate This parameter determines the maximum flow rate through the vessel Number of Operating Absorbers This is the total
206. Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The number of dollars paid per hour to an operator for one hour of work Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Integrated Environmental Control Model User Manual Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor CO Transport and Storage Costs e CO Transportation Cost Transportation of CO product is assumed to take place via pipelines This is the unit cost of CO transport in ton mile e CO Storage Cost This is the unit cost of CO disposal Depending upon the method of CO disposal or storage either there may be some revenue generated Enhanced Oil Recovery Coal Bed Methane which may be treated as a negative cost or additional cost all other disposa
207. O removal efficiency achieved in the absorber The calculated default value assumes compliance with the SO emission limit specified earlier if possible The default value reflects other model parameter values including the sulfur retained in bottom ash This input is highlighted in blue Maximum SO Removal Efficiency This parameters specifies the maximum efficiency possible for the absorber on an annual average basis The value is used as a limit in calculating the actual SO removal efficiency for compliance Integrated Environmental Control Model User Manual Actual SO Removal Efficiency The default value is taken from the removal efficiency reported in the literature references are below This efficiency then determines the mass of SO removed from the flue gas in the collector For more information see also e www netl doe gov publications proceedings 98 98fg hardman pdf e www netl doe gov publications proceedings 98 98f g rubin pdf Particulate Removal Efficiency Ash and particulate matter are assumed to be removed by a separate particulate removal device such as a fabric filter However this parameters is provided for conditions where particulates are removed directly from the scrubber Absorber Capacity This is the percent of the flue gas treated by each operating absorber This value is used to determine the number of operating absorbers and the capital costs Number of Operating Absorbers This is the number of ope
208. Overall Plant Gas Emissions ccccccssseesecccccsseessseeccccssseeseeeesccssseuseceeseuees 39 Combustion Overall Total Cost ccccccccccccsssssccccccessssssececccssceeessssecccssseueeececssssssseeueeeseceess 40 Combustion Overall Plant Cost SUMMALY cc eeeeeeeeesseeeeseeeseecsseeceeeeeesaeecsaeessneaeeesaeeaes 41 Overall NGCC Plant 43 Overall NGCG Plant Diagram lt j sacn ss Was tarts aseetiids EE TEREE E ESET 43 Overall NGCC Plant Performance Inputs 0 esceeseeseseeesseeesneecsseeceseeeesseessaeessseaeessaeeaes 44 Overall NGCC Plant Constraints Inputs 0 ceeceescecesneecesseesneecsseeceseeeesaeecsaeeecesaeeesaeeaes 45 Overall NGCC Plant Financing Inputs ceeeesceceseecesnnccsseecscecsseeeeseeeesaeecseeeseseeeneeeesaes 45 Overall NGCC Plant O amp M Cost Inputs 2 eee eeseeceeceeseeeeseeeeessseeeceseeeseeseseeeseesaeees 47 Overall NGCC Plant Emis Taxes Inputs 0 0 cesceeseccssneeesseeeeseesseeceseeeesaeecsaeessnsaeessaeerses 49 Overall NGCC Plant Performance Results cccccccsssesccccccessscsseeccccssceesesesseccsseeesceeseuess 50 Performance Parameter ccccceesescccccccceeeccccsccccseeessseccccssseeesescssseeeessesseeseessseees 50 Plant Power Requirements 8328 jcc seerti st east achat hind aio idan 51 Overall NGCC Plant Mass In Out Results ooeeneeeeeeeseeneseenseesesrsreresreresreressrerssreresreserresese 52 Overall NGCC Plant Gas Emissions Result
209. Oxygen O2 Total mass of oxygen Total Total of the individual components listed above This item is highlighted in yellow 128 e Gasifier Integrated Environmental Control Model User Manual Gasifier Capital Cost Results File Edit View Go Window Help Configure Plant Set Parameters Get Results ke Separation GE Gasifier Process Area Costs GE Gasifier Plant Costs ae eemo Coal Handling Gasification General Facilities Capital Low Temperature Gas Cooling Eng amp Home Office Fees Process Condensate Treatment Project Contingency Cost i ma Process Contingency Cost Interest Charges AFUDC Royalty Fees Preproduction Startup Cost Inventory Working Capital Costs are in Constant 2005 dollars E o ciac 5 OGM Con 7G Toulon Gasifier Capital Cost results screen The GE Gasifier Capital Cost result screen displays tables for the capital costs Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below GE Gasifier Process Area Costs Coal Handling This is the cost associated with the coal handling process area Coal handling involves unloading coal from a train storing the coal moving the coal to the grinding mills and feeding the gasifier with positive displacement pumps A typical coal handling section contains one operating train and no spa
210. PC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a fabric filter that has been paid off Sulfur Removal O amp M Cost Inputs 7 IECH Interface ioj xi Fie Edit View Go Window Help Configure Plant Selexol Solvent Cost Claus Plant Catalyst Cost Set Parameters CO2 Capture Power Block By Prod ey Mgmt Stack Beavon Stretford Catalyst Cost Sulfur Byproduct Credit Sulfur Disposal Cost Sulfur Sold on Market Electricity Price Base Plant zs t S mle le moo Boenaama nnr Number of Operating Jobs 1 Number of Operating Shifts 12 Operating Labor Rate jobs shift shifts day Shr 13 14 Total Maintenance Cost TPC 15 Maint Cost Allocated to Labor total 16 Administrative amp Support Cost total labor a7 18 4 Process Type Suttur Capture System z 2 Retrofit Cost 3 Capital Cost 4 0 amp M Cost Costs
211. Preheater 139 In Furnace Controls The NOx Control Technology Navigation Tab contains screens that address combustion or post combustion air pollution technologies for Nitrogen Oxides These screens are available if the In Furnace Controls for the Combustion Boiler plant type configurations have been selected for NO control under Combustion Controls If you have selected both In Furnace Controls and a Hot Side SCR for NO control you may switch between the two sets of screens that configure these technologies by using the Process Type pull down menu at the bottom of the screen Process Type Hot Side SCR bd In Furnace Controls i Hot Side SCR The Process Type pull down menu In Furnace Controls Configuration This screen is only available for the Combustion Boiler plant type Inputs for configuring the NO Control technology are entered on the Config input screen Each parameter is described briefly below Integrated Environmental Control Model User Manual In Furnace Controls 141 142 o In Furnace Controls File Edit View Go Window Help 7 eS Configure Plant Set Parameters Get Results TSP s02 co2 By Prod 7 Base Planti eb ercucy Control Control Capture Mgmt Stack 3 Title Value Min Max Default LNB amp SI7 Menu Menu NB amp SNC B SNCR Reagent Type Urea ial Menu Menu Urea gt g R bt pmt pet Opet Opet pe et et AAA a n a
212. Process Type overall Plant z 2 Plant Perf f 3 MassInOut ERSAN EEIN 5 TotaCost f 6 Cost Summary Overall NGCC Plant Gas Emissions result screen Stack Gas Component Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO3 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Integrated Environmental Control Model User Manual Overall NGCC Plant e 53 Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Argon is present in small quantities in atmospheric air The argon emitted from the power plant is shown on a mass basis Total Gases Total of the individual components listed above This item is highlighted in yellow Total SO equivalent SO Total mass of SO as equivalent SO3 Total NO equivalent NO3 Total mass of NO as equivalent NO Overall NGCC Plant Total Cost Results 7 IECM Interface E File Edit Yiew Go Window Help Configure Plant Set Parameters Power Block NOx Control CO2 Capture Fixed O amp M Nae M yr MSi CO2 Capture 3 992 43 24 Power Block 7 087 81 57 Post Combu
213. Prod Control Control Capture Memt Min Max Menu Menu ale le jolelo o Ta ug 3 9 i Process Type Hot Side SCR z 1 Config 3 Perf cont 4 Retrofit Cost 5 Capital Cost Hot Side SCR Config input screen Inputs for configuring the Hot Side SCR NO Control technology are entered on the Config input screen Each parameter is described briefly below Catalyst Replacement Scheme Catalyst is installed in the SCR as a series of layers These activity or effectiveness of these layers decreases with time due to fouling and poisoning The layers are replaced with clean layers on a regular basis in one of two ways all at once or one layer at time staggered The selection of the replacement scheme involves trade offs between capital and annual costs via the initial catalyst requirement and the replacement interval More specifically e Each Individual Layers Replacing individual layers sequentially rather than simultaneously increases the effective catalyst life for a given volume of catalyst decreasing the replacement interval This reduces the O amp M cost relative to simultaneous replacement The default setting is Each e All All Layers Simultaneous replacement may lead to a smaller initial catalyst volume to achieve the same design activity as a sequential replacement scheme This reduces the capital cost but increases the O amp M cost Ho
214. RT OR ANY INFORMATION APPARATUS METHOD PROCESS OR SIMILAR ITEM DISCLOSED IN THIS REPORT Organization s that prepared this report Carnegie Mellon University Copyright Notices Intel Fortran Compiler Integration for Microsoft Visual Studio NET 2003 9 1 Copyright 2002 2006 Intel Corporation All Rights Reserved Spread 6 0 Copyright 2002 FarPoint Technologies Inc All Rights Reserved Tab Pro 3 1 Copyright 1999 FarPoint Technologies Inc All Rights Reserved Graphics Server 6 15 1988 2004 Graphics Server Technologies L P All Rights Reserved Microsoft Visual Studio NET 2003 Copyright 1987 2002 Microsoft Corporation All Rights Reserved Microsoft Visual C NET 7 1 Copyright 1987 2002 Microsoft Corporation All Rights Reserved Microsoft NET Framework 1 1 Copyright 1998 2002 Microsoft Corporation All Rights Reserved Wise for Windows Installer 6 1 Copyright 2005 Wise Solutions Inc All Rights Reserved Microsoft Data Access Components 2 8 Copyright 2003 Microsoft Corporation All Rights Reserved Integrated Environmental Control Model IECM Interface 5 2 0 Copyright 1997 2006 Carnegie Mellon University All Rights Reserved Integrated Environmental Control Model IECM 5 2 0 Copyright 1997 2006 Carnegie Mellon University All Rights Reserved Integrated Environmental Control Model User Manual Introduction 5 Median Latin Hypercube and Hammersley Seque
215. Requirements A second group of results provide a breakdown of the internal power consumption for the individual technology areas These are all given in units of megawatts Individual plant sub components will only be displayed when they are configured in the Configure Plant section of the model Total Generator Output This is the gross power generated by the turbine Air Compressor Use The power required to operate the air compressor Turbine Shaft Losses This variable accounts for any turbine electricity losses that are not incorporated into the lossed due to air compressor use Gross Plant Output This is the net power generated by the turbine This is the gross output of the turbine minus the power required by the air compressor and any miscellaneous losses Misc Power Block Use This is the electrical power required to operate pumps and motors associated with the power block area Air Separation Unit Use This is the power utilization of the compressors in the air separation system Gasifier Use This is the power utilization of the gasification system Sulfur Capture Use This is the power utilization of the sulfur capture system this does not include the claus or beavon stretford systems Claus Plant Use This is the power utilization of the claus plant equipment Beavon Stretford Use This is the power utilization of the beavon stretford system Water Gas Shift Reactor Use This is the power equivalent of the ste
216. Results Some uncertainty parameters may be changed while results are displayed These are modified using the Uncertainty Tools Floating Palette Uncertainty Tools Untitled Uncertainty Areas IV NOx Control IV Sir Preheater V Particulate Control M Solid Waste Mgmt M 502 Control M S02 NOx Control Select All Select None Graph Size 50 Sampling Method Median LHS X The Uncertainty Tools floating palette Integrated Environmental Control Model User Manual Running a Probabilistic Analysis 403 Uncertainty Areas You may choose technology or technologies for which you would like results with uncertain values by clicking the box to the left of each technology You may select all or none by clicking the buttons at the bottom of the palette Graph Size The sample size determines the number of possible data points used to draw a graph This parameter determines how many of the total samples to use for the graph This value cannot exceed the sample size Sample Size You can also specify the number of samples used with the sampling method This is the number of iterations performed in a probabilistic analysis The appropriate sample size depends on the number and types of uncertainty distributions that are specified and on the accuracy with which the distribution is to be estimated especially the tails of the distribution A sample size of 100 is the default The maximum is 200 The calculation time and memory requireme
217. SP Control Revenue Required Selected Variable Choose Y Axis Cumulative Probability X Sessions a graph may have 1 6 lines Bown The graph chooser window The graph chooser window contains several drop down menus a check box and a few buttons Each menu begins in a default state producing a cumulative probability distribution CDF graph of the particular result variable double clicked These drop down menus can be modified to produce many different types of graphs These will be described in the following sections To view the standard CDF graph select the menu items as they appear in the figure above e Graph Type Line 2D e X Axis Selected Variable e Y Axis Cumulative Probability Integrated Environmental Control Model User Manual Working with Graphs e 393 394 e Working with Graphs The graph type and details that will be displayed can be modified later if the initial graph is not what was desired Graph Type Gra hType fiine o Line 2D Scatter 2D X Axis Scatter 3D Y Axis Tape 3D Graph type selection menu The Graph Type drop down menu contains multiple types of graphs Line 2D and Scatter 2D can be selected initially with the line graph as the default option Additional options are available after the graph opens The line graph connects the x y data points consecutively with line segments The scatter graph displays the x y data points with markers instead of line se
218. Set Parameters Get Results CO2 Capture Power Block Atmospheric Air Temperature In F 270 0 Air In tons hs 718 8 Air In acfin 3 141e 05 Air Separation Unit Zie 2 mlr o P o o Temperature Out F 270 0 Oxidant Out tons h 176 9 Nitrogen Out tons h 541 9 Oxidant Out acfin 6 929e 04 Nitrogen Out acfm 2 448e 05 Process Type Jair Separation z Longa LT aca Toulon Air Separation Diagram result screen The Air Separation Diagram result screen displays an icon for the Air Separation Unit and values for major flows in and out of it Each result is described briefly below in flow Integrated Environmental Control Model User Manual Air Separation 89 Atmospheric Air Temperature In Temperature of the atmospheric air entering the air separation unit Atmospheric Air In Mass flow rate of air entering the air separation unit based on the atmospheric air temperature and atmospheric pressure Atmospheric Air In Volumetric flow rate of air entering the air separation unit based on the atmospheric air temperature and atmospheric pressure Nitrogen Out Mass flow rate of the nitrogen exiting the Air Separation Unit Nitrogen Out Volumetric flow rate of the nitrogen exiting the Air Separation Unit Temperature Out Temperature of the oxidant exiting the Air Separation Unit Oxidant Out Mass flow rate of the oxidant exiting the Air Separation Unit Oxidant Out Volumetr
219. The calculated space velocity is determined by several factors including many of the reference parameters in the next Section The space velocity is used to determine the catalyst volume required Ammonia Stoichiometry This is the molar stoichiometry ratio of ammonia to NO entering the SCR device The calculated quantity is based on an assumed NO removal reaction stoichiometry of 1 1 for both NO and NOs and a specified ammonia slip It affects the amount of ammonia used and the amount of NO converted to moisture Steam to Ammonia Ratio The molar ratio of steam to ammonia is used to determine the amount of steam injected to vaporize the ammonia The value assumes the steam is saturated at 450 degrees Fahrenheit and the ammonia is diluted to 5 volume percent of the injected gas Total Pressure Drop Across SCR The total is determined from the individual pressure drops due to air preheater deposits the active catalyst layers the dummy catalyst layers the ammonia injection system and the duct work It is used to calculate the total pressure drop across the SCR and the auxiliary power requirements Oxidation of SO to SOs The oxidation rate is calculated for a high sulfur catalyst and affects the flue gas composition It uses the space velocity and the inlet temperature The SO produced acts as an ash conditioning agent if an ESP is used downstream Hot Side SCR Power Requirement The default calculation of auxiliary power is based on
220. The turbine inlet temperature is carefully controlled to prevent damage or fatigue of the first stage stator and rotor blades This temperature is one of the two most important parameters that impacts system efficiency Turbine Back Pressure The turbine exit pressure must be higher than atmospheric pressure to provide a positive pressure on the flue gas exiting the turbine Adiabatic Turbine Efficiency The adiabatic turbine efficiency adjusts for inefficiencies in real turbines The ratio is an estimate of real to ideal performance Shaft Generator Efficiency The combined shaft generator efficiency adjusts for inefficiencies in generator and shaft between the compressor and the generator The ratio is an estimate of real to ideal performance Air Compressor Pressure Ratio outlet inlet This is the ratio of the compressor exit pressure to the inlet ambient air pressure Compression takes place approximately adiabatically Adiabatic Compressor Efficiency The adiabatic compressor efficiency adjusts for inefficiencies in real compressors The ratio is an estimate of real to ideal performance Combustor Combustor Inlet Pressure The combustor inlet pressure is currently fixed at a single value It is provided for reference purposes only Combustor Pressure Drop Although the combustor operates at essentially constant pressure a small pressure drop is typically observed in the combustor exit from the compressor exit Excess Air F
221. The value reflects a weighted average based on the particular species of mercury present elemental oxidized and particulate 234 Wet FGD Integrated Environmental Control Model User Manual Collected Solids Wet FGD Solids Total solids mass flow rate of solids removed from the scrubber This is a function of the solids content in the flue gas and the particulate removal efficiency of the scrubber The solids are shown on a wet basis Wet FGD Flue Gas Results This screen is only available for the Combustion Boiler plant type The Flue Gas result screen displays a table of quantities of flue gas components entering and exiting the Wet FGD SO Control Technology For each component quantities are given in both moles and mass per hour File Edit view Window Help Configure Plant Set Parameters Get Results CO2 By Prod Capture Mgmt Major Flue Gas Components Gas Out Gas Out h moles hr iom hr Nitrogen N2 1 302e 05 1 302e 05 1823 Oxygen 02 9685 9509 i 152 1 1 671e 04 3 287e 04 i 296 1 Carbon Dioxide COD 2 096e 04 2135e 04 l 469 8 Carbon Monoxide CO 0 0 0 0 i 0 0 Hydrochloric Acid HCH 19 71 1 971 i 3 594e 02 Sulfur Dioxide 02 400 8 8 016 i 0 2568 Sulfuric Acid equivalent 03 2 066 1 033 8 272e 02 4 136e 02 Nitric Oxide NO 11 29 11 29 0 1694 0 1694 Nitrogen Dioxide NOJ 0 5942 0 5942 1 367e 02 1 367e 02 Ammonia NH3 0 3088 0 3088 2629 03 2 629e 03 0 0 zis 2 mla le m
222. This is determined by the flue gas outlet temperature of the module upstream of the air preheater e g the air preheater Flue Gas In Volumetric flow rate of the flue gas entering the particulate control technology based on the flue gas inlet temperature and atmospheric pressure Fly Ash In Total solids mass flow rate in the flue gas entering the air preheater This is determined by the solids exiting the module upstream of the particulate control technology e g the air preheater Mercury In Total mass of mercury entering the particulate control technology The value is a sum of all the forms of mercury elemental oxidized and particulate Flue Gas Exiting ESP Temperature Out Temperature of the flue gas exiting the particulate control technology The model currently does not alter this temperature through the particulate control technology Integrated Environmental Control Model User Manual Cold Side ESP e 199 Flue Gas Out Volumetric flow rate of the flue gas exiting the particulate control technology based on the flue gas exit temperature and atmospheric pressure Fly Ash Out Total solids mass flow rate in the flue gas exiting the particulate control technology This is a function of the ash content of the inlet flue gas and the ash removal efficiency performance input parameter Mercury Out Total mass of mercury exiting the particulate control technology The value is a sum of all the forms of mercury elemen
223. Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow O CO2 Recycle Capital Cost Results 296 e O2 CO2 Recycle This screen is available for Combustion Boiler plant types 7 IECH Interface Fie Edit View Go Window Help Configure Plant Set Parameters Get Results D By Prod Capture Mgmt Stack Flue Gas Recycle Fan General Facilities Capital 7 192 Flue Gas Recycle Ducts Eng amp Home Office Fees 5034 Oxygen Heater Project Contingency Cost 10 79 CO2 Purification System Process Contingency Cost 3 596 Direct Contact Cooler Interest Charges AFUDC 7 741 CO2 Compression System Royalty Fees 0 3596 Preproduction Startup Cost 5 516 9 Inventory Working Capital 0 4927 1 2 3 4 5 6 7 8 9 2DCCGes 3PuifGas ERELARLEI 5 0 amp MCost 6 TotalCost O gt CO Recycle Flue Gas Capital cost result screen The Capital Cost result screen displays tables for the capital costs Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below F
224. a Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Total Capital Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annu
225. a function of the sorbent flow rate Reboiler The regenerator is connected to a reboiler which is a heat exchanger that utilizes low pressure steam to heat the loaded sorbent The reboiler is part of the sorbent regeneration cycle The cost is a function of the sorbent and steam flow rates Steam Extractor Steam extractors are installed to take low pressure steam from the steam turbines in the power plant The cost is a function of the steam flow rate Sorbent Reclaimer A portion of the sorbent stream is distilled in the reclaimer in order to avoid accumulation of heat stable salts in the sorbent stream Caustic is added to recover some of the MEA in this vessel The reclaimer cost is a function of the sorbent makeup flow rate Sorbent Processing The sorbent processing area primarily consists of a sorbent cooler MEA storage tank and a mixer The regenerated sorbent is further cooled with the sorbent cooler and MEA added to makeup for sorbent losses This area is a function of the sorbent makeup flow rate CO Drying and Compression Unit The product CO must be separated from the water vapor dried and compressed to liquid form in order to transport it over long distances The multi stage compression unit with inter stage cooling and drying yields a final CO product at the nominal pressure of 2000 psig This area is a function of the CO flow rate Auxiliary Natural Gas Boiler An auxiliary natural gas boiler is typically combine
226. a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Costs This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a fabric filter that has been paid off Fabric Filter O amp M Cost Inputs This screen is only available for the Combustion Boiler plant type 212 Fabric Filter Integrated Environmental Control Model User Manual File Edit View Go Window Help eS
227. abor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Selexol CO Capture Total Cost Results This screen is only available for the IGCC plant type Integrated Environmental Control Model User Manual Selexol CO2 Capture 315 7 IECH Interface File Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results Power Block Bees Stack gmt Percent Total 8527 Annual Variable Cost 67 90 Annualized Capital Cost 23 57 Zi e mle ole e Process Type 2 Selexol CO2 Capture x Costs are in Constant 2005 dollars 2 Syngas 3 Capital Cost 4 0 amp M Cost 5 Total Cost Selexol CO Capture Total Cost results screen The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Selexol CO Capture Unit Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each resul
228. acfini 1 547e 06 Fly Ash In ton hr 9 726 Fly Ash Out ton hr 12 48 Acid Dew Point Temp 263 0 Carbon is Collected in Particulate Control Process Type Activated Carbon Inj Md Me 2 Flue Gas 2 Capital Cost 4 O amp M Cost 5 Total Cost Mercury Diagram result screen Each result is described briefly below in flow order not from top to bottom and left to right as they display on the screen Flue Gas Prior to Injection Temperature In Temperature of the flue gas prior to flue gas conditioning Flue Gas In Volumetric flow rate of the flue gas prior to flue gas conditioning based on the temperature prior to flue gas conditioning and atmospheric pressure Fly Ash In Total solids mass flow rate in the flue gas prior to flue gas conditioning This includes ash unburned carbon and unburned sulfur Flue Gas After Injection Temperature Out Temperature of the flue gas after flue gas conditioning This should be above the acid dew point temperature at the bottom of the screen 184 e Mercury Integrated Environmental Control Model User Manual Flue Gas Out Volumetric flow rate of the flue gas after flue gas conditioning based on the temperature after flue gas conditioning and atmospheric pressure Fly Ash Out Total solids mass flow rate in the flue gas after flue gas conditioning This includes ash unburned carbon activated carbon and unburned sulfur Acid Dew Point This is the temperature that H SO va
229. actor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens Each parameter is described briefly below Capital Cost Process Area Reactor Housing The reactor housing costs include carbon steel reactor vessel with six inches of mineral wool insulation vessel internals and supports steam sootblowers reactor crane and hoist installation labor foundations structures piping and electrical equipment Ammonia Injection The ammonia unloading storage and supply system includes a storage vessel with a seven day capacity an ammonia vaporizer mixer injection grid ductwork dampers and a truck unloading station Integrated Environmental Control Model User Manual Hot Side SCR e 161 Ducts The ductwork includes economizer bypass and outlet ducts SCR inlet and outlet ducts SCR and economizer control dampers air preheater inlet plenum various expansion joints in the ductwork and air preheater cross over ducting Air Preheater Modifications Thicker and smoother material is used for the heat transfer surfaces in the preheater A larger motor is provided for the heat exchanger High pressure steam soot blowers and water wash spray nozzles are also added ID Fan Differential The ID fan
230. ae ea einai tied 9 Accessing the IECM Help file 0 0 00 eee eeesceceseecesseeeneeessseecscecsseecssaeeessueesseeeseeees 9 Installing the Model 11 Installation Options ysis eee ieee el dares ee lei ine 11 Local and Network Installation ee eeeeesseecesseeeneeeeseeeesaeecsacesseeessaaeesseessnees 11 nternet Installation sss cntekei eich ite Mila el ee die A A E A Sa 12 Fil s Add d by Installs ss scsi cat tstercies bearish aie 16 Help Piles sisit dicwi alia ara eh nna tee ae iio 16 Program Files i 3 oc cn iain inne dn iin iain N dae 16 System Rules saurai ieee tia el ad niente adr E 17 Files Modified by Install 2 02 insiens nnn tenes dee e eb ies Des diners 18 Configure Plant 19 Configuring the Combustion Boiler Plant eee eeeeesseeesssseesneecsseeeeseeeesaeecseessseaeeesaeeeses 19 Combustion Controls 2 h 2chesetchetevseseee iA e a a e erii 19 Post Combustion Controls esceescccsssecessceeceeecsncecsseeeesaeecsaeecseeesesaeeeseeesaeessaeers 20 Solids Ma agem ntesrsiceineic ni i e r serin Tini rri 22 Configuring the Combustion Turbine Plant ec eeceeeseesseeceesecsseecesaeeesseesseecsseeesesaeeses 22 Post Combustion Controls esccceecccsssecesseeeceeecsseecsseeeesseeesseecseeesesseeesseesaeessaeers 22 Configuring the IGC ncn nehna dene eel eee ethan r rines 23 Gasification OP ONS esis tossc osb as eab rate eisses ENSEN EEEE eE EE ER SE EEE SEESE Rn 23 Post Combustion ConttolS sissa sieno eous eoa e ees
231. aintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the dry cooling system that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor for the dry cooling system Air Cooled Condenser O amp M Cost Results This screen is available for all plant types The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the Air Cooled Condenser technology 30 e Water Systems Integrated Environmental Control Model User Manual 7 IECM Interface File Edit Yiew Go Window Help i Untitled Configure Plant f Set Parameters Get Results le ojelo o O amp M Cost O amp M Cost Myr Sr 1 Disposal J 0 0 1 Operating Labor 0 6858 2 Electricity 3 388 2 Maintenance Labor 0 6229 3 Maintenance Material 0 9344 4 Admin amp Support Labor 0 3926 Variable Cost Component Fixed Cost Component e al g R Process
232. aintenance labor costs Integrated Environmental Control Model User Manual Air Separation 93 Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Air Separation Total Cost Results 94 e Air Separation y IECM Interface a File Edit view Window Help Cost Component Annual Variable Cost Annualized Capital Cost Un Annual Fixed Cost M yr 3 375 MWh 2 291 Percent Total 11 83 15 76 9 390 10 70 6 374 55 25 w r 32 92 Caan Process Type Air Separation A TCspilCon 7 40EMCon WEEET Air Separation Total Cost results screen The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Air Separation Unit Each result is described briefly below Cost Component Costs are in Constant 2000 dollars Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and
233. akes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate This is the hourly labor rate for operators working with the amine system This is not used for maintenance administrative or support labor Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor CO2 Transport and Storage Costs CO Transportation Cost Transportation of CO product is assumed to take place via pipelines This is the unit cost of CO transport in ton mile The cost is calculated from the pipeline sub process model CO Storage Cost This is the unit cost of CO disposal Depending upon the method of CO disposal or storage either there may be some revenue generated Enhanced Oil Recovery Coal Bed Methane which may be treated as a negative cost or additional cost all other disposal methods 272 e Amine System Integrated Environmental Control Model User Manual Amine System Diagram This screen is only available for the Combustion Boiler and Comb
234. al basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts 238 Wet FGD Integrated Environmental Control Model User Manual Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the wet FGD that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor for the wet FGD Wet FGD O amp M Cost Results This screen is only available for the Combustion Boiler plant type The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the SO control technology 7 IECH Interface ioj xi Fie Edit View Go Window Help Configure Plant Set Parameters Get Results CO2 By P
235. al entering the boiler on a wet basis Oil Total mass of oil used in the power plant Natural Gas Total mass of natural gas used in the power plant Total Fuels This is the total fuel mass entering the power plant This result is highlighted in yellow Lime Limestone Total mass of this reagent used in the power plant on a wet basis Sorbent This is the total mass of sorbent used in the power plant The sorbent currently used is an amino acid used in the CO capture device Ammonia Total mass of ammonia used in the power plant Urea Total mass of urea used in the power plant Urea is the reagent used to reduce NO in the SNCR technology Dibasic Acid Total mass of dibasic acid used in the power plant Activated Carbon Total mass of activated carbon injected in the power plant Total Chemicals This is the total reagent mass entering the power plant This result is highlighted in yellow Output Flow Rates 36 e Combustion Overall Plant Integrated Environmental Control Model User Manual Bottom Ash Disposed Total mass of bottom ash collected in the power plant on a dry basis Fly Ash Disposed Total mass of fly ash collected in the power plant on a dry basis Scrubber Solids Disposed Total mass of scrubber solid wastes collected in the power plant on a dry basis Particulate Emissions to Air Solids that remain in the flue gas and exit the plant are reported on a mass basis Captured CO If a CO capture technology
236. alue Actual Bypass This displays the actual bypass being used in the model It is based on all of the above and is provided for reference purposes only Wet FGD Performance Inputs This screen is only available for the Combustion Boiler plant type Inputs for performance of the Wet FGD SO control technology are entered on the Performance input screen Each parameter is described briefly below 7 IECM Interface File Edit View Go Window Help ofe Untitled izis t mel e alelo Configure Plant Set Parameters Get Results NOx TSP 2 co Base Plant Mercury Control Contro Capture Scrubber 503 Removal Efficiency Particulate Removal Efficiency Absorber Capacity acim Number of Operating Absorbers integer Number of Spare Absorbers integer Liquid to Gas Ratio gpm 1000 acfm Reagent Stoichiometry mol Ca mol rem 10 Reagent Purity wt 11 Reagent Moisture Content wt 12 Total Pressure Drop Across FGD in H20 gauge 13 Temperature Rise Across ID Fan F delta 14 Gas Temperature Exiting Scrubber 15 Gas Temperature Exiting Reheater 16 Entrained Water Past Demister evap H20 17 Oxidation of Ca303 to CaS04 18 Wet FGD Power Requirement MWe Process Type wet FGD z AR KNR IsI 2 Performance 3 Additives 4 RetrofitCost 5 Capital Cost 6 O amp M Cost Wet FGD Performance input screen Integrated Environmental Cont
237. alysis or to select a range of values to use in sensitivity analysis Integrated Environmental Control Model User Manual Appendix A Introduction to Uncertainty Analysis 407 Philosophy of Uncertainty Analysis The classical approach to probability theory requires that estimates for probability distributions be based on empirical data However in many practical cases the available data may not be available or relevant to the problem at hand Thus statistical manipulation of data may be an insufficient basis for estimating uncertainty Engineering analysis or judgments about the data may be required An alternative approach is the Bayesian view It differs in how probability distributions are interpreted The probability of an outcome is your degree of belief that the outcome will occur based on all of the relevant information you currently have about the system Thus the probability distribution may be based on empirical data and or other considerations such as your own technically informed judgments The assessment of uncertainties requires thought about all possible outcomes and their likelihood not just the most likely outcome The advantage to thinking systematically and critically about uncertainties is the likelihood of anticipating otherwise overlooked problems or identifying potential payoffs that might otherwise be overlooked Types of Uncertain Quantities There are a number of types of uncertainty to consi
238. am recovered from the water gas shift reactor Selexol CO Capture Use MW This is the power utilization of the CO capture system Net Electrical Output This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties Also included are credits from steam generated and reused to produce electricity Integrated Environmental Control Model User Manual Overall IGCC Plant 65 Overall IGCC Plant Mass In Out Results 7 IECM Interface 66 e Overall IGCC Plant Eile Edit Yiew Go Window Help Configure Plant Set Parameters Get Results Air Gasifier Sulfur Ai By Prod Separation Area Removal CO2 Capture Power Block Mgmt Flow Rate Ga Plant Ouiputs ions hr alp le o B 9 0 oal 197 6 Slag 18 68 Oi 0 7203 Ash Disposed 0 0 Natural Gas 0 0 Other Solids Disposed 0 0 Petroleum Coke 0 0 i Particulate Emissions to Air 2 620e 03 Other Fuels 6 303e 02 Captured CO2 469 7 By Product Ash Sold 0 0 7 By Product Gypsum Sold 0 0 8 Lime Limestone 0 0 By Product Sulfur Sold 4 093 9 Sorbent 0 0 By Product Sulfuric Acid Sold 0 0 10 Ammonia 0 0 11 Activated Carbon 0 0 12 Other Chemicals Solvents amp Catalyst 4 665e 03 See Tab 13 14 Oxidant 187 9 ay lig Blo ele 15 Process Water 86 71 Process Type Joverall Plant z 2 Plant Perf 3 Mass In Out 5 Total Cost 6 Cost Summary
239. ameter is described briefly below Catalyst Cost This is the cost of the catalyst used for the SCR technology Ammonia Cost This is the cost of the ammonia used for the SCR technology Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is a combustion boiler and an air preheater Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Integrated Environmental Control Model User Manual Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Hot Side
240. amp M Cost Wet FGD Config input screen with bypass The following five choices are available for flue gas bypass Maximum SO Removal Efficiency This parameters specifies the maximum efficiency possible for the absorber on an annual average Integrated Environmental Control Model User Manual basis The value is used as a limit in calculating the actual SO removal efficiency for compliance Overall SO Removal Efficiency This value is the SO removal efficiency required for the entire power plant to meet the SO emission constraint set earlier It is used to determine the actual flue gas bypass above Scrubber SO Removal Efficiency This is the actual removal efficiency of the scrubber alone It is a function of the SO emission constraint and the actual flue gas bypass This value is also shown on the next input screen Minimum Bypass This specifies the trigger point for allowing flue gas to bypass the scrubber No bypass is allowed until the allowable amount reaches the minimum level set by this parameter Allowable Bypass This is the amount of flue gas that is allowed to bypass the scrubber based on the actual and maximum performance of the SO removal It is provided for reference only The model determines the bypass that produces the maximum SO removal and compares this potential bypass with the minimum bypass value specified above Bypass is only allowed when the potential bypass value exceeds the minimum bypass v
241. an input parameter Temperature Out Temperature of the flue gas immediately after exiting the reheater This is determined by the gas temperature exiting reheater input parameter Flue Gas Out Volumetric flow rate of the flue gas exiting the reheater based on the flue gas temperature exiting the scrubber and atmospheric pressure Solids Out Total solids mass flow rate in the flue gas exiting the reheater This is a function of the ash removal parameter on the scrubber performance input screen Mercury Out Total mass of mercury exiting the scrubber after the reheater The value is a sum of all the forms of mercury elemental oxidized and particulate Integrated Environmental Control Model User Manual Spray Dryer e 251 Spray Dryer Performance Ash Removal Actual particulate removal efficiency in the scrubber This is set by the scrubber performance input parameter SO Removal Actual removal efficiency of SO in the scrubber This is a function of the maximum removal efficiency scrubber performance input parameter and the emission constraint for SO emission constraints input parameter It is possible that the scrubber may over or under comply with the emission constraint SO Removal Percent of SO in the flue gas removed from the scrubber The SO is assumed to combine with H O and leave with the ash solids or sluice water as a sulfate in the form of H2SO4 Mercury Removal Percent of the total mercury removed from
242. ance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity e Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a fabric filter that has been paid off Spray O amp M Cost Inputs This screen is only available for the Combustion Boiler plant type IECM Interface File Edit View Go Window Help Us Untitled Configure Plant Bulk Reagent Storage Time Lime Cost Waste Disposal Cost Base Plant Mercury Set Parameters Get Results Units CO2 By Prod Capture Mgmt Biok days ton ton Electricity Price Base Plant M Wh Number of Operating Jobs jobs shift Number of Operating Shif
243. and fans required for flue gas distribution to SO system plus gas reheat equipment Solids Handling System This area includes the cost of the equipment for fixation treatment and transportation of all sludge dry solids materials produced by scrubbing General Support Area The cost associated with the equipment required to support spray dryer system operation such as makeup water and instrument air are treated here Miscellaneous Equipment Any miscellaneous equipment is treated in this process area Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor a
244. and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a fabric filter that has been paid off 322 e Water Gas Shift Reactor Integrated Environmental Control Model User Manual Water Gas Shift Reactor O amp M Cost Inputs y IECH Interface ioj xi Fie Edit View Go Window Help Configure Plant Set Parameters By Prod Power Block Mgmt Stack Title Sfeuft Low Temperature CatalystCost icu ft Water Cost 4 1000 gal Electricity Price Base Plant awh Number of Operating Jobs jobs shift Number of O
245. and the results A cost index is used 30 e Combustion Overall Plant Integrated Environmental Control Model User Manual by the IECM to scale all costs to the cost year specified by this parameter The cost year is reported on every input and result screen associated with costs throughout the interface Constant or Current Dollars Constant dollar analysis does not include the affect of inflation although real escalation is included Current dollar analysis includes inflation and real escalation This choice allows you to choose the mode of analysis for the entire IECM economics The cost basis is reported on every input and result screen associated with costs throughout the interface Discount Rate Before Taxes This is also known as the cost of money Discount rate before taxes is equal to the sum of return on debt plus return on equity and is the time value of money used in before tax present worth arithmetic i e levelization Fixed Charge Factor FCF The fixed charge factor is one of the most important parameters in the IECM It determines the revenue required to finance the power plant based on the capital expenditures Put another way it is a levelized factor which accounts for the revenue per dollar of total plant cost that must be collected from customers in order to pay the carrying charges on that capital investment One may specify a fixed charge factor or fill in the following inputs and the model will calculate the FC
246. apital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a cold side ESP that has been paid off Cold Side ESP O amp M Cost Inputs This screen is only available for the Combustion Boiler plant type Integrated Environmental Control Model User Manual Cold Side ESP 197 198 o Cold Side ESP Fo oles Pa ne En Configure Plant Set Parameters Get Results 502 co2 By Prod Base mesti Control Capture Mgmt Stack Title Units Waste Disposal Cost ton Electricity Price Base Plant MWh _ Number of Operating Jobs jobs shift Number of Operating Shifts shifts day Operating Labor Rate hr Total Maintenance Cost TPC Maint Cost Allocatedto Labor total Administrative amp Support Cost totallabor CeAAH amp w N zs t S mle moo mF bmt pet pt Opet Det pe
247. apital costs are entered on the Capital Cost input screen Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes
248. ariable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Sorbent MEA is the default sorbent used in the system and this is the annual cost of the MEA This is a function of the concentration of CO2 in the flue gas and the flue gas flow rate Natural Gas If the user has added an auxiliary natural gas boiler the cost of the natural gas used to fuel the boiler is added here Corrosion Inhibitor The inhibitor helps in two ways reduced sorbent degradation and reduced equipment corrosion This is the annual cost of the corrosion inhibitor Activated Carbon This is the cost of activated carbon used to adsorb impurities from the sorbent degradation products of MEA Caustic NaOH This is the annual cost of caustic The presence of acid gas impurities SO SO3 NO and HCl in the flue gas leads to formation of heat stable salts in the sorbent stream which can not be Integrated Environmental Control Model User Manual Amine System 279 280 e Amine System dissociated even on application of heat In order to avoid accumulation of these salts in the sorbent stream and to recover some of this lost MEA sorbent a part of the sorbent stream is periodically distilled in this vessel Addition of caustic helps in freeing of some of the MEA The recovered MEA is taken back to the sorbent str
249. ariable must be probabilistic in order to represent multiple values Input variables in the IECM can be associated with uncertainty functions Result variables must be a direct result of one or more input variables with uncertainty functions assigned For more information on assigning uncertainty functions to input variables see Uncertainty Distributions Selecting Multiple Sessions Sessions a graph may have 1 6 lines Combustion CCS user manual idb Combustion Base user manual idb DoW Multiple session selection area The graph chooser window allows the same variable s from multiple sessions to be displayed on the same graph The sessions you may select to graph simultaneously are listed in the graph chooser window The order of these can be changed by using Integrated Environmental Control Model User Manual Working with Graphs e 395 the Up and Down buttons on the right side of the window Database files listed can be removed by using the Delete button on the right side of the window The default is to display only the variable s from the current session As demonstrated in the figure above only additional sessions are listed in the white area All graphs displayed will use the X Y and Z variables selected in the graph selection window Choose Session HE empty_session_database idb d cmu modelsidoe Menem lense er uimodelsidoelctiecmintisessdbi4 fa Combustion CCS fg user manual idb diemut mimanualsiuser
250. as Integrated Environmental Control Model User Manual Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Sulfur Removal Total Cost Results 7 IECM Interface O x File Edit View Go Window Help
251. as Cleanup Coi gas H CO2 Capture Nowe H Post Combustion Controls NOx Control None Solids Management Slag Lanari z Sulfur Suttur Plant x Base GE Quench IGCC Base Configuration Configure Plant IGCC input screen The figure above shows the base configuration of the IGCC plant Gasification post combustion and solids management controls can be configured by the user The following sections describe each popup menu on the configuration screen Pre configuration settings can be selected using the Configuration menu at the top of the screen Base GE Quench is the default Gasification Options Gasifier There is a pull down menu so that the user may select the gasifier type The choices are e GE Oxygen blown This is the only gasifier currently available in the model Integrated Environmental Control Model User Manual Configure Plant 23 e E Gas Oxygen blown This option is grayed out in the pull down menu and will be available in a future release of the model e KRW Air blown This option is grayed out in the pull down menu and will be available in a future release of the model e Shell Oxygen blown This option is grayed out in the pull down menu and will be available in a future release of the model Gas Cleanup This menu will be used in the future to allow a user to select a suite of gas cleanup technologies Particular devices for removing solids and sulfur while alt
252. as bypass above This is only visible if bypass is specified Scrubber SO Removal Efficiency This is the actual removal efficiency of the scrubber alone It is a function of the SO emission constraint and the actual flue gas bypass This value is also shown on the next input screen This is only visible if bypass is specified Minimum Bypass This specifies the trigger point for allowing flue gas to bypass the scrubber No bypass is allowed until the allowable amount reaches the minimum level set by this parameter This is only visible if bypass is specified Allowable Bypass This is the amount of flue gas that is allowed to bypass the scrubber based on the actual and maximum performance of the SO removal It is provided for reference only The model determines the bypass that produces the maximum SO removal and compares this potential bypass with the minimum bypass value Integrated Environmental Control Model User Manual specified above Bypass is only allowed when the potential bypass value exceeds the minimum bypass value This is only visible if bypass is specified Actual Bypass This displays the actual bypass being used in the model It is based on all of the above and is provided for reference purposes only This is only visible if bypass is specified Reference Plant The following reference plant inputs are used to determine the avoided cost of CO avoidance The default value is zero for both parameters requiring the u
253. ass flow rate of fly ash in to the direct contact cooler Condensed Water The mass flow rate of condensed water leaving the direct contact cooler Released to Atmosphere Temperature Out The temperature of the flue gas being released to the atmosphere Flue Gas Out The mass flow rate of the flue gas being released to the atmosphere Fly Ash Out The mass flow rate of the fly ash being released to the atmosphere Other Condensed Water The mass flow rate of condensed water CO Product Pressure This is the target pressure of product CO being sent to storage CO to Storage The mass flow rate of CO being sent to storage O CO Recycle DCC Gas Results 294 e O2 CO2 Recycle This screen is available for Combustion Boiler plant types 7 IECH Interface Fie Edit View Go Window Help US Untitled Configure Plant Set Parameters Get Results NOx Mercury U 2 S 6 ole o c Oxygen 02 Water Vapor H20 Control Flue Gas In Major Flue Gas Components h moles hr Flue Gas Recycled h moles hr Flue Gas Out b moles hr Capture Flue Gas In tons hr Flue Gas Recycled tons hr Nitrogen ND 6809 4766 2043 95 35 66 75 1514 2 155e 04 1060 3759 454 3 1611 24 23 194 1 16 96 33 87 Carbon Dioxide CO2 T 6 529e 04 4 570e 04 1 959e 04 1437 1006 Carbon Monoxide CO 0 0 0 0 0 0 0 0 0 0
254. at the exit of the economizer Flue Gas Out Volumetric flow rate of the flue gas at the exit of the economizer based on the temperature at the exit of the economizer and atmospheric pressure Fly Ash Out Total solids mass flow rate in the flue gas at the exit of the economizer This includes ash unburned carbon and unburned sulfur Mercury Out Total mass of mercury in the flue gas exiting the economizer The value is a sum of all the forms of mercury elemental oxidized and particulate Gas Reburn Reburn Gas This is the flow rate of natural gas into the boiler This result will only display if Gas Reburn is selected in the In Furnace Controls pull down menu SNCR The SNCR is located in the upper portion of the boiler Several parameters are reported as a summary These results will only display if SNCR or LNB amp SNCR is selected in the In Furnace Controls pull down menu in the Set Inputs part of the interface Stoic This is the actual reagent stoichiometry used in the SNCR Note that urea has double the moles of nitrogen relative to that of ammonia SNCR Reagent This is the mass flow rate of reagent urea or ammonia injected by the SNCR into the boiler Note that water used to dilute the urea is included in this flow rate NO Removal Performance Boiler NOx Removal This is the composite removal efficiency of the boiler NO technologies associated with low NO burners overfire air Integrated Environmental Con
255. ater Control TSP Control Capture Mgmt Mercury Stack Flue Gas Flue Gas Into Flue Gas Out Flue Gas Flue Gas Into Major Flue Gas Components Bypass Scrubber Scrubber Bypass Scrubber b moles hr b moles hr gt metes ia towhr tonhr 0 0 1 302e 05 1 302e 05 0 0 1823 Oxygen 02 oo e5 s509 i 155 0 Water Vapor H20 oo 1 671e 04 3 274e 04 f 150 5 Carbon Dioxide CO2 oo 2096e 04 2135e 04 0 Carbon Monoxide CO oo oo oo Hydrochloric Acid HCD 0 0 19 71 1 971 7 Sulfur Dioxide S02 oo 4008 80m6 Sulfuric Acid equivalent 503 oo 2 066 1 033 i 8 272e 02 Nitric Oxide NO 0 0 11 29 11 29 i 0 1694 Nitrogen Dioxide NOJ oo o5942 05942 i 4 367e 02 Ammonia NH3 00 0 3088 0 3088 i 2 629e 03 Argon At oo oo oo T alr le oloo m ag Z o TOEM Cost Wet FGD Bypass result screen Each result is described briefly below Major Flue Gas Component Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Integrated Environmental Control Mode
256. ater This is the percent water in the sluice Base Plant Power Requirements These parameters specify the electrical power requirements of pulverizers steam pumps forced draft fans cooling system equipment fans and pumps and other miscellaneous equipment excluding gas cleanup systems These power requirements or penalties are expressed as a percent of a gross plant capacity and are used to calculate the net plant performance Coal Pulverizer This is the power needed to run the coal pulverizers prior to the coal being blown into the boiler It is also referred to as an Integrated Environmental Control Model User Manual energy penalty to the base plant The value is calculated and based on the fuel type It is expressed as a percentage of the gross plant capacity Steam Cycle Pumps This is the power needed to operate the pumps in the steam cycle It is also referred to as an energy penalty to the base plant It is expressed as a percentage of the gross plant capacity Forced Draft Fans This is the power required for the forced draft fans and primary air fan expressed as a percentage of the gross plant capacity It is also referred to as an energy penalty for the base plant Cooling System This is the power needed to run the pumps and other equipment for the water cooling system It is expressed as a percentage of the gross plant capacity It is also referred to as a base plant energy penalty Miscellaneous This is the power use
257. ation pumps to supply pressure to overcome the pressure losses encountered by the solvent in the absorber column CO2 Compression Use MW This is the electrical power required to compress the CO product stream to the designated pressure Compression of CO to high pressures takes lot of power and is a principle contributor to the overall energy penalty of a CO capture unit in a power plant Aux Power Produced MW If an auxiliary natural gas boiler is used to provide steam and power for the Amine System this is the additional electricity that it produces Sorbent Regeneration Equiv Power MW This is the electrical equivalent power for the regeneration steam required taken from the steam cycle The equivalent electricity penalty is about 10 15 of the actual regeneration heat requirement Fixed Charge Factor fraction The fixed charge factor is one of the most important parameters in the IECM It determines the revenue required to finance the power plant based on the capital expenditures Put another way it is a levelized factor which accounts for the revenue per dollar of total plant cost that must be collected from customers in order to pay the carrying charges on that capital investment Cost of CO Avoided Many analysts like to express the cost of an environmental control system in terms of the cost per ton of pollutant removed or avoided For energy intensive CO controls there is a big difference between the cost per to
258. atures Bugs Fixed 1 Interation problem in NG ith amine system www iecm online com Download Page 3 Click the text on the left labeled Download IECM 4 Click on the blue button labeled Download IECM A dialog box will appear File Download Security Warning x Do you want to run or save this file C Name IECM_520 exe Type Application 30 9MB From www iecm online com Run Save While files from the Internet can be useful this file type can F A potentially harm your computer If you do not trust the source do not 2 tun or save this software What s the risk File download dialog box save the program to disk 5 Click on the Save button Integrated Environmental Control Model User Manual Installing the Model 13 14 e Installing the Model My Documents on BE My Computer Application ha Save file dialog box use this to select the location to save the program 6 Choose a location to save the setup file and click the Save button 18 of IECM_520 exe from www iecm online com Co le E3 6 n 1 Wpem Wer EGIGer File download progress indicator The download will begin Once it is finished you can proceed to install the IECM software If you receive an error message while running the install program restart your computer and run the installation program again If it still returns an error message contact Technical Support Installing
259. available These are accessed by the Process Type drop down menu Each 350 e By Product Management Integrated Environmental Control Model User Manual management technology has only one Result Navigation Tab Diagram IECM Interface Eile Edit View Window Help ix 0 US Untitled Configure Plant Set Parameters ic 3 amp Wet Bottom Ash ton hr c Mercury lb hr 2 659e 2 659e 03 e Wet Fly Ash ton hr 0 0 ER Mercury b ht 0 0 ia ih zis i Wet Total Solids tons hr 2 432 Total Mercury lb ht 2 659e 03 Process Type IOE CT By Products Management Bottom Ash Pond Diagram result screen The Bottom Ash Pond Diagram result screen displays an icon for the Pond and values for major flows into it Each result is described briefly below Bottom Ash Pond Inputs Solids mixed with sluice water that are collected in the bottom of the boiler and by the particulate removal technologies are transported to the Pond for treatment The IECM currently provides no additional treatment or consideration of these substances and therefore simply reports the quantities entering the technology Wet Bottom Ash Mass flow rate of bottom ash solids on a wet basis Mercury contained in Bottom Ash Mass flow rate of mercury present in the bottom ash solids on a wet basis Wet Fly Ash Mass flow rate of total fly ash solids on a wet basis This value is zero when the fly ash is disposed in a landfill Mercury con
260. ay a loan or investment with interest It is one of the most important parameters in the IECM It determines the revenue required to finance the power plant based on the capital expenditures Put another way it is a levelized factor which accounts for the revenue per dollar of total plant cost that must be collected from customers in order to pay the carrying charges on that capital investment Inflation Rate This is the rise in price levels caused by an increase in the available currency and credit without a proportionate increase in available goods or services It does not include real escalation CO Transport System Retrofit Costs Inputs This screen is available for all plant types File Edit View Go Window Help Configure Plant Set Parameters Get Results Base Plant Mercury 302 ea Control C aptur e Title Units Capital Cost Process Area Material Cost retro new Labor Costs retro new aer le aolo Right of way Cost retro new Booster Pump Cost retro new Miscellaneous Costs retro new Zj tt Process Type co2 Transport gt 1 Config BOM 4 CapitalCost 5 0 amp MCost CO Transport System Retrofit Cost input screen Integrated Environmental Control Model User Manual CO2 Transport System e 357 358 e CO2 Transport System Capital Cost Process Area The retrofit cost factor of each process is a multiplicative co
261. ber of days of bulk storage of reagent This factor is used to determine the inventory capital cost Limestone Cost This is the cost of Limestone for the Wet FGD system Lime Cost This is the cost of Lime for the Wet FGD or Lime Spray Dryer system Dibasic Acid Cost This is the cost of the Dibasic Acid for the Wet FGD or Lime Spray Dryer system Stacking Cost This is the stacking cost as used for the Wet FGD system Waste Disposal Cost This is the sludge disposal cost for the FGD system Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is a combustion boiler and an air preheater Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5S day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Integrated Environmental Control Model User Manual Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be develop
262. bor costs and is given in dollars per mile of pipeline per year CO Transport System Diagram This screen is available for all plant types 101 Eile Edit View Go Window Help US Untitled Configure Plant Set Parameters Get Results Air if S co2 By Prod Cecita Separation Capture HorerBlack Mgmt Stack Pressure In psia 2000 Pressure Out psia 1688 CO2 Stream In acfm 80 32 CO2 Stream Out acfin 95 12 No of Booster Pumps Eh aaa e Ground Temperature F 4208 08 Pipe Segments 1 000 Pipe Size inches 14 00 NE ey Process Type YOAT ba 1 Diagram 3 Capital Cost 4 O amp M Cost 5 Total Cost CO Transport System Diagram From Plant Pressure In This is the pressure of the CO from the plant into the pipeline in absolute pounds per square inch CO Stream In This is the flow of the CO from the plant into the pipeline in actual cubic feet per minute To CO Transport System No of Booster Pumps This is the number of booster pumps used if any Ground Temperature Average ground temperature that the pipeline traverses Pipe Segments Total number of pipe segments from plant to injection site Integrated Environmental Control Model User Manual CO2 Transport System e 361 Pipe Size Outer diameter of the pipe in inches To Storage Pressure Out This is the pressure of the CO when it enters the storage site in absolute pounds per square inch CO Stream Out This
263. bric Filter O amp M Cost Results ceecceesscssseecsscecceeecesceeesaeecsaeecscesseeecssaeessaessseesseeesee 218 Variable Cost COMPOMENL eseeecceeseeceseecceeeeseecseecsseecesaeessaeerceeeeeseseseeeesaes 219 Fixed Cost Component iresi savcidv ai dire iiien tinctures 219 Fabric Filter Total Cost Results 0 00 eecceeseesseecssececeeecesceeesaeecsaeecsacecseecessaeessaeesaeessaeessee 220 Cost COmponent a3 i it a aie ee Ai Eas holies 220 Wet FGD 223 Wet FGD Configuration i 20 0 intitle Ra ie ee sts ee G ges 223 Reagent yinchede nti E a erie a en aa iialigael aia eta 223 Flue Gas Bypass Control 0 cc eeceeeesscecceesesseeessseeceesececessseeecessaaaeeeceeeceesaeeeees 224 Wet FGD Performance Inputs iiini nee e r r a E aa 225 Wet FGD Additives Inputs s esseesreessesseevsrrersrseresseeseeeseeesetesreeseteeseteetesetesredersserasetsdees 227 Wet FGD Retrofit Cost Inputs ee eeeceescecssceecesseesseecseecseecesaeeesaeeecsseesneesssaeeesaeessaeers 228 Capital Cost Process Area iss tesces sines jcehcvesdovscines duscoxstpe ican can eano en teso aeos eki iE teisins 229 Wet FGD Capital Cost Inputs sinioro coi ch es cow dans Hiesea es lov bes cabsevecon aeS ee a 229 Integrated Environmental Control Model User Manual Wet FGD O amp M Cost Inputs eee e a a E E e E E e i an e a ES 231 CIDA DIETEN i a EAE cee E AE E E E pega teat 233 IREKE TEA AEE E ESEE AE EE E S S E EA T 233 FlieGas Entering FGD Rre SB a a a
264. briefly below Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Air Cooled Condenser Configuration This screen is available for all plant types Inputs for configuration of the Air Cooled Condenser are entered on the Config input screen 7 JECM Interface ile Edit View Go Window Help T se Untitled Configure Plant le D F e o Title i Unc Value Cale Min Max Default 1 Configuration Menus 2 Condenser Type Multiple Menu Menu fultiple Roy 3 Configuration A end Menu Menu rame 60d e fai gt g R PRC 2 Ferfomance 3 RetrofitCost 4 Capital Cost 5 O amp M
265. c Turbine Efficiency 95 00 Shaft Generator Efficiency 98 00 Air Compressor Pressure Ratio outlet inlet 15 70 Adiabatic Compressor Efficiency 70 00 Combustor Combustor Inlet Pressure psia 294 0 Combustor Pressure Drop psia 4 000 Excess Air For Combustor stoich 182 2 Process Type Power Block 1 Gas Turbine Power Block Gas Turbine input screen Gas Turbine Generator Gas Turbine Model This is a selection of the type of turbine model used manufacturer types currently include only the 7FA The type Integrated Environmental Control Model User Manual 2 Steam Cycle 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Power Block e 373 determines the inlet temperature pressure ratio and size parameters This parameter list will be expanded in future versions No of Gas Turbines This is the number of gas turbines Since each turbine is able to produce a fixed output the number of turbines will determine the plant size e g gross plant size Total Gas Turbine Output This parameter is provided for reference purposes only It provides the gross power generated from the gas turbines alone Fuel Gas Moisture Content Steam is typically added to the fuel gas prior to being combusted This increases the volume of the fuel gas and results in a higher power output in the gas turbine Turbine Inlet Temperature
266. can be processed by the following equipment options e Sulfur Plant Sulfur is processed into a solid form This option is the only one currently available in the model 24 e Configure Plant Integrated Environmental Control Model User Manual e Sulfuric Acid Plant Sulfur is processed into an acid form This option is grayed out in the pull down menu and may be available in a future release of the model Integrated Environmental Control Model User Manual Configure Plant 25 Combustion Overall Plant The input parameter screens described in the following sections are available when the Combustion Boiler is selected as the plant type from the New Session pull down menu These screens apply to the power plant as a whole not to specific technologies Combustion Overall Plant Diagram 7 IECH Interface 5 10l x File Edit View Go Window Help EJ Urtinea 151 xi eS Configure Plant Set Parameters Get Results all NOx 2 cO2 By Prod Control Capture Mgmt 3 7 No Fly Ash Co Disposal Combustion Controls aan E Fuel Type Coal E NOx Control None gt Post Combustion Controls g NOx Control None Particulates None E f S02 Control None Mercury None CO2 Capture None ei Solids Management Flyash Disposal No Mixing L Disgan OEM Coat Combustion Overall Plant Diagram result screen This Diagram appears in the Configure Plant Set Parameters and Get Results program areas T
267. capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens Integrated Environmental Control Model User Manual Water Systems e 23 7 ECM Interface Eile Edit view Go Window Help i Untitled Configure Plant l F e o Title Capital Cost Process Area Set Parameters Units Max Default Condenser Structure retro new Steam Duct Support retro new Electrical amp Control Equipment retro new 10 00 1 000 10 00 1 000 10 00 1 000 Awiliary Cooling retro new 10 00 1 000 Clearing System retro new 10 00 1 000 Daana WN B El s a Air Cooled Condenser Retrofit Cost Input Screen The parameters are describ
268. cceptable levels of moisture and other impurities e g N2 The size and cost of this unit will be a function of the CO product compression power Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Flue Gas Recycle Plant Costs Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new t
269. ce Electricity Cost of power consumption of the particulate control technology This is a function of the flue gas flow rate ash removal efficiency and the type of coal ash properties Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Component Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Integrated Environmental Control Model User Manual Fabric Filter e 219 Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M
270. ce cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Wet Cooling Tower Total Cost Results This screen is available for all plant types The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Wet Cooling Tower technology 7 JECM Interface ie Untitled Configure Plant Set Parameters lo O P o o ton SO2 Cost Component M yr MWh TR Percent Total EE nnual Fixed Cost 1 304 0 4215 c5 10 61 Annual Variable Cost 4 470 1 444 36 35 Annualized Capital Cost 6 524 2 108 l 2 2 Costs are in Constant 2007 dollars Wet Cooling Tower Total Cost Result Screen 20 e Water Systems Integrated Environmental Control Model User Manual Cost Component Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described
271. ce input screen Leakage Air Volumetric flow rate of the atmospheric air leaking across the air preheater into the flue gas This is based on the leakage temperature and atmospheric pressure Flue Gas Entering Preheater Temperature In Temperature of the flue gas entering the air preheater This is determined by the flue gas outlet temperature of the module upstream of the air preheater e g the boiler economizer Flue Gas In Volumetric flow rate of the flue gas entering the air preheater based on the flue gas inlet temperature and atmospheric pressure Fly Ash In Total solids mass flow rate in the flue gas entering the air preheater This is determined by the solids exiting the module upstream of the air preheater e g the boiler economizer Mercury In Total mass of mercury entering the air preheater in the flue gas The value is a sum of all the forms of mercury elemental oxidized and particulate Air Preheater Performance SO3 Removal Percent of the SO removed from the flue gas Cooled Flue Gas Exiting Preheater Temperature Out Temperature of the flue gas exiting the air preheater This is determined by the parameter on the base plant performance input screen Flue Gas Out Volumetric flow rate of the flue gas exiting the air preheater based on the flue gas exit temperature and atmospheric pressure 136 e Air Preheater Integrated Environmental Control Model User Manual Fly Ash Out Total solids mass flow ra
272. cess Type TSE ee NM 1 Diagram By Products Management Fly Ash Disposal Diagram result screen The By Products Management Fly Ash Disposal Diagram result screen displays an icon for the Landfill and values for major flows into it This screen is only an option if CO2 Capture has been configured for the plant by the user Each result is described briefly below Fly Ash Disposal Inputs Solids mixed with sluice water are collected in the particulate removal technologies and may be transported to the Landfill for treatment The IECM currently provides no additional treatment or consideration of these substances and therefore simply reports the quantities entering the technology Wet Fly Ash Mass flow rate of total fly ash solids on a wet basis Mercury Mass flow rate of mercury present in the fly ash solids on a wet basis Fly Ash Disposal Totals Wet Total Solids The sum of the fly ash and FGD solids on a wet basis Total Mercury Mass flow rate of mercury present in the combined fly ash and FGD solids on a wet basis Integrated Environmental Control Model User Manual By Product Management e 353 By Products Management Geological Resevoir Diagram IECM Interface Edit View Window Help Ei untitled la ollo g ale 2 x By Product Management Geological Reservoir diagram The By Products Management Geological Reservoir Diagram result screen displays an icon for the Geological Reservoir an
273. cified later in the capital and O amp M cost input parameter screens Each parameter is described briefly below Integrated Environmental Control Model User Manual 7 IECH Interface ioj xi File Edit View Go Window Help Configure Plant Set Parameters Get Results Base Plant Mercury Title Units Capital Cost Process Area Reagent Feed System retro new 02 Removal System retro new Flue Gas System retro new Solids Handling System retro new General Support Area retro new Miscellaneous Equipment retro new zs t S mle mo bt pt pet Opet Opet pe et t AAA aa n a kal aie 18 Process Type wet Fob z 1 Config OR 5 Capital Cost 6 O amp M Cost Wet FGD Retrofit Cost input screen Capital Cost Process Area Reagent Feed System This area includes all equipment for storage handling and preparation of raw materials reagents and additives used SO2 Removal System This area deals with the cost of equipment for SO scrubbing such as absorption tower recirculation pumps and other equipment Flue Gas System This area treats the cost of the duct work and fans required for flue gas distribution to SO system plus gas reheat equipment Solids Handling System This area includes the cost of the equipment for fixation treatment and transportation of all sludge dry solids materials produced by
274. city for internal use It is expressed as a percent of the gross plant capacity Power Block Emission Factors This screen is only available for the Combustion Turbine and IGCC plant types Integrated Environmental Control Model User Manual Power Block e 375 y IECM Interface File Edit Yiew Go Window Help Us Untitled Configure Plant Set Parameters Percent SOx as 503 NOx Emission Concentration Percent NOx as NO Percent Total Carbon as CO izi S 2 mle le meoo Process Type Power Block 2 Steam Cycle 3 Emis Factors 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Power Block Emission Factors input screen Emission Factors Input Parameters Percent SO as SOs This is the volume percent of SO that is SO3 The remainder is SO NO Emission Concentration This is the concentration of NO emitted from the gas turbine after combustion Percent NO as NO This is the volume percent of NO that is NO The remainder is NO gt Percent Total Carbon as CO This is the volume percent of the total carbon in the syngas entering the combustor that is emitted from the gas turbine as CO Power Block Retrofit Cost This screen is only available for the Combustion Turbine and IGCC plant types 376 e Power Block Integrated Environmental Control Model User Manual 7 IECH Interface loj x File Edt View Go Window Help
275. cost of the baghouse Bag Life Bag life is typically between 3 5 years The bag life values are dependent on the fabric filter type and are used to calculate the cost of the baghouse Air to Cloth Ratio The Air to Cloth ratio is the most important baghouse parameter It is the ratio of volumetric flue gas flow rate and total bag cloth area The calculated value is a function of fabric filter type It is used to determine the cost and power use of the baghouse Total Pressure Drop across Fabric Filter Baghouse pressure drop flange to flange is caused by pressure losses in gas flow as it moves through the bag fabric and dust cake Typical values range from 6 to 8 in H2O and depend on the baghouse type selected The value affects the power consumption Percent Water in Fabric Filter Discharge This is the water content of the collected fly ash Fly ash disposed with bottom ash is assumed to be sluiced with water and dry otherwise The occluded water in wet fly ash is difficult to remove resulting in a rather high water content when the fly ash is mixed with bottom ash Fabric Filter Power Requirement The default calculation is based on the air to cloth ratio and the flue gas flow rate The power accounts for the auxiliary power requirements and electro mechanical efficiencies of fan motors Fabric Filter Retrofit Inputs This screen is only available for the Combustion Boiler plant type Inputs for the capital costs of modifications
276. costs are not specified with the other process areas This parameter allows any direct capital costs incurred by the addition of bypass ducts to be added to the Flue Gas System process area see retrofit cost screen for a list of the direct cost process areas General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Integrated Environmental Control Model User Manual
277. creen Integrated Environmental Control Model User Manual Major Flue Gas Components Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SOs Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Spray Dryer Capital Cost Results This screen is only available for the Combustion Boiler plant type File Edit View Go Window Help Configure Plant Set Parameters Get Results coz By Prod Capture Mgmt Stack Spray Dryer Process Area Costs a Spray Dryer Plant Costs soiis M Reagent Feed System 5 661 502 Removal System 12 97 Flue Gas System 7 041 Solids Handling System 0 7263 General Support Area 0 6778 Miscellaneous Equipment 1 471 General Facilities Capital 2 855 Eng amp Home Office Fees 2 855 Project Contingency Cost 4 282 Process Contingency Cost 1 142 Interest Charges AFUDC 4 227 Royalty Fees 0 1427 Preproduction
278. cribed briefly below Fixed O amp M The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs for each technology Variable O amp M The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs associated with a technology Total O amp M This is the sum of the annual fixed and variable operating and maintenance costs for each technology Annualized Capital This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Overall NGCC Plant Cost Summary Results lolx Eile Edit View Go Window Help Configure Plant Set Parameters Power Block NOx Control CO2 Capture Capital Revenue Technology Required Required SAC W net M yr CO2 Capture 310 6 67 10 Power Block 774 3 138 2 Post Combustion NOx Control 0 0 0 0 zis lt 2 mle le ole o o o o o Emission Taxes h 6T o f s 053 aa td 8 o 10 11 12 i 13 14 15 Overall Plant Costs are in Constant 2005 dollars LPi Pot 3 Mass In Out 4 Gas Erussions 7
279. ction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Power Block Total Cost Results This screen is only available for the Combustion Turbine and IGCC plant types 7 IECH Interface ioj xi Fie Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results Sulfur weep By Prod PRSNI CO2 Capture PALGA Mgmt Stack Cost Component Annual Fixed Cost Annual Variable Cost win Annualized Capital Cost 4 5 TotalLevelized AnnualCost 2513 sen 6 7 E 9 1o L 1 12 13 14 15 Power Block Costs are in Constant 2005 dollars 1 GT Diagram 2 5T Diagram 3 Syngas 5 Capital Cost 6 0 amp MCost AGC LLE Power Block Total Cost results screen The Total Cost result screen displays a table which totals the annual fixed variable operations maintenance and capital costs Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are giv
280. ctual total capital required TCR to finance the base plant as a percent of the TCR of a new power plant This value is 100 for a new plant and may be set as low as 0 for a base plant that has been paid off Base Plant O amp M Cost Inputs Inputs for the operation and maintenance costs of the Combustion Boiler base plant itself are entered on the O amp M Cost input screen 102 e Base Plant Integrated Environmental Control Model User Manual 7 IECM Interface File Edit View Go Window Help 0 US Untitled Configure Plant Set Parameters NOx TSP 502 Control Control Control Title Units Unc i Shon 160 0 Waste Disposal Cost ton 30 00 Water Use gallons kWh 1 10 00 Water Cost 1000 gal i 2 500 Electricity Price Base Plant MWh 200 0 Number of Operating Jobs number H 100 0 Number of Operating Shifts shifts day 4 10 00 Operating Labor Rate ehr i 100 0 Total Maintenance Cost YTPC i 100 0 Maint Cost Allocated to Labor TMC a 0 0 100 0 Administrative amp Support Cost total labor 100 0 z t Ele e mlo EH ed cl ed baal al eal dl lb Real Escalation Rate Yolyr a i 10 00 Process Type Base Plant Costs are in Constant 2003 dollars h 1 Perfomance 2 Fum Factors f 3 RetrofitCost 4 CapitalCost GEPAS AUICE Base Plant O amp M Cost input screen The EPRI TAG method of categorization has been used for operating and
281. cury is replaced with a pulse jet fabric filter This can be considered a pseudo COHPAC Equipment includes pulse jet FF filter bags ductwork dampers and MCCs instrumentation and PLC controls for baghouse operation Equipment excludes ash removal system power distribution and power supply and distributed control system The direct capital cost is a function of the flue gas flow rate and the air to cloth ratio of the fabric filter NOTE The IECM currently does not support multiple particulate devices in the same configuration nor a modified cold side ESP Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Total Capital Costs Process Facilities Capital See definition above This result is highlighted in yellow General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipm
282. d M Stack Temperature Out F Pressure Out psia Syngas Out ton hr Makeup Catalyst cu fh 42 61 Beavon Stretford Plant The Sulfur Removal Diagram result screen displays an icon for the Sulfur Removal Unit Selexol the Claus Plant the Beavon Stretford Plant and values for major flows in and out of it The user may switch between the three process types results by choosing from the pull down menu labeled Process Type located above the bottom tabs on the left side of the Sulfur Removal Diagram Each result shown on the Sulfur Removal Diagram is described briefly below in flow Temperature In Temperature of the syngas entering the Selexol based sulfur removal unit Pressure In Pressure of the syngas entering the Selexol based sulfur removal unit Syngas In Flow rate of the syngas entering the Selexol based sulfur removal unit Makeup Solvent In This is the Selexol solvent makeup rate into the sulfur removal unit expressed on a continuous basis Makeup Catalyst In This is the catalyst makeup rate for the Claus plant expressed on a continuous basis Temperature Out Temperature of the syngas exiting the Selexol based sulfur removal unit Pressure Out Pressure of the syngas exiting the Selexol based sulfur removal unit Syngas Out Flow rate of the syngas exiting the Selexol based sulfur removal unit Makeup Catalyst In This is the catalyst makeup rate for the Beavon Stretford plant expresse
283. d variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Base Plant 111 Auxiliary Boiler An Auxiliary Boiler System is available as an option from within the amine scrubber system It is specified from the Set Parameters program area of the CO2 Capture configuration input screen using the Process Type pull down menu at the bottom of the screen mony 5 L Process Type Amine System Auxiliary Boiler Process Type Input parameters are included as part of the amine system and not specified separately Several performance result screens are provide separately for the auxiliary boiler system but cost results are incorporated into the amine system The following sections describe the results that are displayed explicitly for the auxiliary boiler system Auxiliary Boiler Diagram The Diagram result screen displays an icon for the Auxiliary Boiler and values for major flows in and out of it The auxiliary boiler is available in the Combustion Boiler
284. d by any other miscellaneous equipment in the base plant not including equipment used for pollution control equipment It is expressed as a percentage of the gross plant capacity It is also referred to as a base plant energy penalty Base Plant Furnace Factors Inputs Inputs for the furnace factors that effect the major flow rates and concentrations of the gas and solids streams are entered on the Furnace Factors input screen This screen accepts inputs for the flue gas and ash products emitted from the boiler into the flue gas and ash streams Factors in emissions include incomplete combustion and thermodynamic equilibrium between gas species associated with the combustion products This screen s inputs are needed to calculate boiler efficiency and air pollutant emissions The emission of carbon ash sulfur and nitrogen are specified by the United States Government s Environmental Protection Agency s EPA compilation of emission factors Also included from the compilation are the incomplete transfer percentages of solid and gaseous forms of these substances This screen is available for all plant configurations Integrated Environmental Control Model User Manual Base Plant 97 ioixi Eile Edit View Window Help Li mx Configure Plant Set Parameters Get Results Base Pl Emission N s02 coz Base Plant Constraint ai 7 a Control Control Capture Sulfur Retained in Flyash Percent of SOx as 503 Preheater 303
285. d in either constant or current dollars for a specified year as shown on the bottom of the screen Each parameter is described briefly below Integrated Environmental Control Model User Manual Amine System 271 MEA Cost This is the unit cost of the makeup MEA Inhibitor Cost Addition of inhibitor makes it possible to use higher concentrations of MEA solvent in the system with minimal corrosion problems Inhibitors are special compounds that come at a cost premium The cost of inhibitor is estimated as a percent of the cost of MEA The model default is 20 Activated Carbon Cost This is the cost of the activated carbon in per ton Caustic NaOH Cost This is the cost of the caustic NaOH in per ton Water Cost Water is mainly required for cooling and also as process makeup Cost of water may vary depending upon the location of the power plant Natural Gas Cost This is the cost of the natural gas This is only visible if an auxiliary boiler is specified Reclaimer Waste Disposal Cost The unit cost of waste disposal for the reclaimer waste Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number t
286. d in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below CO Transport Process Area Costs Material Cost This includes the cost of line pipe pipe coatings and cathodic protection Labor Costs This covers the cost of labor during pipeline construction Right of way Cost This is the cost of obtaining right of way for the pipeline This cost not only includes compensating landowners for signing easement agreements but landowners may be also be paid for loss of certain uses of the land during and after construction loss of any other resources and any damage to property Booster Pump Cost This is the total capital cost of a booster pump Miscellaneous Cost This includes the costs of surveying engineering supervision contingencies telecommunications equipment freight Integrated Environmental Control Model User Manual taxes allowances for funds used during construction AUFDC administration and overheads and regulatory filing fees Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow CO Transport Plant Costs Process Facilities Capital see definition above General Facilitie
287. d into the flue gas are entered on the Carbon Inj input screen Water can be optionally added to reduce the flue gas temperature and enhance the effect of the carbon on removing mercury Note that the actual removal of the carbon and mercury are accomplished in particulate and flue gas desulfurization control technologies downstream Integrated Environmental Control Model User Manual Mercury 177 178 e Mercury y IECM Interface a File Edit Yiew Window Help Emission NOx Base Plant Constraint Etat Control Value Activated Carbon Injection TI Approach to Acid Saturation Temp deg F 18 00 Sorbent Injection Rate tb C Macfm 58 25 ajal le lajajo o Carbon Injection Power Requirem MWg 0 1858 Ei Z E cton A Mercury Removal Efficiency input screen Each parameter is described briefly below Activated Carbon Injection Injection of water to reduce the flue gas temperature and activated carbon to enhance mercury removal are the only control technologies presently incorporated into the IECM Approach to Acid Saturation Temperature When water is selected to be injected with the activated carbon this parameter appears on the Removal Efficiency input screen It is important to keep the flue gas temperature above the sulfuric acid dew point temperature This avoids condensation of acid on equipment This parameter determines the amount
288. d on a continuous basis Integrated Environmental Control Model User Manual Sulfur Removal e 337 Sulfur Out Flow rate of the elemental sulfur collected in both the Claus and Beavon Stretford plants Flue Gas Out The exhaust gas from the Beavon Stretford plant is completely burned and sent to a stack This is the flow rate of combusted exhaust gases Sulfur Removal Capital Cost Results 7 IECH Interface Fie Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results By Prod CO2 Capture Power Block Memt Stack Sulfur Removal Process Area Costs ee Sulfur Removal Plant Costs Sulfur Removal System Hydrolyzer 0 0 Sulfur Removal System Selexol 22 81 General Facilities Capital 5 109 Sulfur Recovery System Claus 6 816 Eng amp Home Office Fees 3 406 Tail Gas Clean Up Beavon Stretford Project Contingency Cost 5109 J Process Contingency Cost 3 065 Interest Charges AFUDC 8 393 D al 8 oh e Ep 5 gt R Royalty Fees 0 1703 ed edd al el an Preproduction Startup Cost 1 606 9 Inventory Working Capital 0 2537 Sulfur Removal Capital Cost results screen The Sulfur Removal Capital Cost result screen displays tables for the capital costs Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is describ
289. d total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Boiler Total Cost Results The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the boiler 110 e Base Plant Integrated Environmental Control Model User Manual zax Eile Edit view Window Help Air NOx Preheater Control piate Cost Component Control 02 Control Get Results co2 By Prod Capture Memt Stack Percent Total 1 Annual Fixed Cost 13 45 Annual Variable Cost z a 8 s lt le mlel 9 770 76 78 Process Type Boiler z 2 Flue Gas 3 Capital Cost 5 Total Cost Boiler Total Cost result screen Cost Component Costs are in Constant 2000 dollars Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed an
290. d transport ammonia into the inlet gas stream This is determined by the steam to ammonia ratio input value and the ammonia injection Catalyst Steam for Soot This is the amount of steam blown into the hot side SCR to remove soot buildup on the catalyst layers The soot blowing steam is assumed to be directly proportional to catalyst volume Initial Catalyst Layers This is the number of initial active catalyst layers Three layers are installed initially It is used to calculate the total pressure drop across the SCR and the auxiliary power requirements This is set by the input parameter Integrated Environmental Control Model User Manual Hot Side SCR e 165 Reserve Catalyst Layers This is the number of reserve or extra catalyst layers These are available for later catalyst additions It is used to calculate the total pressure drop across the SCR and the auxiliary power requirements This is set by the input parameter Dummy Catalyst Layers This is the number of dummy catalyst layers A dummy layer corrects the flow distribution It is used to calculate the total pressure drop across the SCR and the auxiliary power requirements This is set by the input parameter Active Catalyst Layers This is the number of initial active catalyst layers Three layers are installed initially It is used to calculate the total pressure drop across the SCR and the auxiliary power requirements It is equal to the number of initial and reserve catalyst
291. d values for the concentrated CO that flows into it The result is described briefly below Condensed CO Mass flow rate of CO3 354 e By Product Management Integrated Environmental Control Model User Manual CO Transport System The CO Transport System models the transport via pipeline of carbon dioxide CO captured at a power plant from plant site to sequestration site It may be used in all of the plant type configurations CO Transport System Configuration This screen is available for all plant types The screens under the CO2 Capture Technology Navigation Tab display and design flows and data related to the CO3 Transport System 7 IECM Interface File Edit View Go Window Help US Untitled Configure Plant 0 6214 0 0 0 0 Electric Menu 75 00 0 0 Design Pipeline Flow plant cap 100 0 Actual Pipeline Flow 2 677e 06 4 Inlet Pressure powerplant psia 200 E Min Outlet Pressure storage si 1494 2219 Average Ground Temperature i 42 08 86 00 Pipe Material Roughness 1 799e 03 j 3 937e 03 1 799e 03 izis e 2 mlp oleo o 17 Set inlet pressure in CO2 capture Process Type C02 Transport 1 Config 3 Retrofit Cost 4 Capital Cost 5 O amp M Cost CO Transport System Config input screen Each configuration parameter is described briefly below Total Pipeline Length This is the total length of the pipe bet
292. d with a steam turbine to generate some additional power and or low pressure steam The cost is a function of the steam flow rate generated by the boiler The boiler cost is lower if electricity is not being produced Auxiliary Steam Turbine The steam turbine is used in conjunction with the natural gas boiler to generate some additional power and or low pressure steam The cost is a function of the secondary power generated by the turbine Amine System Capital Cost Inputs This screen is only available for the Combustion Boiler and Combustion Turbine plant types Integrated Environmental Control Model User Manual Amine System 269 270 e Amine System 7 IECH Interface ioj xi Fie Edit View Go Window Help Configure Plant Set Parameters Get Results Base Plant Mercury Capture Title 10 00 _ General Facilities Capital i i 50 00 Engineering amp Home Office Fees i 60 00 Project Contingency Cost 100 0 Process Contingency Cost fl 100 0 Royalty Fees i 10 00 CeAANKH amp wn Pre Production Costs Months of Fixed O amp M Months of Variable O amp M 12 Misc Capital Cost i 13 14 Inventory Capital 15 16 17 Zi e 2 me le ooo 18 TCR Recovery Factor Process Type Amine System H h LConfig 4 COZ Storage 5 Retrofit Cost EREEREER Z O amp M Cost Amine System Capital Cost input screen Inputs for c
293. der when developing a probability distribution for a variable Some of these are summarized briefly here Statistical error is associated with imperfections in measurement techniques Statistical analysis of test data is thus one method for developing a representation of uncertainty in a variable Empirical measurements also involve systematic error The mean value of a quantity may not converge to the true mean value because of biases in measurement and procedures Such biases may arise from imprecise calibration faulty reading of meters and inaccuracies in the assumptions used to infer the actual quantity of interest from the observed readings of other quantities Estimating the possible magnitude of systematic error may involve an element of engineering judgment Variability can be represented as a probability distribution Some quantities are variable over time For example the composition of a coal or perhaps a sorbent may vary over time Uncertainty may also arise due to lack of actual experience with a process This type of uncertainty often cannot be treated statistically because it requires predictions about something that has yet to be built or tested This type of uncertainty can be represented using technical estimates about the range and likelihood of possible outcomes These judgments may be based on a theoretical foundation or experience with analogous systems Encoding Uncertainties as Probability Distributions As i
294. derflow as a percent of the quantity of entering water treated This option is only available when the Makeup Water Treatment System is loaded Power Requirement This is the power needed to run the pumps and other equipments for the water cooling system It is also referred to as a base plant energy penalty In the PC power plants it is expressed as a percentage of the gross plant capacity In the IGCC plants it is calculated based on the steam turbine power output and expressed as a scaled percentage of the total gross power outputs including the gas and steam turbines Wet Cooling Tower Retrofit Cost Inputs This screen is available for all plant types Inputs for capital costs of modifications to process areas to implement the Wet Cooling Tower are entered on the Retrofit Cost input screen for the Wet Cooling Tower system The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of
295. described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Fabric Filter Capital Cost Results This screen is only available for the Combustion Boiler plant type The Capital Cost result screen displays tables for the direct and indirect capital costs related to the particulate control technology 216 e Fabric Filter Integrated Environmental Control Model User Manual 7 IECH Interface ioj xi File Edit View Go Window Help Configure Plant Set Parameters Get Results 02 CO2 By Prod Control Capture Mgmt Stack Fabric Filter Process Area Costs Fabric Filter Plant Costs aera 25 87 Process Facilities Capital ai Ductwork 0 7036 General Facilities Capital 0 3114 Fly Ash Handling 4 324 Eng amp Home Office Fees 1 557 Differential 0 2488 Project Contingency Cost 6 229 Process Contingency Cost 0 0 I
296. duct stream to the designated pressure given as a percent of the total gross power generated by the power plant Compression of CO to high pressures requires substantial energy and is a principle contributor to the overall energy penalty of a CO capture unit in a power plant CO2 Transport amp Storage CO Storage Method The following are the optional methods for CO disposal The default option for CO disposal is underground geological storage e Enhanced Oil Recovery EOR e Enhanced Coal Bed Methane ECBM e Geological Reservoir Geologic e Ocean Ocean O CO2 Recycle Retrofit Cost Inputs This screen is available for Combustion Boiler plant types 288 O2 CO2 Recycle Integrated Environmental Control Model User Manual 7 IECH Interface ioj xi File Edit View Go Window Help Configure Plant Set Parameters Get Results Base Plant Mercury Capture Title Units Capital Cost Process Area Boiler Modifications retro new Flue Gas Recycle Fan retro Ginew Flue Gas Recycle Ducts retro new Oxygen Heater retro new Direct Contact Cooler retro new CO2 Compression System retro new Zi e 2 me le ooo bt pmt pet Opet Opet pe et et zanru RESES 1s Process Type Fe Recycle amp Purification gt 1 Config 3 CO2 Storage 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost 0O2 CO Recycle Flue Gas Retrofit co
297. e As Delivered Coal Cost ton A E Natural Gas Cost mscf cf e Water Cost 1000 gal ci Limestone Cost ton w g Lime Cost ton w R Ammonia Cost ton A Urea Cost o E ton A MEA Cost ton A 1 500e 04 Activated Carbon Cost ton vw 5000 Caustic NaOH Cost iton w 2000 Operating Labor Rate hr 4 3 100 0 Process Type Overall Plant z Costs are in Constant 2005 dollars Overall Plant O amp M Cost input screen Internal COE for Comp Allocations This is a pop up selection menu that determines the method for determining electricity costs within the power plant The selection of this pop up menu determines the actual internal electricity price on the next line The options are e Base Plant uncontrolled e User Specified e Total Plant COE Internal Electricity Price This is the price of electricity and is calculated as a function of the utility cost of the base plant The base plant for the Combustion Boiler model is assumed to be a coal pile combustion boiler air preheater and disposal sites This value is calculated and provided for reference purposes only unless User Specified is selected in the pop up in the previous line Integrated Environmental Control Model User Manual As Delivered Coal Cost This is the cost of the coal as delivered Natural Gas Cost This is the cost of natural gas in dollars per thousand standard cubic feet Water Cost This is the cost of water
298. e effects of the boiler efficiency This is considered the gross heat rate Net Plant Heat Rate This is the net heat rate which includes the effect of plant equipment and pollution control equipment Annual Operating Hours This is the number of hours per year that the plant is in operation If a plant runs 24 hours per day seven days per week with no outages the calculation is 24 hours 365 days or 8 760 hours year Annual Power Generation This is the net annual power production of the plant The capacity factor and all energy credits or penalties are used in determining its value Net Plant Efficiency The net plant efficiency is displayed here on a HHV basis Plant Power Requirements A second group of results provide a breakdown of the internal power consumption for the individual technology areas These are all given in units of megawatts Individual plant sub components will only be displayed when they are configured in the Configure Plant section of the model Gross Electrical Output This is the gross output of the generator in megawatts MWg The value does not include auxiliary power requirements The model uses this information to calculate key mass flow rates The value is an input parameter Aux Power Produced If an auxiliary natural gas boiler is used to provide steam and power for the Amine System this is the additional electricity that it produces Component Electrical Uses Power used by various plant and
299. e individual components listed above This item is highlighted in yellow Air Separation Capital Cost Results 7 IECM Interface File Edit view Window Help Configure Plant Set Parameters Get Results CO2 Capture Power Block Air Separation Process Area Costs bigest Air Separation Plant Costs Air Separation Unit 38 85 Capital Cost Mis General Facilities Capital Eng amp Home Office Fees Project Contingency Cost Process Contingency Cost Interest Charges AFUDC Royalty Fees Preproduction Startup Cost Inventory Working Capital Die So CSA Aw aw ni 2 2 4i 5 6 z s 9 10 1 ProcessFusies Copal aes 12 13 14 15 Effective TCR 6 Process Type Air Separation Costs are in Constant 2000 dollars 3 Capital Cost 4 O amp M Cost 5 Total Cost Air Separation Capital Cost results screen The Air Separation Capital Cost result screen displays tables for the capital costs Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Air Separation Process Area Costs Air Separation Unit The cost of oxygen plants depends mostly on the oxygen feed rate to the gasifier because size and cost of compressors and air separation systems are proportional to this flow rate The number of trains is determined based on the total mass flow rate of o
300. e me e aoo Process Type 6 Costs are in Constant 2005 dollars 3 Syngas 4 Capital Cost 5 O amp M Cost 6 Total Cost Gasifier Total Cost results screen The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Gasifier Unit 132 e Gasifier Integrated Environmental Control Model User Manual Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted
301. e narrow temperature window provides the primary challenge Ammonia slip and ash contamination are additional concerns that must be considered with SNCR LNB amp SNCR Low NO burners can be used in conjunction with SNCR to achieve very high NO removals Both technologies are described in detail above If a Tangential or Wall Furnace Type have been selected in Configure Plant then all five options will display If you have selected a Cyclone Furnace type then only Gas Reburn and SNCR will display The default for Tangential and Wall furnaces is LNB amp SNCR The default for a Cyclone furnace is Gas Reburn SNCR Reagent Type Only displayed when SNCR or LNB amp SNCR have been selected in the In Furnace Controls pull down menu Nitrogen based reagent injection is used in an SNCR to reduce NO in the presence of oxygen to form nitrogen and water vapor The reagent choices are Urea Urea CO NH is typically diluted to a 15 20 concentration with water Urea has the advantage of safety and ease of storage and handling Urea is the default reagent used in the IECM Ammonia Ammonia can be supplied in two forms anhydrous NH3 and aqueous NH OH The IECM considers only anhydrous ammonia Ammonia may be an advantage when using an SNCR in conjunction with an SCR system In Furnace Controls Performance Input This screen is only available for the Combustion Boiler plant type Integrated Environmental Control Model User
302. e natural gas flow rate to the turbine Heating Value Higher heating value HHV is the thermal energy produced in Btu Ib of fuel Methane CH The volume by percent of methane in the natural gas Ethane C2H6 The volume by percent of ethane in the natural gas Propane C3Hsg The volume by percent of propane in the natural gas Carbon Dioxide CO2 The volume by percent of carbon dioxide in the natural gas Oxygen O2 The volume by percent of oxygen in the natural gas Nitrogen N2 The volume by percent of nitrogen in the natural gas Integrated Environmental Control Model User Manual Fuel e 83 Hydrogen Sulfide H2S The volume by percent of hydrogen sulfide in the natural gas 84 Fuel Integrated Environmental Control Model User Manual Air Separation This chapter illustrates the configuration inputs and results of the air separation technology It is presently used only for the IGCC plant configurations Air Separation Performance Inputs i o File Edit View Go Window Help Bow O ix Gasifier Sulfur By Prod PEA Removal CO2 Capture Power Block Mgmt D Value Min Max _ Oxidant Composition 02 vol 95 00 30 00 100 0 4 234 0 0 100 0 0 7657 0 0 100 0 Final Oxidant Pressure psia 580 0 o0 800 0 BAA wali Maximum Train Capacity Tb moles hr 1 135e 04 1 135e 041 135e 04 Number of Operating Trains integer 1 Menu Cale Number of Spare Trains
303. e of the cooling water entering the wet tower Cooling Water Temperature Drop This parameter specifies the temperature drop range of cooling water across the wet tower Cycles of Concentration That is a measure of the degree to which dissolved solids are being concentrated in the circulating water and is estimated in terms of concentration ratio of dissolved solids in the circulating versus makeup water That is reversely related to the blowdown Improving the quality of makeup water for the cooling system can increase the cycle of concentration and decrease the amount of tower blowdown Tower Drift Loss This parameter specifies a percent of the quantity of cooling water as drift loss Auxiliary Cooling Load This parameter specifies additional heat load on the auxiliary equipments and expressed as a percentage of the load on the primary steam cycle The default value comes from the PISCES model Overdesign Factor This parameter overdesigns the wet tower size Integrated Environmental Control Model User Manual Slip Stream Inlet This parameter specifies the underflow as a percent of the quantity of cooling water This option is only available when the Slip Stream Treatment System is loaded Slip Stream Underflow This parameter specifies the underflow as a percent of the quantity of slip stream This option is only available when the Slip Stream Treatment System is loaded Cooling Makeup Underflow This parameter specifies the un
304. e their particular capital costs considered here Each process area direct capital cost is a reduced form model based on regression analysis of data collected from several reports and analyses They are described in general below The primary factors in the model that effect the capital cost of the base plant are the plant size the amount of water injected the amount of activated carbon injected and the sulfur and moisture content of the coal Spray Cooling Water This capital cost area represents the materials and equipment necessary to inject water into the flue gas duct for the purpose of cooling the flue gas to a prerequisite temperature Equipment includes water storage tanks pumps transport piping injection grid with nozzles and a control system The direct capital cost is a function of the water flow rate Sorbent Injection This capital cost area represents the materials and equipment necessary to deliver the activated carbon into the flue gas Equipment includes silo pneumatic loading system storage silos hoppers blowers transport piping and a control system The direct capital cost is a function of the sorbent flow rate Sorbent Recycle This capital cost area represents the materials and equipment necessary to recycle ash and activated carbon from the particulate collector back into the duct injection point The purpose is to create a equilibrium state where the carbon is reintroduced to improve performance Equipment includ
305. e triangle distribution is excellent for screening studies Fractiles Fractiles If n is the number of elements in the list L Fractiles L returns a continuous probability distribution where the first element is the 0 fractile the second is the 1 n 1 fractile the third is the 2 n 1 fractile and so on The values must be enclosed in square brackets to register as a list This distribution looks like a histogram for large sample sizes and can be used to represent any arbitrary data or judgment about uncertainties in a parameter when the parameter is continuous It explicitly shows detail of the uncertainties It is used in the IECM Model to represent all trace species data in the default databases The finite range of possible values is divided into subintervals Within each subinterval the values are sampled uniformly according to a specified frequency for each subinterval Wedge Distribution tWedge min max returns a continuous wedge shaped probability distribution increasing linearly from min to max Use this when you are able to specify a finite range of possible values The wedge distribution increases linearly from zero probability at the minimum value to the maximum probability at the maximum value Like the uniform distribution this distribution indicates that additional details about uncertainty are not yet known This is a special case of the triangular distribution described below Configuring Uncertainty in
306. eam while the bottom sludge reclaimer waste is sent for proper disposal Reclaimer Waste Disposal This is the reclaimer waste disposal cost per year Electricity The cost of electricity consumed by the Amine System Auxiliary Power Credit An auxiliary natural gas boiler can be added by the user to provide steam and power for the Amine System If it is added by the user then the additional power it provides is subtracted from the overall operating and maintenance cost Steam elec equiv Cost of steam used in the regeneration of the sorbent This is a cost that is incurred only when steam is taken from the base plant Water This is the annual cost for water to the amine scrubber system it is mainly required for cooling and also as process makeup CO Transport The CO captured at the power plant site has to be carried to the appropriate storage disposal site Transport of CO to a storage site is assumed to be via pipeline This is the annual cost of maintaining those pipelines CO Storage Once the CO is captured it needs to be securely stored sequestered This cost is based upon the storage option chosen on the Amine System Storage input screen Total Variable Costs This is the sum of the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowat
307. eat to the main circulating cooling water system Piping This area deals with the cost for the circuiting cooling water piping Makeup Water System This area deals with the cost for the capital equipments to provide makeup water for the cooling system Cooling Water System This area deals with the cost for the component cooling water system Foundation amp Structures This area deals with the cost for the circulating water system foundation and structures Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly That is regressed as a function of the recirculating cooling water flow rate Integrated Environmental Control Model User Manual Water Systems e 17 based on the National Energy Technology Laboratory baseline studies for fossil fuel power plants 2007 The cooling tower used for cost estimation is a multi cell wood frame counterflow mechanical draft cooling tower This result is highlighted in yellow Total Capital Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering am
308. echnology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Integrated Environmental Control Model User Manual O2 CO2 Recycle e 297 Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the spray dryer that is used in determining the total power plant cost The effective TCR
309. echnology modules alone This is the total abatement cost The subtotal is highlighted in yellow Emission Taxes This is the sum of the user assessed taxes on the plant emissions of SO NO and CO Total This is the total cost of the entire power plant This result is highlighted in yellow Each cost category column is described briefly below Fixed O amp M The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs for each technology Variable O amp M The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs associated with a technology Total O amp M This is the sum of the annual fixed and variable operating and maintenance costs for each technology Annualized Capital This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Overall IGCC Plant 69 Overall IGCC Plant Cost Summary Results 7 IECM Interface File Edit Yiew Go Window Help Configure Plant Set Parameters Get Results Air Gasifier Sulfur Ai By Prod S
310. econdary stack Equivalent SO gt This is the emission rate of sulfur dioxide from the auxiliary boiler It is emitted from a secondary stack Equivalent NO This is the emission rate of nitrogen dioxide from the auxiliary boiler It is emitted from a secondary stack Auxiliary Boiler Natural Gas Results This screen is only available for the Combustion Boiler and Combustion Turbine plant types It is a sub system inside the amine scrubber when the auxiliary boiler option is added 114 e Auxiliary Boiler Integrated Environmental Control Model User Manual y IECM Interface Eile Edit View Go Window Help Us Untitled Configure Plant Set Parameters Natural Gas Components Hydrogen H2 Methane CH4 Ethane C2H6 Propane C3H8 Hydrogen Sulfide H25 Carbonyl Sulfide COS Ammonia NH3 Hydrochloric Acid HCD 10 Carbon Dioxide COD 11 Water Vapor H20 12 Nitrogen ND 13 Argon An 14 Oxygen 02 zis Lee 2 lala baled io 15 Process Type faux Boiler x 2 Neturl Gos MIE Auxiliary Boiler System Natural Gas Natural Gas Components The breakdown of components in the natural gas entering the auxiliary boiler are described briefly below Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H2 Total mass of hydrogen Methane CH Total mass of methane Ethane C2He Total mass of ethane Propane C3Hsg Total mass of propane H
311. ect capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for Integrated Environmental Control Model User Manual each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens IECM Interface File Edit View Go Window Help Us Untitled Configure Plant Set Parameters ISP 02 co2 By Prod ae Control Control Capture Mgmt Title Units Capital Cost Process Area Particulate Collector retro new Ductwork retro new Fly Ash Handling retro new Differential ID Fan retro new izi t 2 mle e oeo Cold Side ESP Pe 2 Capital Cost 4 O amp M Cost Cold Side ESP Retrofit Cost input screen Each parameter is described briefly below Capital Cost Process Area Particulate Collector This area covers the material
312. ed is often a convenient way of expressing uncertainty distributions when a little information is available 412 e Appendix A Introduction to Uncertainty Analysis Integrated Environmental Control Model User Manual Appendix B Technical Support Reaching Technical Support Questions issues or concerns regarding the Integrated Environmental Control Model should be directed to Carnegie Mellon University BERKENPAS MICHAEL B Office Baker Hall 128B Location Pittsburgh PA 15213 Phone 412 268 1088 FAX 412 268 1089 Email mikeb cmu edu Web www iecm online com support html National Energy Technology Laboratory GROL ERIC P E Office Office of Systems Analysis and Planning Location Pittsburgh PA 15236 Phone 412 386 5463 Email Eric Grol netl doe gov Web www netl doe gov Questions can also be directed through the IECM web site The web site distributes the question to a team of engineers that will address your question and reply to you Integrated Environmental Control Model User Manual Appendix B Technical Support 413 Integrated Environmental Control Model Support Windows Internet Explorer ioj xj go jE http www iecm online com support html 91 X IGoogle Piz w ene Integrated Environmental Control Model Support Page 9 Tools ied Welcome to the Integrated Environmental Control Model Support hnic ort is provided by researchers at Mellon Uni y If you
313. ed briefly below Sulfu 338 e Sulfur Removal r Removal Process Area Costs Sulfur Removal System Hydrolyzer This is the capital cost for the hydrolyzer system which converts carbonyl sulfide to hydrogen sulfide Sulfur Removal System Selexol H S in the syngas is removed through counter current contact with Selexol solvent The cost of the Selexol section includes the acid gas absorber syngas knock out drum syngas heat exchanger flash drum lean solvent cooler mechanical refrigeration unit lean rich solvent heat exchanger solvent regenerator regenerator air cooled overhead condenser acid gas knock out drum regenerator reboiler and pumps and expanders associated with the Selexol process Sulfur Recovery System Claus The Claus plant contains a two stage sulfur furnace sulfur condensers and catalysts Integrated Environmental Control Model User Manual Tail Gas Clean Up Beavon Stretford The capital cost of a Beavon Stretford unit varies with the volume flow rate of the input gas streams and with the mass flow rate of the sulfur produced The regression model is based only on the sulfur produced by the Beavon Stretford process Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result
314. ed briefly below Reagent Dry Reagent The total mass flow rate of lime limestone or limestone with dibasic acid injected into the scrubber This is a function of the SO removal efficiency the reagent purity and the reagent stoichiometric all performance input parameters Makeup Water Water needed to replace the evaporated water in the reagent sluice circulation stream Wet FGD 233 Flue Gas Entering FGD Temperature In Temperature of the flue gas entering the scrubber This is determined by the flue gas outlet temperature of the module upstream of the scrubber e g a particulate removal technology Flue Gas In Volumetric flow rate of flue gas entering the scrubber based on the flue gas temperature entering the scrubber and atmospheric pressure Fly Ash In Total solids mass flow rate in the flue gas entering the scrubber This is determined by the solids exiting from the module upstream of the scrubber e g a particulate removal technology Mercury In Total mass of mercury entering the scrubber The value is a sum of all the forms of mercury elemental oxidized and particulate Temperature Temperature of the flue gas entering the scrubber after the forced draft fan This is determined by the flue gas inlet temperature of the FGD and the temperature rise across ID fan input parameter Flue Gas Exiting FGD Temperature Temperature of the flue gas immediately on exiting the scrubber prior to any flue gas by
315. ed briefly below Capital Cost Process Area Condenser Structure This area deals with the air cooled condenser equipments including finned tube heat exchanger elements fans and motors ACC support structure steam exhaust duct piping and valves air removal equipment and support for start up training and testing The erection and installation of the ACC at the site is also included in this area Steam Duct Support This area deals with steam duct support and column foundations Electrical amp Control Equipment This area deals with fan pump motor wiring and controls etc Costs are in Constant 2007 dollars Auxiliary Cooling That deals with separate fin fan unit or others Typically that is 5 additional heat load Clearing System That area handles with cleaning finned tube surfaces That is small but required at most sites Air Cooled Condenser Capital Cost Inputs This screen is available for all plant types 24 e Water Systems Integrated Environmental Control Model User Manual 7 ECM Interface Eile Edit view Go Window Help Untitled Ea Configure Plant Set Parameters Get Results l F e o Title i Cale Min Max Default Construction Time A 0 2500 10 00 3 000 General Facilities Capital 0 0 60 00 10 00 Engineering amp Home Office Fees f 0 0 50 00 10 00 Project Contingency Cost l PFC 0 0 0 100 0 15 00 Process Contingency Cost werc oo o
316. ed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Wet FGD Diagram This screen is only available for the Combustion Boiler plant type The Diagram result screen displays an icon for theWet FGD SO control technology selected and values for major flows in and out of it 7 IECM Interface E File Edit View Window Help Configure Plant Get Results cO2 Capture Set Parameters NOx Ai By Prod Preheater Control Mgmt Stack Me ee a f Control Temperature F Sa Temperature CF Temperature Out CF 132 0 zis R aF le lolo Temperature In CF Flue Gas In acfim Fly Ash In ton hr Mercury In lb hr Ash Removal 502 Removal 503 Removal Mercury Removal 300 0 1 645e 06 0 1344 2 754e 02 _ 98 00 50 00 94 50 Flue Gas Out acfim Fly Ash Out ton hr Mercury Out lb hr a Dry Reagent ton hr Makeup Water ton hr Wet FGD Solids ton hr 1 397e 06 6 722e 02 1 515 03 21 97 144 5 39 92 Integrated Environmental Control Model User Manual Process Type Wet FGD 7 2 Flue Gas 4 Capital Cost 5 0 amp M Cost 6 Total Cost 1 Diagram Wet FGD Diagram Each result is describ
317. eeesneeceesecsscecescecesaeecsaeecsaeeecessecnseeesaeesseessneeesee 121 Capital Cost Process 2A reat faces sty fat ranea aeae aeoea oaee e oeoa EE eea Ene apee 122 Gasifier Capital Cost Inputs 2 0 0 0 cee eeeeeeeeeeessececeseceseecescecesaeecsaeecsseeceesaecsecesaeecsaeeseneessee 123 Gasifier O amp M Cost Tnputs e ene epes ieta aeea eaeoe aeea eee aee aeei ekoi Eana aves 124 G sifi f Diafani enben eoe np ara ea ee ae e eaae aes a Eee vent seee eana 126 Gasifier Oxidant Result8s i2 eaaa aetra aae a eatin aaa i a aaa artes E EAEE 127 Gasifier Syngas RE SU ES a T aae a aa a E Oa EEE a a EE ERE 128 Gasifier Capital Cost ResUl Sra raaes ra aa eaa E re a E AEEA AE ES 129 GE Gasifier Process Area Costs is a a ees o EEE e aE Eaa EEEO 129 GE Gasifier Plant Costs is sici eh ereina eee Eae eE ERA 130 Gasifier O amp M Cost ResultSet costs ee aa Eea eaten ANS Toa EEU AE ET 131 Variable Cost Comporient a a cali a aai a Era aeaeo aKO nin ERT 131 Fixed Cost Components a aa oe rae a eE E e E E R RT 132 Gasifier Total Cost Result8ii onines ai aeee aea a iin anaa aE Ae AANE EE ET 132 Air Preheater 135 Air Pr heater Diagram ocino iea aa e a E E nda Mona ONEA 135 Air Prehedter Flue Gas Results ivnisi a a a a a aaa 137 Major Flue Gas Components cccsscecesseeesseeceeeecsseeceseecesseessaeecsaeeecesaeeneeeenaes 137 Air Pr heater Oxidant Results 25sssisicsyteatscenhghices satan Veetediets sneak ae a ae a a raei 138 Oxidant Gas Com
318. een is only available for the Combustion Boiler plant type Inputs for configuration of the Lime Spray Dryer SO control technology are entered on the Config input screen 7 IECM Interface p oj xj File Edit View Window Help Us Untitled Configure Plant Set Parameters Emission Ne Base Plant Constraint Control Title Reagent Type izi R e lalelo Process Type Spray Dryer 3 Retrofit Cost 4 Capital Cost 5 0 amp M Cost Spray Dryer Config input screen Each parameter is described briefly below Reagent For the Lime Spray Dryer the only option is Lime Integrated Environmental Control Model User Manual Spray Dryer 243 e Lime Magnesium Enhanced Lime System A magnesium sulfite and lime slurry maglime is used to remove SO2 and form a precipitate high in calcium sulfite The high alkalinity of the maglime slurry allows very high SO2 removal However the reagent cost is also higher and solid waste is not easily disposed Spray Dryer Performance Inputs 244 e Spray Dryer This screen is only available for the Combustion Boiler plant type Inputs for performance of the Lime Spray Dryer SO control technology are entered on the Performance input screen y IECM Interface Eile Edit View Window Help Us Untitled io x I Configure Plant Set Parameters Get Results Emission TSP 302 CO2 By Prod Base Plant Constra
319. eesseecsseecseecsneeeesaeeeseeeeees 149 Gas R butn acai neni re daa ee a a aaa dated 149 SNGR eaat tidsed ei i Re Ra a pete 149 NO Removal Performance c 0ceeeeeeeeeeseceeceseeeseeeseetsessestseseseeeeeeensestetenees 149 In Furnace Controls Flue Gas Results eeeeeceesceeeeeeesneeesneeeceeseeecessneeececeseeenseeeees 150 Major Flue Gas Components sccceseccesseessseeceeeecsseeceseecesseessaeecsaeeecesaesneeeesaes 150 In Furnace Controls Capital Cost Results 0 0 00 ceeeesecesseecsseeesseeceseeeesaeessaeesseeesneaeessaeers 151 Integrated Environmental Control Model User Manual In Furnace Controls O amp M Cost Results ccccccccccsssccccesecceseseccceeeecceceueccesesecceeaeceeeneceees 152 Variable Cost Components eeeeceeseeceseeesssceceeecseeceseecesaeeesaeecsneesesaesneeeesaes 152 Fixed Cost Components einen nar naene e aks aeneae an a i eaaa 152 In Furnace Controls Total Cost Results 0 0 0 eee eeeseeeesesseeeeseeesesseeeecesseeecessaaaeeeeeeaaees 153 Cost COMPON EDK airea is cere EaR atoms E E e E E i 153 Hot Side SCR 155 Hot Side SCR Configuration se esesesesseerrceereeereecsreeereeerteettesrreoereorrprerteeeneerrereseseteeretere 155 Hot Side SCR Performance Inputs ceseeeseecsscesesececeeecesseecsseecseecseecesaeeeesaeesseeseeeese 156 Hot Side SCR Performance Continued cccccccccccssesssseceeeeecssesseceeeeeceesesseeeeeeeeeeeeeees 158 Hot Side SCR Retrofit C
320. egrated Environmental Control Model User Manual Effective TCR The TCR of the water and carbon injection controls that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor for the water and carbon injection system Mercury O amp M Cost Results This screen is only available for the Combustion Boiler plant type The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs related to the water and carbon injection systems both part of the overall mercury control option The variable O amp M costs are calculated from the variable costs for carbon water consumption and fly ash disposal from the particulate control device The fixed O amp M costs are based on maintenance and labor costs 7 IECM Interface ioj x File Edit View Go Window Help Configure Plant Set Parameters Get Results 502 CO2 By Prod Control Capture Mgmt Stack Variable Cost Component Fixed Cost Component Chan tes My Activated Carbon Water Additional Waste Disposal Electricity 1 578e 02 _ Operating Labor 5 272e 02 Maintenance Labor 2 8260 06 Maintenance Material 4 239e 06 Admin amp Support Labor 1 318e 02 ajwa w zs t 5e alelo oo a ee lalaja a w n L Activated Carbon Inj Costs are in Constant 2005 dollars 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cos
321. egrated Environmental Control Model User Manual Base Plant e 109 credit for the base plant When comparing individual components of the plant these utility charges are taken into consideration For total plant costs they balance out and have no net effect on the plant O amp M costs Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable an
322. eloo oaan aw Argon AD oo 0 0 C Process Type wet FGD v 2 Flue Gas 4 Capital Cost 5 O amp M Cost 6 Total Cost Wet FGD Flue Gas result screen Each result is described briefly below Major Flue Gas Component Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Integrated Environmental Control Model User Manual Wet FGD e 235 Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Wet FGD Bypass Results 236 Wet FGD This screen is only available for the Combustion Boiler plant type The Flue Gas Bypass result screen displays a table of quantities of flue gas components entering and bypassing the Wet FGD SO Control Technology For each component quantities are given in both moles and mass per hour 7 IECM Interface File Edit View Window Help Configure Plant Set Parameters Get Results NOx Ai c02 By Prod Prehe
323. em and ash storage silos Differential ID Fan The complete cost of the ID fan and motor due to the pressure loss that results from particulate collectors Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Integrated Environmental Control Model User Manual Total Capital Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as
324. em up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a dry cooling system that has been paid off Air Cooled Condenser O amp M Cost Inputs 26 e Water Systems This screen is available for all plant types Integrated Environmental Control Model User Manual 7 IECM Interface File Edit view Go Window Help is Untitled Configure Plant Set Parameters l O F e o Title Units i Max Default Bulk Reagent Storage Time days 120 0 60 00 Waste Disposal Cost ton T i 10 00 cale Electricity Price Base Plant MWh 0 0 200 0 calc Number of Operating Jobs jobssshit a 3000 2000 Number of Operating Shifts shifts day i 10 00 4 750 Operating Labor Rate i hr i i 100 0 33 00 Daanan Nye e e b R 10 11 Total Maintenance Cost TPC 10 00 1 500 12 Maint Cost Allocated to Labor total i 100 0 40 00 13 Administrative amp Support Cost total labor 100 0 30 00 14 15 16 17 18 Process Type 1 ndenser Costs are in
325. emperature exiting the air preheater Heated Air Volumetric flow rate of the air at the burners based on the air temperature at the burners and atmospheric pressure Flue Gas Exiting the Economizer Temperature Out Temperature of the flue gas at the exit of the economizer Flue Gas Out Volumetric flow rate of the flue gas at the exit of the economizer based on the temperature at the exit of the economizer and atmospheric pressure Fly Ash Out Total solids mass flow rate in the flue gas at the exit of the economizer This includes ash unburned carbon and unburned sulfur Mercury Out Total mass of mercury exiting the economizer The value is a sum of all the forms of mercury elemental oxidized and particulate Bottom Ash Sluice Water Water added to the dry bottom ash This water is added for transportation purposes Dry Bottom Ash Total solids mass flow rate of the bottom ash This includes ash unburned carbon and unburned sulfur The value is given on a dry basis Wet Bottom Ash Total solids mass flow rate of the bottom ash for waste management This includes dry bottom ash and sluice water The value is given on a wet basis Integrated Environmental Control Model User Manual Base Plant e 105 Boiler Flue Gas Results The Flue Gas result screen displays a table of quantities of flue gas components entering the combustion boiler in heated air and exiting the boiler in the flue gas For each component quantiti
326. ems to be 90 with few others reporting as high as 96 capture efficiency Here it has been assumed to be 90 SO Removal Efficiency SO is removed at a very high rate The default efficiency is 99 5 SO Removal Efficiency SO is removed at a very high rate The default efficiency is 99 5 NO Removal Efficiency A small amount of NO is removed The default efficiency is 25 HCI Removal Efficiency HCI is removed at a high rate The default efficiency is 95 Particulate Removal Efficiency Particulates are removed in any wet scrubbing system at a rate of approximately 50 Maximum Train CO Capacity The default maximum train size is used with the actual CO capture rate to determine the number of trains required Number of Operating Absorbers This is the total number of operating absorber vessels It is determined by the train capacity specified above and is used primarily to calculate capital costs The value must be an integer Number of Spare Absorbers This is the total number of spare absorber vessels It is used primarily to calculate capital costs The value must be an integer Integrated Environmental Control Model User Manual Amine System 263 Max CO Compressor Capacity This is the maximum amount of CO product that can be compressed per hour at the specified pressure see the storage input screen No of Operating CO Compressors This is the total number of operating CO compressors It is used pri
327. en as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow 388 e Power Block Integrated Environmental Control Model User Manual Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Power Block 389 Units Units Inputs Inputs may be entered using different units Changing the units in which inputs are entered using the Input Tools floating palette is described in Getting Started This section will describe the various unit settings in detail Input Tools Untitled Unit System The Input Tools Floating Palette Unit System The Unit System option determines the unit system in which input values are entered The choices are English and Metric The default setting is English Units Results Results may be d
328. en This is the weight percent of hydrogen in the fuel on a wet basis Oxygen This is the weight percent of oxygen in the fuel on a wet basis Chlorine This is the weight percent of chlorine in the fuel on a wet basis Sulfur This is the weight percent of sulfur in the fuel on a wet basis Nitrogen This is the weight percent of nitrogen in the fuel on a wet basis Ash This is the weight percent of ash in the fuel on a wet basis Moisture This is the weight percent of moisture in the fuel on a wet basis Cost This is the total as delivered cost of the coal on a wet basis A default value is provided for the default coals provided in the model This value can be updated on this input screen or the fuel cost screen Ash Properties The property value spreadsheet is also used to display the oxide content of the ash in coal on a percent of total ash basis The data can be edited only in the Current Fuel pane The ash content is used to determine the resistivity of the ash This in turn determines the specific collection area SCA of the cold side ESP The editable ash properties are SiO3 The percent by weight of silicon dioxide in the ash Al2O3 The percent by weight of Aluminum Oxide in the ash Fe O3 The percent by weight of ferric oxide in the ash CaO The percent by weight of calcium oxide in the ash MgO The percent by weight of magnesium oxide in the ash Na O The percent by weight of sodium oxide in the ash
329. enerally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start Integrated Environmental Control Model User Manual Water Systems e 25 up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the syst
330. ent or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Int
331. entory Capital y y 10 00 TCR Recovery Factor Cold Side ESP 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Cold Side ESP Capital Cost input screen The necessary capital cost input parameters associated with the electrostatic precipitator control technology are shown on this input screen Indirect Capital Costs Costs that are indirectly applied to the technology are based on the process facilities cost Each of the cost factors below is expressed as a percentage of the process facilities cost and is entered on this screen Each parameter is described briefly below Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower
332. entration in the flue gas and NO removal efficiency Mercury Out Total mass of mercury exiting the hot side SCR in the flue gas The value is a sum of all the forms of mercury elemental oxidized and particulate SCR Performance NOx Removal Actual removal efficiency of NO in the SCR This is a function of the minimum 50 and maximum removal efficiencies 166 Hot Side SCR Integrated Environmental Control Model User Manual SCR performance input parameter and the emission constraint for NO emission constraints input parameter It is possible that the SCR may over or under comply with the emission constraint TSP Removal Actual particulate removal efficiency in the SCR This is set by the SCR input parameter Collected Solids Dry Solids Total solids mass flow rate of solids removed from the SCR This is a function of the solids content in the flue gas and the particulate removal efficiency of the SCR Hot Side SCR Flue Gas Results This screen is only available for the Combustion Boiler plant type File Edit View Window Help Configure Plant Set Parameters Get Results TSP 02 cor ByProd Stack Control Control Capture Mgmt Major Flue Gas Components h moles hr o eT Nitrogen ND 1 093e 05 1 093e 05 1531 Oxygen 02 4818 4816 77 09 Water Vapor H20 _ 4 298e 04 1 343e 04 1170 Carbon Dioxide COJ 2 050e 04 2 050e 04 451 0 Carbon Monoxide CO 0 0 0 0 0 0 Hydrochloric Acid HC 5 64
333. enus provided The common input parameters are Sorbent Used MEA is the sorbent used in the system and the nominal values of various parameters are based on a process simulation model that uses MEA At present no other sorbents are included Direct Contact Cooler DCC Used A DCC is configured by default to cool the flue gas before it enters the amine system The lower flue Integrated Environmental Control Model User Manual Amine System 259 260 Amine System gas temperature enhances the absorption reaction absorption of CO in MEA sorbent is an exothermic process and decreases the flue gas volume The typically acceptable range of flue gas temperature is about 120 140 F A DCC is often not needed if a wet FGD is installed upstream Temperature Exiting DCC This is the temperature exiting the DCC The desirable temperature of the flue gas entering the CO capture system is about 113 122 F If the inlet temperature to the DCC is at or below this temperature the DCC is not used This variable is only displayed if a DCC is specified Auxiliary Natural Gas Boiler An auxiliary natural gas fired boiler can be added to the amine system The options available are None Steam Only and Steam Power It may be added to generate separate power for the amine system mainly compressors and low pressure steam for sorbent regeneration When used the original steam cycle of the power plant remains undisturbed and the net power generati
334. eparation Area Removal Fuel Mgmt CO2 Capture Power Block Revenue Technology Req ape yr Air Separation Unit 55 33 Gasifier Area 4 107 4 Particulate Control 0 0 Sulfur Control 14 52 Mercury Control j 0 0 CO2 Capture i 63 68 Power Block 5 25 38 Post Combustion NOx Control i 0 0 Zis e lP le lalelo Process Type fo verall Plant X Costs are in Constant 2005 dollars LPP i Mass InOut 4 Oas Emissions 3 TotlCot EE Overall IGCC Plant Cost Summary result screen Technology Air Separation Unit This is the capital cost for the Air Separation process area of the plant Gasifier Area This is the capital cost for the gasifier process area of the plant Particulate Control This is the capital cost for the equipment that captures particulates in the plant Sulfur Control This is the capital cost for the equipment that captures sulfur in the plant Mercury Control This is the capital cost for the mercury process area of the plant CO Capture This is the capital cost for the equipment that captures CO in the plant Power Block This is the capital cost for the power block process area of the plant Post Combustion NO Control This is the capital cost for the post combustion equipment that captures NO in the plant Total This is the sum of the capital costs for all the process areas in the plant Each cost category column is described briefly
335. er click the Start button 2 Choose Run from the Start menu 3 Type X XXX Media SETUP EXE where X XXXV is the drive and directory on your local hard drive to which you copied the files The Installation Program will begin Follow the instructions on the screen If you receive an error message while running Setup restart your computer and run the installation program again If Setup still returns an error message call Technical Support Installing the IECM from a Network To install from a network hard drive Integrated Environmental Control Model User Manual Installing the Model 11 12 o Installing the Model 1 Copy the contents of the IECM compact disk CD disk into one sub directory or folder on a network hard drive 2 On the personal computer click the Start button Choose Run from the Start menu 4 Type X XXX Media SETUP EXE where X AXXXV is the drive and directory on the network hard drive to which you copied the files The Installation Program will begin Follow the instructions on the screen If you receive an error message while running Setup restart your computer and run the installation program again If Setup still returns an error message call Technical Support Internet Installation The contents of the IECM CD ROM are also available on the worldwide web www iecm online com The media documentation and various text files can be d
336. er requirement for the SNCR is a function of gross electrical output of the power plant The value is determined by the need for tank heaters when urea reagent is used In Furnace Controls Capital Cost This screen is only available for the Combustion Boiler plant type Unlike most capital cost input screens these technologies costs are provided as total capital costs on an energy input basis File Edit View Go Window Help Configure Plant Set Parameters Base Plant Mercury Title Base Capital Costs excluding retrofit using gross KW Combustion Modifications E lew gross SNCR Boiler Modifications _ kw gross Retrofit Capital Cost Factors Combustion Modifications retro new SNCR Boiler Modifications retro new zs t mle le moo Boanaamna unr Total Capital Costs Gncluding retrofit using gross kW 12 Combustion Modifications 13 SNCR Boiler Modifications 14 15 16 17 _ 18 TCR Recovery Factor 100 0 oo 100 0 Process Type In Furnace Controls z Costs are in Constant 2005 dollars 1 Config 3 Capital Cost 4 O amp M Cost In Furnace Controls Capital Cost input screen The Combustion Modifications inputs will not display if SNCR is selected in the In Furnace Controls pull down menu The SNCR Boiler Modifications inputs will only display if SNCR or LNB amp SNCR is selected Base Capital Costs
337. er day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Mercury Total Cost Results 190 e Mercury This screen is only available for the Combustion Boiler plant type The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs related to the water and carbon injection systems both part of the overall mercury control option Integrated Environmental Control Model User Manual File Edit View Go Window Help Configure Plant Set Parameters Get Results TSP 02 CO2 ByProd Stack Control Control Capture Mgmt pe Cost Component MWh Percent Total Annual Fixed Cost 6 591e 02 3 01 3e 02 A 73 43 Annual Variable Cost 1 568e
338. er generator it uses a quasi random number generator based on Hammersley points to uniformly sample a unit hypercube These points are an optimal design for placing n points on a k dimensional hypercube The sample points are then inverted over a cumulative probability distribution to define the sample set for any uncertainty variable Hammersley has the advantage of high precision and consistent behavior in addition to better computational efficiency The method reduces the number of samples required relative to the other sampling methods for calculating uncertainty by a factor of 2 to 100 The actual sample reduction varies with the uncertainty function being sampled Integrated Environmental Control Model User Manual Running a Probabilistic Analysis e 405 Appendix A Introduction to Uncertainty Analysis Uncertainty Analysis The following section is provided as a means of introducing uncertainty analysis as a tool for model design and operation However you should consult standard statistical and other texts e g Morgan and Henrion Uncertainty Cambridge Press 1990 to develop a more complete understanding of the subject Introduction Nearly all analyses of energy and environmental control technologies involve uncertainties The most common approach to handling uncertainties is either to ignore them or to use simple sensitivity analysis In sensitivity analysis the value of one or a few model input parameters are varied usually f
339. er of operating trains are estimated based on the total syngas mass flow rate and the range of syngas flow rates per train used Integrated Environmental Control Model User Manual Process Condensate Treatment This model is based upon one data point from AP 5950 Because the treated process condensate is used as make up to the gas scrubbing unit and because blowdown from the gas scrubbing unit is the larger of the flow streams entering the process condensate treatment section it is expected that process condensate treatment cost will depend primarily on the scrubber blowdown flow rate Gasifier Capital Cost Inputs This screen is only available for the IGCC plant type File Edit View Go Window Help Configure Plant Set Parameters By Prod tee Mgmt Siak aP le lololo 1 10 00 2 3 General Facilities Capital i i 50 00 4 Engineering amp Home Office Fees 60 00 Ei 5 Project Contingency Cost 100 0 s 6 Process Contingency Cost fl 100 0 7 Royalty Fees j 10 00 8 9 Pre Production Costs R 10 Months of Fixed O amp M Months of Variable O amp M 12 Misc Capital Cost 13 14 Inventory Capital 15 16 17 18 TCR Recovery Factor Process Type ce 2 Syngas Out 3 Retrofit Cost 4 Capital Cost 5 0 amp M Cost Gasifier Capital Cost input screen Inputs for capital costs are entered on the Capital Cost input screen
340. er the operator training equipment checkout major changes in unit equipment extra Integrated Environmental Control Model User Manual CO2 Transport System e 359 maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital re
341. erating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate This is the hourly cost of labor for maintenance administrative and support personnel The same rate is applied to all jobs across all technologies in the power plant Integrated Environmental Control Model User Manual Water Gas Shift Reactor 323 Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Water Gas Shift Reactor Diagram 7 IECM Interface Eile Edit View Window Help Set Parameters Get Results By Prod Memt Stack Power Block High Low Temperature Temperature Reactor Reactor in cases with CO2 capture output is to S removal unit Temperature In CF 500 0 Temperature Out CF Syngas In ton hr 487 1 Syngas Out ton hr Process Type RVE GETUN 1 Diagram 2 Syngas 3 Capital Cost 4 O amp M Cost 5 Total Cost Water Gas Shift Reactor Diagram result screen The Water Gas Shift Reactor Dia
342. eration retro new CO2 Compressors retro new Final Product Compressors retro new Tl Heat Exchangers retro new CeRAAH amp wn zs t S mle e moo bt pt eee Aan A wn 18 Process Type fe Selexol CO2 Capture gt 1 Reference Plant 3 CO2 Storage 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Selexol CO Capture Retrofit Cost input screen Capital Cost Process Area The retrofit ratios can be specified for the following process areas Absorbers The Selexol absorbers use physical absorption to capture CO Because the solubility of CO2in the solvent is proportional to its partial pressure in the gas phase the performance of the absorbers increases with increasing CO partial pressures Power Recovery Turbines The COQ rich solvent from the absorber is fed into a set of hydraulic power recovery turbines to recover some of the pressure energy before it is fed into the slump tanks Slump Tanks A slight pressure drop in the slump tanks releases a majority of H and CH and a small amount of CO This process area enriches the CO concentration Recycle Compressors Gases from the slump tank are recycled back into the absorber A compressor is used to compress the gases to the operating pressure of the absorber Flash Tanks CO is released in multiple stages by reducing the pressure in successive flash tanks Three flash tanks are
343. ering the syngas temperature are loaded with this menu Presently Cold gas Cleanup is used with the GE Oxygen blown gasifier in the model The future choices will be e None This option is grayed out in the pull down menu and will be available in a future release of the model e Warm gas This option is grayed out in the pull down menu and will be available in a future release of the model e Cold gas This is implemented in the model CO Capture The default is None The user may select from the CO Capture pull down menu whether or not to capture CO and the method of capture e None no CO capture is used e Sour Shift Selexol This option is the only one currently available in the model e Sweet Shift Selexol This option is grayed out in the pull down menu and will be available in a future release of the model e Shift Comb CO H2S This option is grayed out in the pull down menu and will be available in a future release of the model Post Combustion Controls NO Control At present the only option available for selection is None The following are provided in the menu e None No NO control is used e SCR This option is grayed out and will be available in a future release of the model Solids Management Slag Landfill is the default The following choices are available e None Slag collected is not sent to a landfill e Landfill The slag collected is disposed in a landfill Sulfur Sulfur captured
344. ers The choice of the bag cleaning method is usually based on the type of coal used and therefore the filterability of the ash and your experience with filtering the particular kind of ash The particular option you select determines the air to cloth ratio bag life bag length power requirements pressure drop capital costs and O amp M costs The choices available are e None for no post combustion particulate control e Cold Side ESP for a Cold Side Electrostatic Precipitator e Reverse Gas Fabric Filter Uses an off line bag cleaning technique in which an auxiliary fan forces a relatively gentle flow of filtered flue gas backwards through the bags causing them to partially collapse and dislodge the dust cake Over 90 of baghouses in U S utilities use reverse gas cleaning Integrated Environmental Control Model User Manual Reverse Gas Sonic Fabric Filter Uses a variation of Reverse Gas cleaning in which low frequency pneumatic horns sound simultaneously with the flow of reverse gas to add energy to the dust cake removal process Shake amp Deflate Fabric Filter Uses a method for off line cleaning in which the bags are mechanically shaken immediately after or while a small quantity of filtered gas is forced back to relax the bags The amount of filtered gas used is smaller than that used in Reverse Gas cleaning Pulse Jet Fabric Filter Uses a method for on line cleaning in which pulses of compressed air are blown down inside
345. erties of Natural Gas Higher Heating Value Higher heating value HHV is the thermal energy produced in Btu lb of fuel from completely burning the fuel to produce carbon dioxide and liquid water The latent heat of condensation is included in the value This value is calculated from the natural gas composition below and cannot be changed by the user Natural Gas Composition Methane CH4 The volume by percent of methane in the natural gas Ethane C2H6 The volume by percent of ethane in the natural gas Propane C3H8 The volume by percent of propane in the natural gas Carbon Dioxide CO2 The volume by percent of carbon dioxide in the natural gas Oxygen O2 The volume by percent of oxygen in the natural gas Nitrogen N2 The volume by percent of nitrogen in the natural gas Hydrogen Sulfide H2S The volume by percent of hydrogen sulfide in the natural gas Natural Gas Density The natural gas density is a weighted average of the individual densities of the natural gas constituents This value is used in many unit conversion operations Integrated Environmental Control Model User Manual Fuel e 81 Fuel Coal Diagram The Fuel Technology Navigation Tab in the Get Results program area contains the Diagram result screen It displays the properties set up in the Fuel Properties input screens of the of the Set Parameters program area 82 eo Fuel y IECM Interface a File Edit View Window Help Rank z e
346. es are given in both moles and mass per hour Eile Edit view Window Help Set Parameters Get Results Air NOx 502 co2 By Prod Preheater Control Mercury Control Control Capture Mgmt Stack sen tr Flue Gas Out Heated Air In Major Flue Gas Components h moles hx h moles hr tow hr 1 091e 05 1 093e 05 1528 Oxygen 02 2 901e 04 4813 464 2 Water Vapor H20 3981 1 297e 04 35 87 Carbon Dioxide CO2 oo 2 049e 04 0 0 Carbon Monoxide CO 0 0 0 0 0 0 Hydrochloric Acid HCH 0 0 5 643 0 0 Sulfur Dioxide 502 0 0 214 2 0 0 Sulfuric Acid equivalent 303 0 0 1 728 0 0 6 916e 02 Nitric Oxide NO 0 0 51 63 0 0 0 7747 Nitrogen Dioxide NOD 0 0 2 717 0 0 6 251e 02 Ammonia NH3 0 0 0 0 0 0 Argon Ar 0 0 0 0 0 0 z 2 lale le o e o 0 BAA nw a nN Process Type Boiler z 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost Boiler Flue Gas result screen Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO3 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Di
347. es hoppers blowers transport piping and a control system The direct capital cost is a function of the recycle rate of ash and spent sorbent NOTE Sorbent recycling is a feature to be added in a future version of the IECM Additional Ductwork This capital cost area represents materials and equipment for ductwork necessary beyond the other process areas Extra ductwork may be required for difficult retrofit installations NOTE Future versions of the IECM will include parameters to determine a capital cost for this area The current version assumes no additional ductwork Sorbent Disposal This capital cost area represents materials and equipment required to house and dispose the collected sorbent Equipment includes hoppers blowers transport piping and a control system This is in excess of existing hoppers tanks and piping used for existing particulate collectors The direct capital cost is determined by the incremental increase in collected solids in the particulate collector CEMS Upgrade This capital cost area represents materials and equipment required to install a continuous emissions monitoring system CEMS upgrade The direct capital cost is determined by the net electrical output of the power plant Pulse Jet Fabric Filter This capital costs area represents an upgrade to an existing cold side ESP where one section at the back end of the unit Integrated Environmental Control Model User Manual Mercury 187 188 e Mer
348. es loans and mortgage bonds Percent Equity Preferred Stock This is the percent of the total capitalization that is associated with the sale of preferred stock Percent Equity Common Stock This value is the remainder of the capitalization calculated as 100 minus the percent debt minus the percent equity in preferred stock Federal Tax Rate This is the federal tax rate It is used to calculate the amount of taxes paid and deferred State Tax Rate This is the state tax rate It is used to calculate the amount of taxes paid and deferred Property Tax Rate The property tax rate or ad valorem is used to calculate the carrying charge Investment Tax Credit This is an immediate reduction in income taxes equal to a percentage of the installed cost of a new capital investment It is zero by default It is used to set the initial balance and the book depreciation Overall NGCC Plant O amp M Cost Inputs This screen combines the variable O amp M unit costs from all the model components and places them in one spot These values will also appear in the technology input screens where they are actually used Values changed on this screen will reflect exactly the same change everywhere else they appear O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Integrated Environmental Control Model User Manual Overall
349. es typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials Months of Variable O am
350. esaeeeeeneeeens 176 Fabric Filter eneren nition vee eine vad le Re eee 176 Cold Side ESP rn n Geil navel hdl sir dund cadens ain Sl siete 176 Wet FGD e 5 4 nivnind ina aind iain i ain aii aw EEE 177 Spray EVR amono ora eh a E les as es Baie iene T 177 Percent Increase in Speciation 0 e ec eeeeeeseeceseeeesssecneeeesseecsaeecsseeceseeseseaeeseeeeees 177 Mercury Carbon and Water Injection Inputs eeseeesecsseceeeeeessaeessseesseeseseeensaeeees 177 Activated Carbon Injection eeeeeescecesseesssneeceeecsseeesseecesseeesaeecssneesesaeeneeeesaes 178 Mercury Retrofit Cost Inputs sceeccessecesseeceesecsseecesceeesaeecsaeecsaeeecesaecaeeesseesseeseneeeses 179 Capital Cost Process Area escsesseceseeceseceesenecsscecssceceseeceseeeeseeecseneeceseseseeeenars 179 Mercury Capital Cost Inputs sssaaa ra a a a a an 181 Mercury O amp M Cost Inputs seere E ai inhi ain E TA T 183 Mercury Diagrami hereni neni ie RG aa Sate EE E AE Ea i 184 Flu Gas Prior to Injection iinnine teense e a Tih 184 Flue Gas After Inject onnenie ioe cul ead E a A i ee a 184 Hue Gas Conditioning i255 2 ssh at Se e rr ee ee a 185 Mercury Flue Gas Results s tisiccccsisctccelaschs n a eere cohen E EEE ievenven hth seedeaubbestedess 185 Major Flue Gas Components scceeecceesseessneecceeecsneeceseecesseeesaeecsaeescesaesnaeeesaes 186 Mercury Capital Cost Results ft0 ccnic ity ideation latin 186 Mercury O amp M C
351. eseaesceecsececseeseeessesseseesaeeseseeeaeed 33 Water Consumption Results ioeie irer nea i o enee renees i eria eriei s iE es 34 4 e Water Systems Integrated Environmental Control Model User Manual Cooling System Configuration This screen is only available for pulverized coal power plants However the option of Cooling System is available for all plant types Inputs for configuration of the Cooling System are briefly introduced below 7 IECM Interface ile Edit Yiew Go Window Help sa Untitled Configure Plant T Set Parameters l O B e o Configuration No Devices Combustion Controls mie T NOx Control None No Fly Ash Co Disposal Lols izi lt T Mercury None CO2 Capture None Lelle ile ila ila Water and Solids Management Cooling System Once Through Wastewater Ash Pond Flyash Disposal No Mixing rN Post Combustion Controls NOx Control None Particulates None H20 S02 Control None e aS se Lelle ila 1 Diagram Cooling System Configuration Plant Input Screen Cooling System This option determines the cooling technology Once Through Wet Cooling Tower and Air Cooled Condenser The default technology is the Once Through cooling system Once Through Cooling water is withdrawn from a natural waterbody passed through the steam condenser and returned to the waterbody Wet Cooling Tower Cooling water is recirculated through the
352. essed as a levelized cost factor or fixed charge factor The fixed charge factor is a function of many items The fixed charge factor can be specified directly or calculated from the other input quantities below it on the financial input screen Each parameter is described briefly below Year Costs Reported This is the year in which all costs are given or displayed both in the input screens and the results A cost index is used by the IECM to scale all costs to the cost year specified by this parameter The cost year is reported on every input and result screen associated with costs throughout the interface Constant or Current Dollars Constant dollar analysis does not include the affect of inflation although real escalation is included Current dollar analysis includes inflation and real escalation This choice allows you to choose the mode of analysis for the entire IECM economics The cost basis is reported on every input and result screen associated with costs throughout the interface Discount Rate Before Taxes This is also known as the cost of money It is the return required by investors in order to attract investment capital It is equal to the weighted sum of the return on debt and equity It is the time value of money or the discount rate used in present worth arithmetic Fixed Charge Factor FCF The fixed charge factor is one of the most important parameters in the IECM It determines the revenue required to finance t
353. etermined by the TCR Recovery Factor Spray Dryer O amp M Results This screen is only available for the Combustion Boiler plant type 7 IECH Interface Fie Edit Yiew Go Window Help Us Untitled Configure Plant Set Parameters Get Results CO2 By Prod Capture Mgmt Stack O amp M Cost Variable Cost Component MS Fixed Cost Component Steam 0 6308 Solid Waste Disposal 0 9538 Electricity 0 9081 Water 1 339e 02 ale le lololo ne Operating Labor Maintenance Labor Maintenance Material Admin amp Support Labor On amp tai Zj tt e a om omt ee ee fee BEB S E S G Process Type Spray Dryer z Costs are in Constant 2005 dollars 2 Flue Gas 2 Capital Cost 4 O amp M Cost 5 Total Cost Spray Dryer O amp M Cost result screen The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the SO control technology O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Integrated Environmental
354. ew Go Window Help Configure Plant Set Parameters Get Results Sulfur c02 PewerEicee Bere emt Removal Capture Se Capital Cost Mis Selexol CO2 Plant Costs Selexol CO2 Process Area Costs Absorbers 1 Power Recovery Turbines 2 General Facilities Capital 7 280 Slump Tanks 3 Eng amp Home Office Fees 4 853 Recycle Compressors 4 Project Contingency Cost 7 280 5 6 7 Flash Tanks Process Contingency Cost 4 853 Selexol Pumps Interest Charges AFUDC 12 04 Royalty Fees 0 2427 8 Preproduction Startup Cost 5 327 L9 Inventory Working Capital 0 3640 Heat Exchangers 10 ll 12 13 14 15 zis t Eel aleo alan alee Refrigeration CO2 Compressors Final Product Compressors Costs are in Constant 2005 dollars Process Type 2 Selexol CO2 Capture 2 Syngas 3 Capital Cost 4 O amp M Cost 5 Total Cost Selexol CO Capture Capital Cost results screen The Selexol CO Capture Capital Cost result screen displays tables for the capital costs Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Selexol CO2 Capture Process Area Costs Absorbers This is the series of columns where the syngas is made to contact with the Selexol solvent Some of the CO is absorbed by the CO lean solvent at high pressure in the counter flow absorber
355. excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a fabric filter that has been paid off Selexol CO Capture O amp M Cost Inputs This screen is only available for the IGCC plant type 308 e Selexol CO2 Capture Integrated Environmental Control Model User Manual File Edit View Go Window Help R eS Configure Plant Set Parameters Get Results Power Block Gan 3 1 2 3 Giycol Cost 4 Waste Disposal Cost Electricity Price Base Plant Mwh 6 gt 7 Number of Operating Jobs jobs shift 8 Number of Operating Shifts shifts day g 9 Operating Labor Rate hr R 10 Il Total Maintenance Cost TPC T12 Maint Cost Allocated to Labor i total 13 Administrative amp Support Cost total labor 14 15 Transport and Storage Costs 16 CO2 Transportation Cost ton 2 088 A i 10 00 17
356. f the solids removed for waste management This includes dry fly ash and sluice water The value is given on a wet basis Fabric Filter Flue Gas Results This screen is only available for the Combustion Boiler plant type The Flue Gas result screen displays a table of quantities of flue gas components entering and exiting the Particulate Control Technology For each component quantities are given in both moles and mass per hour Integrated Environmental Control Model User Manual Fabric Filter e 215 y IECM Interface File Edit Yiew Window Help Configure Plant Set Parameters Get Results 502 co2 By Prod Control Capture Mgmt A Flue Gas In Flue Gas Out Flue Gas In Flue Gas Out ADUTE E h moles hr h moles tx tonhr ton hr Nitrogen N2 1 266e 05 1 266e 05 1773 1773 Oxygen 02 9372 9372 149 9 149 9 Water Vapor H20 2 369e 04 2369 213 4 21 34 Carbon Dioxide CO2 2 050e 04 2 050e 04 451 1 451 1 Carbon Monoxide CO 0 0 0 0 0 0 0 0 Hydrochloric Acid HCD 5 643 5 643 0 1029 0 1029 Sulfur Dioxide S02 41 24 41 24 1 321 1 321 Sulfuric Acid equivalent 03 8 639e 02 8 639e 03 3 458e 03 3 458e 04 Nitric Oxide NO 35 11 35 11 0 5268 0 5268 Nitrogen Dioxide NOD 1 848 1 848 4 251 02 4 251e 02 Ammonia NH3 2713 2 713 2 310e 02 2 310e 02 Argon At 0 0 0 0 0 0 0 0 2 le lalelo i Fabric Filter Flue Gas result screen Each result is
357. factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the fabric filter that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor
358. ffice buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to O amp M costs over a specified period of time months e Fixed Operating Cost Time period of fixed operating costs operating and maintenance labor administrative and suppor
359. fidence consider extreme high or low values before asking about central values of the distribution In general experts judgments about uncertainties tend to improve when e the expert is forced to consider how things could turn out differently than expected e g high and low extremes and e the expert is asked to list reasons for obtaining various outcomes While the development of expert judgments may be flawed in some respects it does permit a more robust analysis of uncertainties in a process when limited data are available Furthermore in many ways the assessment of probability distributions is qualitatively no different than selecting single best guess values for use in a deterministic estimate For example a best guess value often represents a judgment about the single most likely value that one expects to obtain The best guess value may be selected after considering several possible values The types of heuristics and biases discussed above may play a similar role in selecting the value Thus even when only a single best guess number is used in an analysis a seasoned engineer usually has at least a sense for how good that number really is This may be why engineers are usually able to make judgments about uncertainties because they implicitly make these types of judgments routinely 410 Appendix A Introduction to Uncertainty Analysis Integrated Environmental Control Model User Manual
360. fit Cost input screen File Edit View Go Window Help T Untitled Ox Configure Plant Set Parameters Base Plant 02 coz Control Title Units Capital Cost Process Area Spray Cooling Water retro new Sorbent Injection retro new Sorbent Recycle T retro new Additional Ductwork retro new Sorbent Disposal retro new CEMS Upgrade retro new Pulse Jet Fabric Filter retro new lo ele 2 me le oeoo Activated Carbon Inj 1 Removal Eff 2 Carbon Inj 3 Retrofit Cost 4 Capital Cost 5 0 amp M Cost Mercury Retrofit Cost input screen The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the
361. flow rate of DBA Wet FGD Retrofit Cost Inputs 228 e Wet FGD This screen is only available for the Combustion Boiler plant type Inputs for capital costs of modifications to process areas to implement the SO control technology are entered on the Retrofit Cost input screen for the Wet FGD system The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties spe
362. for a specified year as shown on the bottom of the screen Each result is described briefly below Power Block Process Area Costs Gas Turbine The capital cost of the gas turbines the air compressor and the combustor Heat Recovery Steam Generator The heat recovery steam generator is a set of heat exchangers in which heat is removed from the gas turbine exhaust gas to generate steam for the steam turbine Steam Turbine The cost of a steam turbine is depends on the mass flow rate of steam through the turbine the pressures in each stage and the generator output HRSG Feedwater System The boiler feedwater system consists of equipment for handling raw water and polished water in the steam cycle including a water mineralization unit for raw water a dimineralized water storage tank a condensate water a condensate polishing unit and a blowdown flash drum Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Power Block Plant Costs Process Facilities Capital see definition above Integrated Environmental Control Model User Manual Power Block 385 General Facilities Capital The general facilities include construction costs of roads office buildings shops labo
363. for a specified year as shown on the bottom of the screen 7 IECH Interface ioj x File Edit View Go Window Help 0 DA Untitled 5 k ol x Configure Plant Set Parameters Get Results Power Block NOx Control CO2 Capture 8 Title Sulfur Dioxide S02 i e Nitrogen Oxide equiv NOZ Carbon Dioxide CO2 gt R Process Type Overall Plant Costs are in Constant 2005 dollars Emission Constraint Emission Taxes input screen The Emis Taxes input screen allows the user to enter the taxes on emissions in dollars per ton The final costs determined from these inputs are available under the stack tab in the results section of the IECM The costs are added to the overall plant cost not a particular technology Tax on Emissions Sulfur Dioxide S02 The user may enter a cost to the plant of emitting sulfur dioxide in dollars per ton Nitrogen Oxide equiv NO2 The user may enter a cost to the plant of emitting nitrogen oxide in dollars per ton Carbon Dioxide CO2 The user may enter a cost to the plant of emitting carbon dioxide in dollars per ton Integrated Environmental Control Model User Manual Overall NGCC Plant 49 Overall NGCC Plant Performance Results y IECH Interface Fie Edit View Go Window Help 0 US Untitled Configure Plant Set Parameters Get Results Power Block NOx Control CO2 Capture Perf
364. for the fabric filter Fabric Filter O amp M Cost Results This screen is only available for the Combustion Boiler plant type The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the particulate control technology 218 e Fabric Filter Integrated Environmental Control Model User Manual 7 IECH Interface ioj xi Fie Edit Yiew Go Window Help e Configure Plant Set Parameters Get Results s02 CO2 By Prod Stack Control Capture Mgmt eu 8 a Variable Cost Component Fixed Cost Component MS Electricity Maintenance Labor 0 1777 Maintenance Material 0 2665 Admin amp Support Labor 0 1735 lig tt oaoa wn Fabric Filter Costs are in Constant 2005 dollars 3 Copitel Cost E 5 Total Cost Fabric Filter O amp M Cost result screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Component Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Solid Waste Disposal Total cost to dispose the collected fly ash This does not consider by product ash sold in commer
365. gasification but prior to the raw gas quench process Syngas Out This is the volumetric flow rate of syngas exiting the gasification but prior to the raw gas quench process Integrated Environmental Control Model User Manual Wet Slag Slag collected is removed from the gasifier Sluice water may or may not be used to facilitate its transportation This is the total slag flow rate leaving the gasifier on a wet basis Gasifier Oxidant Results 7 IEC Interface File Edit View Go Window Help 0 GA Untitled Configure Plant Set Parameters Get Results Major Oxidant Components NirogenW i Oxygen 02 Water Vapor H20 Carbon Dioxide CO Carbon Monoxide CO Hydrochloric Acid HC Sulfur Dioxide 302 Sulfuric Acid equivalent 503 Nitric Oxide NO Nitrogen Dioxide NO2 Ammonia NH3 12 Argon A izi t a me e alelo 2 Oxidant 3 Syngas 4 Capital Cost 5 O amp M Cost 6 Total Cost Gasifier Gas Flow result screen Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total
366. geometric standard deviation must be 1 or greater This distribution is usually used to represent uncertainty in physical quantities which must be positive values that are positively skewed such as the ambient concentration of a pollutant This distribution may be appropriate when uncertainties are expressed on a multiplicative order of magnitude basis e g factor of 2 or when there is a probability of obtaining extreme large values Uniform Distribution tUniform min max returns a continuous probability distribution in which every value between min and max has an equal chance of occurring Use this when you are able to specify a finite range of possible values but are unable to decide which values in the range are more likely to occur than others The use of the uniform distribution is also a signal that the details about uncertainty in the variable are not known It is useful for screening studies 402 e Running a Probabilistic Analysis Integrated Environmental Control Model User Manual Triangular Distribution Triangular min mode max returns a continuous triangular probability distribution bounded by min and max and with the specified mode Use this when you are able to specify both a finite range of possible values and a most likely mode value The triangle distribution may be symmetric or skewed Like the uniform distribution this distribution indicates that additional details about uncertainty are not yet known Th
367. gh SO removal However the reagent cost is also higher and solid waste is not easily disposed Flue Gas Bypass Control This popup selection menu controls whether or not a portion of the inlet flue gas may bypass the scrubber and recombine with the treated flue gas Bypass allows the scrubber to operate at full efficiency while allowing some of the flue gas to go untreated Two choices are available No Bypass This option forces the entire flue gas to pass through the scrubber This is the default option Bypass This option allows for the possibility of a portion of the flue gas to bypass the scrubber The amount of bypass is controlled by several additional input parameters described below 7 IECH Interface Fie Edit View Go Window Help US Untitled Configure Plant Set Parameters NOx TSP co2 Base Eleni Mercury Control Control Capture Mgmt Value Max swiAcg menu menu Limestone Flue Gas Bypass Control Bypass Menu No Bypass Maximum S02 Removal Efficiency 98 00 i 99 00 98 00 Overall 302 Removal Efficiency a 80 66 99 00 calc Required by 502 emis constraint i Scrubber S02 Removal Efficiency 98 00 30 00 99 00 cale Minimum Bypass 0 0 0 0 100 0 0 0 Alloy ss 17 69 0 0 100 0 calc Actual B 17 69 0 0 100 0 calc j Zis t e mlel le alelo Process Type Wet FGD F 1 Config 3 Additives 4 Retrofit Cost 5 Capital Cost 6 O
368. gments Because the IECM generates sorted x y data with x values always increasing the two graphs will appear very similar The only difference is the use of line segments and data markers X Axis X Axis cross Electrical Output TSP Control Revenue Required Selected Variable Y Axis Gross Electrical Output X Axis variable selection menu The X Axis drop down menu allows you to select the independent variable The menu initially contains only one item the variable you double clicked This is the selected variable as shown in the figure above If the Choose button immediately to the right of the drop down menu is clicked any input or result variable that exists in the IECM can be selected see Variable Chooser on page 395 Y Axis Cumulative Probability Z Axis TSP Control Revenue Required Selected Variable Y Axis variable selection menu The Y Axis drop down menu allows you to select the dependent variable The menu initially contains only two items Cumulative Probability and the variable you double clicked The second item is the selected variable as shown in the figure above Cumulative Probability is the default option If the Choose button immediately to the right of the drop down menu is clicked any input or result variable that exists in the IECM can be selected see Variable Chooser Z Axis Z Axis rrr Oy Z Axis variable selection menu The Z Axis drop down men
369. gram result screen displays an icon for the Water Gas Shift Reactor Unit and values for major flows in and out of it Each result is described briefly below in flow Steam In This is the flow rate of steam added The steam reacts with CO to produce H and CO in the presence of the catalyst in the two reactors Temperature In Temperature of the syngas entering the high temperature reactor Syngas In Flow rate of the syngas entering the high temperature reactor Temperature Out Temperature of the syngas exiting the final heat exhanger Syngas Out Flow rate of the syngas exiting the final heat exchanger 324 e Water Gas Shift Reactor Integrated Environmental Control Model User Manual Water Gas Shift Reactor Syngas Results iix Fie Edit view Window Help Eue cx Configure Plant Set Parameters Get Results Power Block eee Stack Syngas Out Syngas In b moles hr ton hr 1 837e 04 9184 267 2 Hydrogen HJ 1 432e 04 3 177e 04 14 47 Methane CH4 135 2 1352 1 084 Ethane C2H6 i 0 0 0 0 Propane C3H3 i oo o0 Hydrogen Sulfide H25 E 247 5 4 217 Carbonyl Sulfide COS 1415 04251 Ammonia NH3 i 3 196 2 722e 02 2 722e 02 Hydrochloric Acid HCD i J oo o0 0 0 Carbon Dioxide COZ 2 2430 04 109 7 493 7 Water Vapor H20 6639 61 39 59 82 Nitrogen NZ i 352 5 4 937 4 937 z gt alel le oao Argon An 417 3 8336 8 336 Oxygen 02 0 0 0 0 0 0
370. guration This screen is only available for the Combustion Boiler and Combustion Turbine plant types The screens under the CO Capture Technology Navigation Tab display and design flows and data related to the Amine System 7 IECM Interface 5 x Eile Edit View Window Help ioj x Configure Plant Set Parameters Get Results 502 OME 7 Control EEA Mgmt Steck i Max Default Direct Contact Cooler DCC Used Yes Menu Yes Temperature Exiting DCC 122 0 i 250 0 calc Auxiliary Natural Gas Boiler None Menu None _ Flue Gas Bypass Control Bypass Menu No Bypass Maximum CO2 Removal Efficiency 90 00 i 100 0 90 00 Overall CO2 Removal Efficiency 90 00 w 100 0 calc Required by CO2 emis constraint i ber CO2 Removal Efficiency 90 00 99 00 calc A A zis e me le loeo Minimum Bypass 0 0 i 100 0 0 0 Allo ss 0 0 100 0 calc Actual 0 0 4 100 0 calc Reference Plant puts for Avoidance Cost Cale CO2 Emission Rate los kWh Cost of Electricity MWh Process Type JAmine System Mee 2 Peformance 3 Capture 4 CO2Storage 5 RetrofitCost 6 CapitalCost 7 O amp M Cost Amine System Config input screen flue gas bypass added The parameters below describe the amine system alone Additional parameters may be added to the screen if an auxiliary boiler or flue gas bypass is specified in the m
371. has been selected the mass flow of CO captured is reported It is transported off site See the CQ Transport System page 355 for more information Byproduct Ash Sold Total mass of ash bottom and fly ash sold in commerce as a by product on a dry basis Byproduct Gypsum Sold Total mass of flue gas treatment solids sold in commerce as a by product on a dry basis Byproduct Sulfur Sold Total mass of elemental sulfur recovered from flue gas and sold in commerce as a by product on a dry basis Byproduct Sulfuric Acid Sold Total mass of sulfuric acid recovered from the flue gas and sold in commerce as a by product Total This is the total wet solid mass exiting the power plant This result is highlighted in yellow Combustion Overall Plant Solids Emissions Ja File Edit View Go Window Help E a e Configure Plant Set Parameters Get Results 302 Control 8 pA Solid Components at technology exit A Economizer SCR unless noted tons hr tons hr e Lime CaO Limestone aCO3 Calcium Sulfite Ca303 0 5H20 Gypsum CaSO4 2H20 Calcium Sulfate Ca304 Calcium Chloride Cac Miscellaneous UBC Sulfur 1 775e 02 7 098e 02 Water 0 0 0 0 ha ea leo llt Oonan Nye 10 11 12 13 1 15 K f Process Type Overall Plant 2 Plant Perf 3 Mass In Out APEC 5 GasInOut 6 TotalCost f7 Cost Summary Combustion Overall Plant Solids Emiss
372. have to be carried over long distances Hence it is necessary to compress and liquefy it to very high pressures so that it maybe delivered to the required destination in liquid form and as far as possible without recompression facilities en route The critical pressure for CO is about 1070 psig The typically reported value of final pressure to which the product CO stream has to be pressurized using compressors before it is transported is about 2000 psig CO Compressor Efficiency This is the effective efficiency of the compressors used to compress CO to the desirable pressure CO Unit Compression Energy This is the electrical energy required to compress a unit mass of CO product stream to the designated pressure Compression of CO to high pressures requires substantial energy and is a principle contributor to the overall energy penalty of a CO capture unit in a power plant CO Transport amp Storage Storage Method The default option for CO disposal is underground geological storage e EOR Enhanced Oil Recovery e ECBM Enhanced Coalbed Methane Recovery e Geologic Geological Reservoir e Ocean Amine System Retrofit Cost Inputs This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECH Interface File Edit View Go Window Help US Untitled Configure Plant Direct Contact Cooler Flue Gas Blower CO2 Absorber Vessel Base Plant Mercury Tit
373. he Auto Hide option of the Taskbar properties in Windows The current version of MDAC is 2 8 This is installed with the full installer for the IECM Any update installers provided for upgrading the IECM from a previous version to the current version do not upgrade MDAC unless the user updates MDAC separately 4 o Introduction Integrated Environmental Control Model User Manual Disclaimer of Warranties and Limitation of Liabilities This report was prepared by the organization s named below as an account of work sponsored or cosponsored by the U S Department of Energy National Energy Technology Laboratory NETL NEITHER NETL ANY MEMBER OF NETL ANY COSPONSOR THE ORGANIZATION S NAMED BELOW NOR ANY PERSON ACTING ON BEHALF OF THEM A MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER EXPRESS OR IMPLIED I WITH RESPECT TO THE USE OF ANY INFORMATION APPARATUS METHOD PROCESS OR SIMILAR ITEM DISCLOSED IN THIS REPORT INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR II THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS INCLUDING ANY PARTY S INTELLECTUAL PROPERTY OR M THAT THIS REPORT IS SUITABLE TO ANY PARTICULAR USER S CIRCUMSTANCE OR B ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER INCLUDING ANY CONSEQUENTIAL DAMAGES EVEN IF DOE OR ANY DOE REPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES RESULTING FROM YOUR SELECTION OR USE OF THIS REPO
374. he inlet NO concentration associated with the reference design specifications for the SCR system It is used to determine the actual space velocity Reference Catalyst Activity Integrated Environmental Control Model User Manual Hot Side SCR e 159 Catalyst activity decreases with operating time due to plugging and catalyst poisoning The loss is a complex function of the catalyst formulation and geometry the operating conditions associated with the flue gas including temperature and composition and the loading and composition of the fly ash This complex function is represented by an exponential decay formula in the IECM The following parameters are used to determine the reference catalyst activity assuming the initial activity has a value of unity Minimum Activity The minimum activity is a lower limit for catalyst activity decay The actual activity approaches this value over a long period of time Reference Time This is the time that corresponds to a particular activity known for the catalyst It is used to determine a decay rate constant Activity at Reference Time A second activity reference point is needed to determine the activity decay rate The activity should correspond to the reference time specified It is used to determine a decay rate constant Ammonia Deposition on Preheater This is the percent of the ammonia slip that is deposited as ammonium salts in the air preheater It is treated like a partition coefficient
375. he power plant based on the capital expenditures Put another way it is a levelized factor which accounts for the revenue per dollar of total plant cost that must be collected from customers in order to pay the carrying charges on that capital investment Integrated Environmental Control Model User Manual One may specify a fixed charge factor or fill in the following inputs and the model will calculate the FCF based on them Inflation Rate This is the rise in price levels caused by an increase in the available currency and credit without a proportionate increase in available goods or services It does not include real escalation Plant or Project Book Life This is the years of service expected from a capital investment It is also the period over which an investment is recovered through book depreciation Real Bond Interest Rate This is a debt security associated with a loan or mortgage It is the most secure form of security but the lowest in its return Real Preferred Stock Return This equity security is the second most speculative type and pays the second highest rate of return The holder of the stock is a part owner of the company Real Common Stock Return This is the most speculative type of equity security sold by a utility and pays the highest relative return The holder of the stock is a part owner of the company Percent Debt This is the percent of the total capitalization that is associated with debt money This includ
376. he screen displays the plant configuration settings on the left side of the page and a diagram of the configured plant on the right of the page No input parameters or results are displayed on this screen Integrated Environmental Control Model User Manual Combustion Overall Plant 27 Combustion Overall Plant Performance Inputs 28 e Combustion Overall Plant al lol x Fie Edit View Go Window Help NOx TSP 2 co2 Control Control Capture Unc Value Cale Min i 500 0 mM 1000 trical Output V 470 8 mM 1000 MW output for reference only Ambient Air Temperature 77 00 130 0 77 00 Ambient Air Pressure psia 14 70 15 00 14 70 Ambient Air Humidity 1b H20 lb dry air 1 800e02 I 3 000e 02 1 800e 02 8 Content in Air Oxidant vol 20 37 100 0 calc Process Type overall Plant 2 Performance 5 O amp M Cost Combustion Overall Plant Performance input screen The parameters available on this screen establish the plant availability electrical requirements and ambient conditions for the power plant These parameters have a major impact on the performance and costs of each of the individual technologies Capacity Factor This is an annual average value representing the percent of equivalent full load operation during a year The capacity factor is used to calculate annual average emissions and materials flows Gross Electrical Output This is the gross ou
377. he total abatement cost The subtotal is highlighted in yellow Base Plant The total cost of the base plant without consideration of any abatement technologies This can be used to compare with other power plant types Total This is the total cost of the entire power plant This result is highlighted in yellow Each cost category column is described briefly below Capital Required The total capital requirement TCR This is the money that is placed capitalized on the books of the utility on the service date The total cost includes the total plant investment plus capitalized plant startup Escalation and allowance for funds used during construction AFUDC are also included The capital cost is given on both a total and an annualized basis Revenue Required Amount of money that must be collected from customers to compensate a utility for all expenditures in capital goods and services The revenue requirement is equal to the carrying charges plus expenses The revenue required is given on both an annualized and a net power output basis Integrated Environmental Control Model User Manual Overall NGCC Plant The input parameter screens described in the following sections are available when the Combustion Turbine is selected as the plant type from the New Session pull down menu These screens apply to the power plant as a whole not to specific technologies Overall NGCC Plant Diagram lolx File Edit Yiew Go Window Help
378. he total cost of the base plant without consideration of any abatement technologies This can be used to compare with other power plant types Emission Taxes The total cost of taxes assessed to stack emissions is provided here Integrated Environmental Control Model User Manual Total This is the total cost of the entire power plant This result is highlighted in yellow Each cost category column is described briefly below Fixed O amp M The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs for each technology Variable O amp M The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs associated with a technology Total O amp M This is the sum of the annual fixed and variable operating and maintenance costs for each technology Annualized Capital This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Combustion Overall Plant Cost Summary oy e x File Edit View Go Window Help 7 x eS Configure Plant Set Parameters Get Results 3 NOx Contr
379. he various stages of the power plant Each result is described briefly below Note that each column represents the flow rate at the exit of the technology specified at the top of the column These are also reported elsewhere in the particular technology result screens but duplicated here to provide a broad look at gas emissions Stack Gas Components Nitrogen N2 Total mass of emitted nitrogen Oxygen Oz Total mass of emitted oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Argon is present in small quantities in atmospheric air The argon emitted from the power plant is shown on a mass basis Total Gases Total flow rate of all gases This result is highlighted in yellow Integrated Environmental Control Model User Manual Combustion Overall Plant 39 Combustion Overall Total Cost 40 e Combustion Overall Plant sito a xi File Edit View Go Window Help Configure Plant Set Parameters Get Results Combustion NOx Control Post Combustion NOx Control Mercury Control TSP Control 502 Control
380. hnology are entered on the Retrofit Cost input screen The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens Integrated Environmental Control Model User Manual File Edit View Go Window Help Configure Plant Set Parameters Base Plant Mercury Title Units Capital Cost Process
381. hould be cautious in inferring patterns from data with a small number of samples Anchoring and adjustment involves using a natural starting point as the basis for making adjustments For example an expert might choose to start with a best guess value which represents perhaps an average or most likely modal value and then make adjustments to the best guess to achieve worst and best outcomes as bounds The worst and best outcomes may be intended to represent a 90 percent probability range for the variable However the adjustment from the central best guess value to the extreme values is often insufficient with the result that the probability distribution is too tight and biased toward the central value This phenomenon is overconfidence because the expert s judgment reflects less uncertainty in the variable than it should The anchor can be any value not just a central value For example if an expert begins with a worst case value the entire distribution may be biased toward that value Integrated Environmental Control Model User Manual Appendix A Introduction to Uncertainty Analysis 409 Motivational Bias Judgments also may be biased for other reasons One common concern is motivational bias This bias may occur for reasons such as e aperson may want to influence a decision to go a certain way e the person may perceive that they will be evaluated based on the outcome and might
382. hydrochloric acid Carbon Dioxide CO3 Total mass of carbon dioxide Water Vapor H20 Total mass of water vapor Integrated Environmental Control Model User Manual CO2 Transport System e 363 Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Oxygen O2 Total mass of oxygen Total Total of the individual components listed above This item is highlighted in yellow CO Transport System Capital Cost Results 364 e CO2 Transport System This screen is available for all plant types y IECH Interface File Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results TSP 502 CO2 By Prod Control Control e apt ure Mgmt Stack CO2 Transport Process Area Costs Snan Material Cost Labor Costs 2 General Facilities Capital Right of way Cost l 3 Eng amp Home Office Fees Booster Pump Cost 4 Project Contingency Cost Miscellaneous Costs 5 Process Contingency Cost 6 Interest Charges AFUDC 7 Royalty Fees 8 Preproduction Startup Cost 9 Inventory Working Capital 10 1 12 13 14 15 Process Type C02 Transport Costs are in Constant 2005 dollars 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost zs t Eel alelo BIE B e e najala H CO Transport System Capital Cost result screen The Capital Cost result screen displays tables for the capital costs Capital costs are typically expresse
383. i 394 X AXIS rareta aT E A E T EEE E A E A ae 394 Y AXIS eean e ee aia hl eed ei A A oh eee eve 394 Z AXISt aia hialinn davaeh ai ails wn Ga lanai aie 394 Variable Chooser nicis eu e a e inti aed abi aaa 395 Selecting Multiple Sessions srani sete ar e Eea E e E e E 395 Difference Graphs Accsin erna Ea e o EE EEE EA ETEen EEn 396 Graph Window sinisin n ESR A Ln a se 397 Importing and Exporting Grapsi ieseni ae a a a a 398 Graph Window Helpies n es A See 399 Running a Probabilistic Analysis 401 Uncertainty Analysis sssnanorn nenie ee a dan stele ian 401 Uncertainty Dist butons icen ise seee eeste e aeei Eiee EEEE EEE EEEE ONEAN RES EER EE E E 401 Uncertainty Parameters ec seneese iee raset bdescuvs ioe iets de S ENSE NEES ER EEE Ees 401 Integrated Environmental Control Model User Manual Contents xiii xiv e Contents Distribution Types 3 22 2 iha cet eae ae eel alae ae ae 402 Configuring Uncertainty in Results 2 0 0 0 cee eeseeescecsseeccnceeesseecsseecseeceseecssaeecesaeeceesseeeees 403 Uncertainty Areas so 2s csie enable Oe A sees at een ae Re ost ath etal eas 404 Graph SIZE a she ek hes ati oO Sat vat Lah Beer neater seer eben 404 Sample S1Z6 is ish hose eh AS MENT le ee en ahak on eenntetes E 404 Sampling Methods neresen Ea EE anea a Saa 404 Appendix A Introduction to Uncertainty Analysis 407 Uncertainty AD lySi Senen eeen enee anuara ea aea e ear e Eae Eoaea Ee EERTE Ea raeas 407 Introd CtiOn es Kea en a e a
384. iable Cost Component Utility Power Credit Power consumed by abatement technologies result in lower net power produced and lost revenue The IECM charges each technology for the internal use of electricity and treats the charge as a credit for the base plant When comparing individual components of the plant these utility charges are taken into consideration For total plant costs they balance out and have no net effect on the plant O amp M costs Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Component Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Integrated Environmental Control Model User Manual Power Block 387 Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fra
385. ic power industry This system of reporting is used by a wide audience including energy engineers researchers planners and managers The IECM has been developed around this TAG system so that costs associated with various technologies can be compared directly on a consistent basis and communicated in the language used by the audience listed above Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at
386. ic flow rate of the oxidant exiting the Air Separation Unit Air Separation Gas Flow Results File Edit Yiew Go Window Help 90 e Air Separation Air In Nitrogen Out b moles hr h moles hr h moles hr Nitrogen NJ 3 878e 04 3 870e 04 83 85 Oxygen 02 1 040e 04 0 0 1 040e 04 Major Gas Components ic a B E S gt R Water Vapor H20 0 0 0 0 0 0 Carbon Dioxide COD oo oO 0 0 Carbon Monoxide CO 0 0 0 0 Hydrochloric Acid HCI i 0 0 0 0 Sulfur Dioxide 02 i o0 0 0 Sulfuric Acid equivalent 503 0 0 0 0 Nitric Oxide NO i 0 0 0 0 Nitrogen Dioxide NO2 i oo 0 0 Ammonia NH3 0 0 0 0 Argon As 3 052e 05 eaaa e Air Separation Gas Flow result screen Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO3 Total mass of carbon dioxide Integrated Environmental Control Model User Manual Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCl Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total Total of th
387. iew Go Window Help Us Untitled Ae E Configure Plant Set Parameters Base Plant Mercury a By Prod Title Construction Time General Facilities Capital Engineering amp Home Office Fees Project Contingency Cost Process Contingency Cost Royalty Fees Pre Production Costs Months of Fixed O amp M Months of Variable O amp M 12 Misc Capital Cost i 13 14 Inventory Capital 15 16 17 zs t 5e aleo Boenaama unr 18 TCR Recovery Factor Process Type FG Recycle amp Purification gt 1 Config 3 CO2 Storage 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost O gt CO Recycle Flue Gas Capital cost input screen Inputs for capital costs are entered on the Capital Cost input screen Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to 290 e O2 CO2 Recycle Integrated Environmental Control Model User Manual the architect engineering company These fe
388. ight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 Integrated Environmental Control Model User Manual Base Plant 103 Boiler Diagram 104 e Base Plant day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Real Escalation Rate This is the annual rate of increase of an expenditure due to factors such as resource depletion increased demand and improvements in design manufacturing or construction techniques negative rate The real escalation rate does not include inflation The Diagram result screen displays an icon for the Combustion Boiler and values for major flows in and out of it Eile Edit view Window Help Set Parameters Get Results Air N
389. in Air Oxidant vol 29 35 0 0 100 0 Particulate Removal Efficiency a 1 100 0 E Flue Gas Cooling Power Requirem a 15 00 e Recycled Gas Temperature 5 350 0 Recycle Fan Pressure Head 14 Hl 2 000 Recycle Fan Efficiency e 100 0 g _9 Flue Gas Recycle Power Requirem i 15 00 R Flue Gas Purification Unit Is Flue Gas Purification Present CO2 Capture Efficiency CO2 Product Purity CO2 Unit Purification Energy kWh ton CO2 CO2 Purification Energy MWg Process Type FG Recycle amp Purification MEU 2 CO2Storage f 4 RetroftCost 5 CapitalCost 6 O amp M Cost O2 CO 2 Recycle Flue Gas Performance input screen Flue Gas Recycle Stream Flue Gas Recycled This is the percentage of the total flue gas that is to be recycled Oxygen Content in Air Oxidant This is the volume percent that is oxygen Particulate Removal Efficiency This is the percentage of particulates that are removed by the Flue Gas Recycle system Integrated Environmental Control Model User Manual Flue Gas Cooling Power Requirement This is the percentage of the total gross power of the plant required to cool the flue gas being recycled Recycled Gas Temperature This is the temperature of the recycled flue gas Recycle Fan Pressure Head A fan is used to provide a small pressure head for the recycled flue gas stream going back to the boiler This FGR fan pressure head along with the recycled flue gas
390. in the model Net Plant Size MW This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties Annual Operating Hours hours This is the number of hours per year that the plant is in operation If a plant runs 24 hours per day seven days per week with no outages the calculation is 24 hours 365 days or 8 760 hours year Annual CO2 Removed ton yr This is thel amount of CO removed from the flue gas by the CO capture system per year Annual SO2 Removed ton yr This is the amount of SO removed from the flue gas by the CO capture system per year Annual SO3 Removed ton yr This is the amount of SO removed from the flue gas by the CO capture system per year Integrated Environmental Control Model User Manual Annual NO2 Removed ton yr This is the amount of NO removed from the flue gas by the CO capture system per year Annual HCI Removed ton yr This is the amount of HCl removed from the flue gas by the CO capture system per year Flue Gas Fan Use MW The flue gas has to be compressed in a flue gas blower so that it can overcome the pressure drop in the absorber tower This is the electrical power required by the blower Sorbent Pump Use MW The solvent has to flow through the absorber column generally through packed media countercurrent to the flue gas flowing upwards This is the power required by the solvent circul
391. in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor Integrated Environmental Control Model User Manual e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new
392. in yellow Integrated Environmental Control Model User Manual Gasifier 133 Air Preheater The Air Preheater Technology Navigation Tab in the Get Results program area contains result screens that display the flow rates and temperatures of substances through the air preheater This is only available in the Combustion Boiler plant type Air Preheater Diagram This screen is only available for the Combustion Boiler plant type 7 IECM Interface File Edit Yiew Go Window Help Configure Plant Set Parameters Get Results NOx TSP 02 co2 gt pr D Q By Prod Control Mercury Control Control Capture Hei Mgmt k Temperature In CF 700 zls t a mlel le oo Flue Gas In acfm Fly Ash In tons hr Mercury In lbh 503 Removal 2 096e 06 9 722 3 531e 02 50 00 Temperature Out F Flue Gas Out acfim Fly Ash Out tons hr Mercury Out lb hr Leakage Air Temp CF Leakage Air acfim 300 0 1 582e 06 9 722 3 531e 02 77 00 1 473e 05 499 6 1 662e 06 Total Oxidant Temp F Total Oxidant actin Recycled Flue Gas Temp Recycled Flue Gas acfin Ambient Air Temp CF Ambient Air acfm 77 00 9 302e 05 Process Type Jair Preheater 7 P Trese 7 oonan J 1 Diagram Air Preheater Diagram The Diagram result screen displays an icon for the Air Preheater and values for major flows in and out of it Each result is described briefly below in flow order n
393. ine system the costs associated with the Auxiliary Boiler are displayed by the Amine System cost screens View these by selecting the Amine System from the Process Type menu on the bottom of the screen Integrated Environmental Control Model User Manual Auxiliary Boiler e 117 Gasifier This gasifier chapter describes the coal gasification equipment used in the IGCC plant types Gasifier Performance Inputs This screen is only available for the IGCC plant type 7 IEC Interface File Edit View Go Window Help US Untitled Configure Plant Set Parameters Sulfur Removal CO2 Capture Power Block By Prod Mgmt Stack 615 0 600 0 0 4419 nput from ASU Sulfur Loss to Solids mol O2 mol C 0 4550 X 0 0 0 0 1 000 100 0 Coal Ash in Raw Syngas 0 0 0 0 100 0 Percent Water in Slag Sluice 0 0 0 0 99 00 zi klt 2 Bleh eaP Number of Operating Trains integer 2 Menu Menu Number of Spare Trains integer H Menu Menu Raw Gas Cleanup Area Particulate Removal Efficiency Power Requirement 1 Performance 2 Syngas Out 3 Retrofit Cost 4 Capital Cost 5 0 amp M Cost Gasifier Performance input screen Gasifier Area Gasifier Temperature This is the temperature of the syngas exiting GE Entrained Flow Reactor Gasifier Pressure This is the press
394. ined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow O CO Recycle Total Cost Results This screen is available for Combustion Boiler plant types Integrated Environmental Control Model User Manual O2 CO2 Recycle e 299 7 IECH Interface File Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results 502 Control ton CO2 ao Percent Total aeh elol 2057 9061 14 05 61 88 6 599 Zj tt Costs are in Constant 2005 dollars 2 DCC Gas 2 Purif Gas 4 Capital Cost 5 0 amp MCost EMEC OLE O gt CO Recycle Flue Gas Total cost result screen The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Flue Gas Recyc
395. ineering amp Home Office Fees i 50 00 E Project Contingency Cost i 100 0 Process Contingency Cost 100 0 Royalty Fees t 10 00 Pre Production Costs R Months of Fired O amp M months 1 000 Months of Variable O amp M months 1 000 Misc Capital Cost TPI 2 000 Inventory Capital TPC 0 5000 TCR Recovery Factor I 100 0 Process Type fe Selexol CO2 Capture M 1 Reference Plant 3 CO2 Storage 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Selexol CO Capture Capital Cost input screen Inputs for capital costs are entered on the Capital Cost input screen Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower
396. ing Cost 0 0 ne k al 8 oe e Ep 5 gt R ela aa ala CO Transport System Total Cost result screen The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the CO Transport System CO Control technology Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Integrated Environmental Control Model User Man
397. ing of the sorbent to a sufficiently high reaction temperature would result in a regeneration efficiency of just over 99 percent at a 30 minute residence time A potential problem that may be occurring in the test units is that regenerated sorbent in the regenerator may be reabsorbing some of the evolved SO2 However this was not considered in the modeling study of the regenerator Based on this information it appears that it may be possible to achieve the design target of over 99 percent regeneration efficiency Clearly however it is possible that the actual efficiency may be substantially less than this target value As a worst case we might consider the known test results as a lower bound Thus there is a small Integrated Environmental Control Model User Manual Appendix A Introduction to Uncertainty Analysis 411 chance the regeneration efficiency may be less than 50 percent We expect the regeneration efficiency to tend toward the target value of 99 2 percent Thus to represent the expectation that the efficiency will be near the target value but may be substantially less we can use a negatively skewed distribution In this case we assume a triangle with a range from say 50 to 99 2 percent with a mode also at 99 2 percent The triangle in this case gives us a distribution with a mean of about 83 percent and a median of about 85 percent This type of triangular distribution in which a minimum maximum and modal value are specifi
398. installation and may be set as low as 0 for a hot side SCR that has been paid off Hot Side SCR O amp M Cost Inputs This screen is only available for the Combustion Boiler plant type Integrated Environmental Control Model User Manual Hot Side SCR e 163 164 o Hot Side SCR iT lolx File Edit Yiew Window Help Configure Plant Set Parameters Emission Base Plant Constraint Mercury Units Min x Get Results Max Title Catalyst Cost Ammonia Cost eu ft ton 400 0 750 0 Electricity Price Base Plant MWh ple le e 9 0 Number of Operating Jobs Fa tig jobs shift 30 00 Number of Operating Shifts Operating Labor Rate shifts day hr 100 0 10 00 Zl Total Maintenance Cost TPC 10 00 Maint Cost Allocated to Labor total 100 0 Administrative amp Support Cost total labor 100 0 Costs are in Constant 2000 dollars Process Type Hot Side SCR 1 Config 3 Perf cont 5 Capital Cost 6 0 amp M Cos Hot Side SCR O amp M Cost input screen Inputs for the operation and maintenance costs of the Hot Side SCR NO control technology are entered on the O amp M Cost input screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each par
399. installed All user files are stored in the C Program Files IECM_CS Sessdb directory 18 Installing the Model Integrated Environmental Control Model User Manual Configure Plant Configuring the Combustion Boiler Plant The following configuration options are available when the Combustion Boiler is selected as the plant type from the New Session pull down menu y IECM Interface File Edit View Go Window Help Us Untitled Configure Plant No Devices Combustion Controls No Fly Ash Co Disposal vie E NOx Control None gt rN Post Combustion Controls NOx Control None Particulates None S02 Control None Mercury None CO2 Capture None 8 H l El gt 2 K Solids Management Flyash Disposal io Mixing Configure Plant Combustion Boiler input screen The figure above shows the base configuration of the PC plant Combustion post combustion and solids management controls must be configured by the user The following sections describe each popup menu on the configuration screen Pre configuration settings can be selected using the Configuration menu at the top of the screen No Devices is the default Combustion Controls These configuration options determine the type of furnace and any technologies for reducing NO emissions Integrated Environmental Control Model User Manual Configure Plant 19 20 e Configure Plant Fuel Type Coal is the primary fuel
400. int o Capture Mgmt Maximum 502 Removal Efficiency Actual 503 Removal Efficiency Particulate Removal Efficiency Absorber Capacity acfm Number of Operating Absorbers i number Number of Spare Absorbers number Reagent Stoichiometry mol Ca mol S in CaO Content of Lime wt H20 Content of Lime wt Total Pressure Drop Across FGD inH20 gauge Approach to Saturation Temperat deg F 3 Temperature Rise Across ID Fan deg F Gas Temperature Exiting Scrubber deg F Oxidation of CaSO3 to CaSO04 Slurry Recycle Ratio 1b slurry lb lime Spray Dryer Power Requirement MWg 0 6707 Process Type Spray Dryer y AEn 2 RetrofitCost 4 Capital Cost 5 O amp M Cost Spray Dryer Performance input screen In a Lime Spray Dryer an atomized spray of a mixture of lime slurry and recycled solids is brought into contact with the hot flue gas The water in the slurry evaporates leaving dry reaction products and flyash which drops out of the scrubber A particulate control device such as a baghouse is also used to remove the rest of the dry products from the flue gas before releasing it The SO removal efficiency is the total of SO removed in the scrubber and the baghouse Many lime spray dryer input parameters are similar to those defined above for wet lime limestone systems Each parameter is described briefly below Actual SO Removal Efficiency This is the annual average S
401. ion Overall Plant Constraints Inputs The Constraints input parameters define the emission constraints as they apply to the gases emitted from the power plant 5 15 x File Edit View Go Window Help ioix Configure Plant Set Parameters Get Results NOx TSP 502 CO2 By Prod Control Control Control Capture Mgmt Mercury Title Units Unc Value pass osoo Nitrogen Oxide Emission Constraint 1b MBtu 0 1500 Particulate Emission Constraint 1b MBtu 3 000e02 Total Mercury Removal Efficiency 70 00 Total CO2 Removal Efficiency 90 00 z t P le olo Process Type Joverall Plant z 3 Constraints F O amp M Cost 6 Emis Taxes Overall Plant Emission Constraints input screen This screen accepts input for the allowable emission limits for sulfur dioxide nitrogen oxides and particulate matter Mercury and carbon dioxide are constrained by their removal efficiencies across the entire plant The default values for the calculated inputs reflect current United States New Source Performance Standards NSPS which are applicable to all units constructed since 1978 SO emission limits are based on the NSPS limits that are a function of the sulfur content of the coal The emission constraints determine the removal efficiencies of control systems for SO2 NO and particulate matter required to comply with the specified emission constraints As discu
402. ions in dollars per ton The final costs determined from these inputs are available under the stack tab in the results section of the IECM The costs are added to the overall plant cost not a particular technology Integrated Environmental Control Model User Manual Combustion Overall Plant 33 Tax on Emissions Sulfur Dioxide S02 The user may enter a cost to the plant of emitting sulfur dioxide in dollars per ton Nitrogen Oxide equiv NO The user may enter a cost to the plant of emitting nitrogen oxide in dollars per ton Carbon Dioxide CO2 The user may enter a cost to the plant of emitting carbon dioxide in dollars per ton Combustion Overall Plant Performance Results 7 IECH Interface 34 e Combustion Overall Plant File Edit View Go Window Help Configure Plant Set Parameters Get Results Performance Parameter Plant Energy Requirements Net Electrical Output MW 331 8 Gross Electrical Output MWg 500 0 Aux Power Produced MW 0 0 Primary Fuel Power Input MBtu ht 4419 Aux Fuel Power Input Btushs 0 0 Boiler Use MW 29 25 Total Plant Power Input MBtu hr 4419 Hot Side SCR Use MW 2 721 Gross Plant Heat Rate HHY Btu kWh 8838 Cold Side ESP Use MW 0 9125 Net Plant Heat Rate HHV Btu kWh 1 332e 04 Wet FGD Use MW 14 02 Activated Carbon Inj Use MW 5 839e 02 Annual Operating Hours hours 6575 Amine Scrubber Use MW 121 2 Annual Power Generation BkWhiy 2 181 zs t Eel
403. ions monitoring system CEMS upgrade The direct capital cost is determined by the net electrical output of the power plant Pulse Jet Fabric Filter This capital costs area represents an upgrade to an existing cold side ESP where one section at the back end of the unit is replaced with a pulse jet fabric filter This can be considered a pseudo COHPAC Equipment includes pulse jet FF filter bags ductwork dampers and MCCs instrumentation and PLC controls for baghouse operation Equipment excludes ash removal system power distribution and power supply and distributed control system The direct capital cost is a function of the flue gas flow rate and the air to cloth ratio of the fabric filter NOTE The IECM currently does not support multiple particulate devices in the same configuration nor a modified cold side ESP 180 e Mercury Integrated Environmental Control Model User Manual Mercury Capital Cost Inputs This screen is only available for the Combustion Boiler plant type Inputs for the capital costs of the activated carbon and water injection system are entered on the Capital Cost input screen File Edit View Go Window Help D Untitled Ox Configure Plant Set Parameters Get Results ry coz k s02 Base Plant Control Title 10 00 General Facilities Capital i 20 00 Engineering amp Home Office Fees ji A 20 00 Project Contingency Cost i 100 0 Process Contingency Cost i 100 0 Royalty Fees A H
404. ions result screen The Solids In Out result screen displays the values for the flow of the solid components in the gas and condensed streams throughout the various stages of the power plant Each result is described briefly below Note that each column Integrated Environmental Control Model User Manual Combustion Overall Plant 37 38 e Combustion Overall Plant represents the flow rate at the exit of the technology specified at the top of the column Note that the solids are not reported in this detail inside the technology result screens Solid Components Ash Total mass of ash primarily solid oxides Lime CaO Total mass flow of lime This is typically added as a reagent and will react with the flue gas to form another compound Limestone CaCOs Total mass flow of limestone This is typically added as a reagent and will react with the flue gas to form another compound Calcium Sulfite CaSO 2H2O Total mass flow of calcium sulfite a byproduct of lime or limestone reacting with sulfur in the flue gas Gypsum CaSO 2H 0 Total mass flow of gypsum a byproduct of lime or limestone reacting with sulfur in the flue gas Calcium Sulfate CaSO Total mass flow of calcium sulfate a byproduct of lime or limestone reacting with sulfur in the flue gas Calcium Chloride CaCl Total mass flow of calcium sulfate a byproduct of lime or limestone reacting with chlorine or chlorine compounds in the flue gas Miscellaneous
405. irect capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Each Capital Cost Process Area is described briefly below Integrated Environmental Control Model User Manual Capital Cost Process Area High Temperature Reactor This area accounts for the high temperature reactor vessel used for water gas shift The iron based catalyst is designed to be effective at high temperatures 650 1100 F The high temperature reactor has a high reaction rate and converts a large amount of CO into CO Low Temperature Reactor This area accounts for the low temperature reactor vessel used for water gas shift The copper based catalyst is designed to be effective at lower temperatures 450 650 F The low temperature reactor has a lower reaction rate but converts a very high percentage of the remaining CO into CO Heat Exchangers The water gas shift process involves substantial cooling because of the exothermic reaction Heat is recovered and temperature control is maintained through heat exchangers added after each reactor This proce
406. ired removal to meet the mercury emission constraint Fabric Filter Fabric Filter total w o control Mercury present in ash is removed from the fabric filter through the removal of captured fly ash The speciation is not known so the removal is specified as a total removal The value shown is determined without regard to particular mercury control methods It has a substantial effect on the amount of activated carbon needed to meet the required removal of mercury Fabric Filter oxidized The fabric filter typically removes some mercury without adding a specific mercury control technology This mercury is present in the ash and is removed with the collected ash When a mercury control technology is added the removal is enhanced The default value is set to meet the overall removal efficiency constraint with consideration given to the mercury removed by flue gas desulfurization and elemental mercury oxidized in a NO control technology The lower limit is set by the removal efficiency of ash alone as specified by Fabric Filter total w o control specified above Fabric Filter elemental Elemental mercury is assumed to be removed with the same efficiency as the removal of oxidized mercury specified above Cold Side ESP Cold Side ESP total w o control Mercury present in ash is removed from the cold side ESP through the removal of captured fly ash The speciation is not known so the removal is specified as a total removal
407. is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Air Cooled Condenser Total Cost Results 32 e Water Systems This screen is available for all plant types The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Air Cooled Condenser technology 7 JECM Interface Fie Edit view Go Window Help Us Untitled Configure Plant Set Parameters Get Results z ton S02 Cost Component M yr MWh Tie Percent Total 1 Annual Fixed Cost J 2 636 0 8579 4 11 18 2 Annual Variable Cost 3 388 1 103 j 14 37 3 4 Annualized Capital Cost 17 55 5 713 i 74 45 Costs are in Constant 2007 dollars Air Cooled Condenser Total Cost Result Screen Cost Component
408. is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Wet FGD Total Cost Results This screen is only available for the Combustion Boiler plant type The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the SO control technology The result categories are the same for both the Wet FGD and the Lime Spray Dryer 240 Wet FGD Integrated Environmental Control Model User Manual File Edit View Go Window Help Configure Plant Set Parameters Get Results CO2 By Prod Capture Mgmt Stack Cost Component Percent Total ae eloj Annual Fixed Cost i i i 25 04 Annual Variable Cost 2 29 13 lig Annualized Capital Cost 45 84 Ze tt Process Type Wet FGD z Costs are in Constant 2005 dollars 4 CopitalCont A 06MCost ERA Wet FGD Total Cost result screen Cost Component Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly bel
409. is the flow of the CO from the pipeline into the storage site in actual cubic feet per minute CO Transport System Flue Gas Results 362 e CO2 Transport System This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECM Interface F loj xj File Edit View Go Window Help US Untitled Configure Plant Set Parameters Flue Gas Out h moles hr Nitrogen N2 0 0 Oxygen 02 0 0 Water Vapor H20 0 0 Carbon Dioxide COZ 1 843e 04 Carbon Monoxide CO i 0 0 0 0 Hydrochloric Acid HCD i 5 358 9 768e 02 9 768e 02 Sulfur Dioxide 502 213 1 6 825 6 825 Sulfuric Acid equivalent 303 j 0 8592 3 439e 02 3 439e 02 Nitric Oxide NO y i 0 0 0 0 Nitrogen Dioxide NO2 i j 1 562e 02 1 562e 02 1 lanmori i oo foo oo Argon Af o il 0 0 0 0 Blo S amp P e lt omelo Process Type coz Transport 2 Flue Gas Z CapitalCost 4 0 amp MCost 5 TotalCost CO Transport System Flue Gas result screen Major Flue Gas Components Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid
410. is used primarily to calculate capital costs The value must be an integer Number of Spare Trains This is the total number of spare trains It is used primarily to calculate capital costs The value must be an integer Thermal Energy Credit The Water Gas Shift reaction is an exothermic process producing heat that can be extracted and converted to steam for use in generating electricity This is the thermal energy credit for steam produced and used in the steam cycle Water Gas Shift Reactor Retrofit Cost Inputs 320 e Water Gas Shift Reactor 7 IECH Interface ioj xi Fie Edit View Go Window Help Configure Plant Set Parameters Get Results c02 Power BRE By Prod O Mgmt paste Capture Capital Cost Process Area High Temperature Reactor retro new Low Temperature Reactor _ retro new i Heat Exchangers retro new aP le aloo Zj tt bt pmt Opet pet pet pe ee at EEA d a ad kal bal kad adia 18 Process Type fi Water Gas Shift Reactor EN 2 Capital Cost 4 O amp M Cost Water Gas Shift Reactor Retrofit Cost input screen The retrofit cost factor of each process is is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital cost directly and the operating and maintenance costs indirectly D
411. isplayed in different units Changing the units in which results are displayed using the Result Tools floating palette is described in Getting Started This section will describe the various unit settings in detail Result Tools Untitled Result Type Deterministic Units Unit System Engin O Time Period Defaut gt Perf Table Default z Cost Table MSCap MSyr O amp M X Revenue Cost Year fse t it s sSS Inflation Ctrl Constant k The Result Tools floating palette Integrated Environmental Control Model User Manual Units 391 Result Type The Result Type option determines the type of values displayed in the result tables The choices available are Deterministic Mean Median 50th percentile 2 5 percentile 97 5 percentile and Standard Deviation The default setting is Deterministic Unit System The Unit System option determines the unit system in which result values are displayed The choices available are English and Metric The default setting is English Time Period The Time Period option determines the time period for which result values are displayed The choices available are Default Max Hourly and Annual Avg The default setting is Default Performance Table The Perf Table option determines the units in which values are displayed on performance result screens The choices available are Default Total mass k Wh and mass Btu in The default setting is Default NOTE The
412. it Separation Major Gas Components ap Air In b moles ftr tom hr m 2 Hydrogen H3 3 Methane CH9 Ethane C2H6 Propane C3H8 Hydrogen Sulfide H2S Carbonyl Sulfide COS Ammonia NH3 Hydrochloric Acid HCN 10 Carbon Dioxide CO2 11 Water Vapor H20 12 Nitrogen N2 13 Argon An 14 Oxygen 02 15 Process Type 4 Claus Plant M 2 Treated Gas Sulfur Removal Claus Plant Air results screen Major Syngas Components Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H2 Total mass of hydrogen Methane CH Total mass of methane Ethane C2He Total mass of ethane Propane C3Hg Total mass of propane Integrated Environmental Control Model User Manual Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbonyl sulfide Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of hydrochloric acid Carbon Dioxide CO2 Total mass of carbon dioxide Water Vapor H20 Total mass of water vapor Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Oxygen O2 Total mass of oxygen Total Total of the individual components listed above This item is highlighted in yellow Sulfur Removal Claus Plant Treated Gas Results 7 IECM Interface Eile Edit Yiew Window Help Configure Plant Set Parameters Get Results By Prod Mgmt Air Sulfur Separation Faaora CO2 Ca
413. ital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra m
414. ith the emission constraints specified in this screen Each parameter is described briefly below Total CO Removal Constraint The emission constraint applies to all the air emission sources in the power plant primary or secondary The default value is based on recent discussions and is not based on any currently enforced law Overall NGCC Plant Financing Inputs Inputs for the financing costs of the base plant itself are entered on the Financing input screen Integrated Environmental Control Model User Manual Overall NGCC Plant e 45 46 e Overall NGCC Plant 7 IECH Interface File Edit View Go Window Help US Untitled Configure Plant Set Parameters Get Results By Prod Power Block NOx Control CO Mgmt Or specify all the following Inflation Rate Plant or Project Book Life Real Bond Interest Rate Real Preferred Stock Retum Real Common Stock Retum Percent Debt Percent Equity Preferred Stock Percent Equity Common Stock zis t mel eloelo Federal Tax Rate State Tax Rate Property Tax Rate Investment Tax Credit Process Type Overall Plant 4 Financing JETT Overall NGCC Plant Financing input screen This screen describes the factors required to determine the carrying charge for all capital investments The carrying charge is defined as the revenue required for the capital investment The total charge can also be expr
415. ithin the tower it is necessary to blow down a portion of the water that depends on the cycle of concentration and evaporation loss Drift Loss A relatively small amount of entrained water lost as fine droplets in the air discharge from a tower which is frequently referred to as tower drift loss Basin Sludge This output specifies the amount of the basin sludge of the cooling tower system That is an intermittent waste stream that contains collected soil dust and suspended solids in the tower basin Wet Cooling Tower Cooling Water Diagram This screen is available when the wet cooling tower is loaded Integrated Environmental Control Model User Manual Water Systems e 15 7 IECM Interface 6 2 File Edit View Go Window Help a Untitled Configure Plant Set Parameters e e o Steam Cycle tons h 5 54864 Total Cooling tons ht 548e 4 R Qo CO2 Control Process Tee OTTE 1 Diagram Wet Cooling Tower Cooling Water Result Screen Each result is described briefly below Total Cooling This variable presents the amount of cooling water through the main steam cycle plus auxiliary cooling Steam Cycle This variable presents the amount of cooling water through the main steam cycle Wet Cooling Tower Capital Cost Results This screen is available for all plant types The Capital Cost result screen displays tables for the direct and indirect capital costs related to the Wet Cooling To
416. l 2 000 Pre Production Costs Fixed Operating Cost 1 000 Variable Operating Cost 1 000 Misc Capital Cost 2 000 zis lt me aeoo Inventory Capital 0 5000 TCR Recovery Factor 100 0 Activated Carbon Inj 1 Removal Eff 2 Carbon Inj 3 Retrofit Cost 4 Capital Cost 5 0 amp M Cost Mercury Capital Cost input screen The necessary capital cost input parameters associated with the base plant are on this input screen The capital cost parameters and terminology used in the IECM are based on the methodologies developed by the Electric Power Research Institute EPRI They have prepared a Technical Assessment Guide TAG in order to provide a consistent basis for reporting cost and revenues associated with the electric power industry This system of reporting is used by a wide audience including energy engineers researchers planners and managers The IECM has been developed around this TAG system so that costs associated with various technologies can be compared directly on a consistent basis and communicated in the language used by the audience listed above Total Plant Cost TPC is the sum of the process facilities capital general facilities capital engineering and home office fees and the contingencies project and process This is considered the cost on an instantaneous basis overnight and expressed in December dollars of a reference
417. l Model User Manual Hot Side SCR O amp M Cost result screen The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the Hot Side SCR NO control technology O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Catalyst Replacement catalyst cost per year for the hot side SCR This is a function of the number of catalyst layers the number of layers replaced each year and the catalyst space velocity all three are performance input parameters Ammonia Ammonia reagent cost per year for the hot side SCR This is a function of the concentration of NO in the flue gas and the ammonia mass flow rate Steam Annual cost of steam used for ammonia vaporization and ammonia injection This is a function of the steam to ammonia ratio performance input parameter and the ammonia mass flow rate Water Cost of water used to wash ammonia that deposits in the air preheater This is a function of the efficiency and concentration of ammonia removed by wash water performance input parameters and the amount of ammo
418. l User Manual Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Wet FGD Capital Cost Results This screen is only available for the Combustion Boiler plant type The Capital Cost result screen displays tables for the direct and indirect capital costs related to the SO control technology File Edit View Go Window Help Configure Plant Set Parameters Get Results 02 CO2 By Prod Control Capture Mgmt Stack Wet FGD Process Area Costs ea Wet FGD Plant Costs een Ms Reagent Feed System 8 163 302 Removal System 20 72 Flue Gas System 8 553 Solids Handling System 8 228 General Support Area 0 6223 Miscellaneous Equipment 1 805 General Facilities Capital 4 809 Eng amp Home Office Fees 4 809 Project Contingency Cost 7 214 Process Contingency Cost 0 9618 Interest Charges AFUDC 3 393 Royalty Fees 0 2405 Preproduction Startup Cost 2 439 Inventory Working Capital 0 3321 uk WN AA ne wn zs t Ele aleo aje Kika 15 Bete TCR oa Process Type wet FGD z Costs are in Constant 2005 dollars 2 Flue Gas 4 Capital Cost 5 O amp M Cost 6 Total Cost Wet FGD Capital Cost result screen Capital costs are typically expressed in either constant or current dollars for a specified
419. l by weight on an elemental Cl and wet basis Sulfur The sulfur content of the coal by weight on an elemental S and wet basis Integrated Environmental Control Model User Manual Nitrogen The nitrogen content of the coal by weight on an elemental N and wet basis Ash The ash content of the coal by weight on a wet basis Moisture The inherent moisture content of the coal by weight Trace Element Flows Trace elements are now supported in the IECM The mass flow rate is reported in units of pounds per unit of time All values reflect the elemental mass flow rate Mercury This is the elemental mercury flow rate in coal At present mercury is not tracked in the IGCC plant type and is displayed as a zero value Fuel Natural Gas Diagram z Em interface Eile Edit View Window Help Configure Plant Set Parameters Get Results By Prod Power Block NOx Control Memt Gas Flow Rate ton hr 74 37 aje e o e o o ma we ES lt P Heating Value Btu lb 2 276e 04 Methane CHG vol 83 40 Ethane C2H6 vol 15 80 Propane C3H8 vol 0 0 Carbon Dioxide COZ vol 0 0 Oxygen 02 vol 0 0 Nitrogen ND vol 0 8000 Hydrogen Sulfide H25 0 0 Process Type Natural Gas Properties 1 Diagram Fuel Diagram result screen for natural gas The Natural Gas Diagram result screen displays fuel composition and flow rate information which is described briefly below Gas Flow Rate Th
420. l cost This is an overhead fee paid to Integrated Environmental Control Model User Manual Water Gas Shift Reactor 321 the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment
421. l efficiency below Note that the removal is not a function of the NO emission constraint This input is highlighted in blue Maximum NOx Removal Efficiency The maximum removal efficiency of NO sets the upper bound for the actual NO removal efficiency above The maximum removal is a function of the In Furnace control type and the boiler type Natural Gas Heat Input This input will only display if Gas Reburn is selected in the In Furnace Controls pull down menu The flow rate of natural gas injected is determined by this input on a Btu heat input basis SNCR NO Control These inputs will only display if SNCR or LNB amp SNCR is selected in the In Furnace Controls pull down menu 144 In Furnace Controls Integrated Environmental Control Model User Manual Actual NOx Removal Efficiency The actual NO removal efficiency is a function of the maximum NO removal efficiency below and the NO emission constraint This input is highlighted in blue Maximum NOx Removal Efficiency The maximum removal efficiency is calculated as a function of the gross electrical output Because of difficulty mixing the reagent in the flue gas for larger boilers the maximum efficiency decreases with increasing plant size Urea Concentration Injected Urea is typically injected as a liquid diluted by water This parameter defines the amount of water used to dilute the urea prior to injection SNCR Power Requirement As mentioned above the pow
422. l methods O 2 CQO2 Recycle Diagram This screen is available for Combustion Boiler plant types 7 IECH Interface Fie Edit View Go Window Help DA Untitled D Configure Plant Set Parameters 3 a Temperature F 4000 Temperature Out F 400 0 Flue Gas Flow acfm 3 938e 05 Flue Gas Out acfm 3 467e 04 Fly Ash Flow tons h 2 200e 02 Fly Ash Out tons hr 9 427e 03 tated El Direct Contact Cooler Temperature In F 142 3 gt Flue Gas In acfm 7 236e 05 Fly Ash In tons hr 6 285e 02 K pte Condensed Water as Prod Pressure psia Condensed Water wae 46 8 SE to Storage tons h Process Type Z FG Recycle amp Purification amp Purification 1 Diagram 2 DCC Gas 4CapitalCost 5 O amp MCost 6 TotalCost 7Misc A O2 CO 2 Recycle Flue Gas Diagram Recycled Flue Gas Temperature The temperature of the Recycled Flue Gas from the direct contact cooler Flue Gas Flow The mass flow rate of the Recycled Flue Gas from the direct contact cooler Fly Ash Flow The mass flow rate of fly ash in the Recycled Flue Gas from the direct contact cooler Direct Contact Cooler Temperature In The temperature of the flue gas to be recycled entering the direct contact cooler Integrated Environmental Control Model User Manual O2 CO2 Recycle e 293 Flue Gas In The mass flow rate of the flue gas to be recycled entering the direct contact cooler Fly Ash In The m
423. l the uncertainties of the entire set of input variables The value m is referred to as the sample size The model contains two variations of Latin Hypercube sampling Random and Median Random Latin Hypercube RLH samples each strata randomly while the Median Latin Hypercube MLH samples each strata by its median value See Diwekar U M and J R Kalagnanam 1997 Efficient Sampling Technique for Optimization under Uncertainty AIChE Journal Vol 43 No 2 pp 440 7 Median Latin Hypercube is the default sampling method Both forms of Latin Hypercube have the advantage of sampling more uniformly over the input distributions relative to Monte Carlo sampling resulting in less noise in the final distribution Another advantage is the reduced number of samples that must be taken to satisfy a given precision Latin Hypercube has the drawback that the precision is more difficult to calculate using statistical methods Finally the output is random but not independent Hammersley A new sampling technique has been added to the IECM which is more efficient than either the Monte Carlo or Latin Hypercube sampling techniques It is called the Hammersley sequence sampling technique See Diwekar U M and J R Kalagnanam 1997 Efficient Sampling Technique for Optimization under Uncertainty AIChE Journal Vol 43 No 2 pp 440 7 The sampling method is loosely based on the Monte Carlo method However instead of using a random numb
424. late control technology based on the flue gas exit temperature and atmospheric pressure Fly Ash Out Total solids mass flow rate in the flue gas exiting the particulate control technology This is a function of the ash content of the inlet flue gas and the ash removal efficiency performance input parameter Mercury Out Total mass of mercury exiting the particulate control technology The value is a sum of all the forms of mercury elemental oxidized and particulate Fabric Filter Performance Ash Removal Ash removal efficiency of the fabric filter technology This is a function of the ash emission constraint and the inlet ash mass flow rate SO3 Removal Percent of SO in the flue gas removed from the particulate control technology The SO is assumed to combine with H O and leave with the ash solids as a sulfate in the form of H2SO3 Mercury Removal Percent of the total mercury removed from the particulate control technology The value reflects a weighted average based on the particular species of mercury present elemental oxidized and particulate Collected Fly Ash Dry Ash Total mass flow rate of the solids removed from the fabric filter This is a function of the solids content in the flue gas and the particulate removal efficiency of the fabric filter The value is given on a dry basis Sluice Water Water added to the dry fly ash This water is added for transportation purposes Wet Ash Total mass flow rate o
425. lated parameters The combined effect of all uncertain parameters is then calculated This chapter describes again how to specify input probability distributions and how to set several additional parameters needed to conduct a probabilistic analysis Even after probabilistic values have been set you do not have to use them Probabilistic analysis can be turned on or off individually for technologies or input types or all at once Turning the probabilistic calculations on and off for particular portions of the plant allows you to evaluate the major sources of uncertainty Uncertainty Distributions The entry of uncertainty distributions is covered briefly in Getting Started This section gives a more detailed description of the process Uncertainty Parameters Each uncertainty distribution requires one or more parameters The table below lists the parameters and numerical value limits required for each distribution type Function operator frin or mean frode frar or saov Normal Half t x gt 0 N A x gt 0 normal s x N A x gt 0 LogNormal x gt 0 N A x gt 1 x gt 0 N A x gt 1 Uniform i x gt 0 N A x gt 0 een Triangular x x gt 0 x gt 0 x gt 0 ice SA a a a Fractiles x gt 0 N A N A aa La a A Integrated Environmental Control Model User Manual Running a Probabilistic Analysis 401 Distribution Types Several types of probability distributions are provided with the IECM Brief descriptions of each uncertai
426. lay flows and costs related to the particulate control technology These screens are available only if the Cold Side ESP TSP control technology is selected in the Combustion Boiler plant type configurations Cold Side ESP Performance Inputs This screen is only available for the Combustion Boiler plant type Inputs for the performance of the Cold Side ESP TSP control technology are entered on the Performance input screen Many of the parameters are calculated by the IECM Each parameter is described briefly below 11x File Edit Yiew Window Help Emission Base Plant Constraint Percent Water in ESP Discharge 0 0 A 0 0 100 0 calc Cold Side ESP Power Requirement A 0 0 10 00 calc Cold Side ESP 1 Performance 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Cold Side ESP Performance input screen ESPs consist of a series of parallel plates with rows of electrodes in between them and carry a high voltage of opposite polarity As the particle laden flue gas enters the unit the particles are charged by the electrodes and is attracted to the plates At controlled intervals the plates are rapped which shakes the dust to a hopper below However some of the dust is re entrained and carried to the next zone or out of the Integrated Environmental Control Model User Manual Cold Side ESP e 193 stack Most ESPs use rigid collecting plates with shielded air pockets
427. layed in the text box titled Source the Save in Database button will be grayed out not active Activate the Save in Database by opening another database or creating a new database Deleting a Fuel A fuel that is displayed in the Fuel Databases pane may be deleted using the Delete this Fuel button if it is not a model default fuel Fuels in the model default database model_default_fuels mdb cannot be deleted Open Database Press the Open Database button on the Fuels Database pane and the Windows Open Screen will appear A valid fuel database file as an fdb extension Click on the database file to open and press the Open button The Fuels Database displays the first fuel in the selected database and the Source text box displays the full path and file name of the database that has just been opened LL 2x Lookin Sreten ssid VK Debug a test3 fdb intdb Release res a test fdb a test2 Fdb File name Files of type IECM Fuel Database fdb z Cancel I Open as read only Fuels Windows Open screen New Database Press the New Database button on the Fuels Database pane and the Windows Save As Screen will appear Type in the name of the new database file into the File name text box All fuel database files have an fdb extension Press the Save button The Source text box displays the full path and file name of the new database and all other fuel values in the Fuels Database pane will be blank Integ
428. layers Layers Replaced Yearly Average catalyst layer replacement rate per year This assumes that all catalyst layers are of equal depth Flue Gas Entering SCR Temperature In Temperature of the flue gas entering the SCR This is determined by the flue gas outlet temperature of the module upstream of the SCR e g the boiler economizer Flue Gas In Volumetric flow rate of flue gas entering the SCR based on the flue gas temperature entering the SCR and atmospheric pressure Fly Ash In Total solids mass flow rate in the flue gas entering the SCR This is determined by the solids exiting from the module upstream of the SCR e g the boiler economizer Mercury In Total mass of mercury entering the hot side SCR in the flue gas The value is a sum of all the forms of mercury elemental oxidized and particulate Flue Gas Exiting SCR Temperature Out Temperature of the flue gas exiting the SCR The model currently does not alter this temperature through the SCR Flue Gas Out Volumetric flow rate of the flue gas exiting the SCR based on the flue gas temperature exiting the SCR and atmospheric pressure Fly Ash Out Total solids mass flow rate in the flue gas exiting the SCR This is a function of the ash removal parameter on the SCR performance input screen Ammonia Slip Total mass flow rate of ammonia that is unreacted and exits the SCR in the flue gas stream This is a function if the ammonia injection flow rate NO conc
429. lculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens Each Capital Cost Process Area is described briefly below Steam Generator This area accounts for the steam cycle equipment and pumps Turbine Island This area accounts for the turbine island and associated pumps Coal Handling This area accounts for the mechanical collection and transport equipment of coal in the plant Ash Handling This area accounts for the mechanical collection and transport of ash in the plant Water Treatment This area accounts for the pumps tanks and transport equipment used for water treatment Auxiliaries Any miscellaneous auxiliary equipment is treated in
430. le Capital Cost Process Area retro new retro new retro new Heat Exchangers retro new Circulation Pumps retro new Sorbent Regenerator retro new Reboiler retro new Steam Extractor retro new Zis lt a me e aeo Sorbent Reclaimer Sorbent Processing retro new retro new CO2 Drying and Compression Unit retro new Auxiliary Natural Gas Boiler retro new Auxiliary Steam Turbine retro new Process Type Amine System 1 Config 4 CO2 Storage BRE 6 CapitalCost 7 O amp M Cost Integrated Environmental Control Model User Manual Amine System 267 268 e Amine System Amine System Retrofit Cost input screen Capital Cost Process Area The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process
431. le Edit View Go Window Help B Configure Plant Set Parameters Get Results Power Block rete Stack 3 oy Variable Cost Component Fixed Cost Component e 1 High Temperature Catalyst _1 Operating Labor El 2 Low Temperature Catalyst 2 Maintenance Labor 3 Electricity 3 Maintenance Material 4 Thermal Power Credit 4 Admin amp Support Labor III 5 wae C5 Taara _ q 6 Totavariatiecosts f ss 6 7 iff k 8 8 eami T 9 p 10 i Water Gas Shift Reactor O amp M Cost result screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Variable Cost Component High Temperature Catalyst Cost This is the replacement cost of the iron based high temperature catalyst The initial cost is not included in this parameter Low Temperature Catalyst Cost This is the replacement cost of the copper based low temperature catalyst The initial cost is not included in this parameter Electricity The cost of electricity consumed by the water gas shift process areas Thermal Power Credit The credit for thermal power generated from steam provided by the heat exchangers in the water shift reactor vessels Water Cost This is total cost of water used to drive the water gas shift reaction Total Variable Costs This is the sum of all of the variable O amp M cost
432. le Edit View Window Help Configure Plant Set Parameters Get Results Air R By Prod Separation i Major S c ts SeS T jor Syngas Componeni Qh molesa yes 1 Carbon Monoxide CO 918 4 918 4 12 86 2 Hydrogen HD 3 177e 04 3 177e 04 32 09 3 Methane CH9 135 2 135 2 1 084 4 Ethane C2H6 i 0 0 5 Propane C3H8 i 0 0 6 8 Syngas In ton hr ale le o P e zje Hydrogen Sulfide H25 4 746e 03 4 746e 03 Carbonyl Sulfide COS E a 0 2848 0 2848 Ammonia NH3 2 722e 02 2 722e 02 9 Hydrochloric Acid HC i 0 0 0 0 10 Carbon Dioxide CO2 49 37 49 37 11 Water Vapor H20 1 766e 04 59 82 159 1 12 Nitrogen N2 352 5 4 937 4 937 13 Argon Ad 14 Oxygen 02 ds Toa Aae 5351e 04 1688 2681 Process Type Power Block ns Power Block Syngas result screen Major Syngas Components Carbon Monoxide CO Flow rate of carbon monoxide in the syngas Hydrogen H2 Flow rate of hydrogen in the syngas Methane CH Flow rate of methane in the syngas Ethane C2He Flow rate of ethane in the syngas Propane C3Hs Flow rate of propane in the syngas Hydrogen Sulfide H2S Flow rate of hydrogen sulfide in the syngas Carbonyl Sulfide COS Flow rate of carbon sulfide in the syngas Ammonia NH3 Flow rate of ammonia in the syngas Hydrochloric Acid HCI Flow rate of hydrochloric acid in the syngas Carbon Dioxide CO3 Flow rate of carbo
433. le portion of the CO2 Control technology Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow O CO2 Recycle Miscellaneous Results This screen is available for Combustion Boiler plant types 300 O2 CO2 Recycle Integrated Environmental Control Model User Manual 7 ECM Interface File Edit View Go Window Help US Untitled alej e Eje E Net Plant Size MW 334 5 Capture Plant Configure Plant Set Parameters Get Results TSP Mercury Control
434. lighted in yellow Hot Side SCR Capital Cost Results This screen is only available for the Combustion Boiler plant type File Edit View Go Window Help Configure Plant Set Parameters Get Results 502 co2 By Prod TSP Control Control Capture Mgmt Stack SCR Plant Costs P melolo a Eg it Z e E Ammonia Injection 2 General Facilities Capital 2 045 Ducts ee 3 Eng amp Home Office Fees 2045 Air Preheater Modifications 4 Project Contingency Cost 2 045 ID Fan Differential B Process Contingency Cost 4 009 Structural Support ji 6 Interest Charges AFUDC 1 421 Misc Equipment 7 Royalty Fees 0 0 8 9 Initial Catalyst Preproduction Startup Cost 0 9104 Inventory Working Capital 0 1380 Hot Side SCR Capital Cost result screen The Capital Cost result screen displays tables for the direct and indirect capital costs related to the Hot Side SCR NO control technology Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Direct Capital Costs Each process area direct capital cost is a reduced form model based on regression analysis of data collected from several reports and analyses of hot side SCR units They are described in general with specific model parameters that effect them described in particular
435. located to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Power Block Gas Turbine Diagram This screen is only available for the Combustion Turbine and IGCC plant types y IECM Interface File Edit Yiew Window Help Us Untitled Configure Plant Set Parameters Temperature In CF Temperature Out CF Air In tonshr Flue Gas Out ton hr Heated Syngas Temperature In CF Pressure In psia Syngas In ton hr ale le jo e 9 o lt E Turbine Syngas Temperature In CF Pressure In psia Syngas In ton hr i Power Block Z 1 GT Diagram 2 5T Diagram 3 Syngas 4 Flue Gas 5 Capital Cost 6 0 amp M Cost 7 Total Cost Power Block Gas Turbine Diagram result screen 380 e Power Block Integrated Environmental Control Model User Manual Air Entering Compressor Temperature In Temperature of the atmospheric air entering the air compressor Air In Volumetric flow rate of the air entering the air compressor Syngas Entering Combustor Temperature In Temperature of the syngas entering the fuel heater and saturator Pressure In This is the pressure of the synas as it enters the fuel heater and saturator Syngas In This is the mass flow rate of the syngas to the fuel heater and saturator Heated Syngas Entering Combustor Temperat
436. lt is highlighted in yellow Effective TCR The TCR of the spray dryer that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor Integrated Environmental Control Model User Manual Amine System O amp M Cost Results This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECM Interface O x File Edit View Go Window Help Air Preheater Variable Cost Component EREN Fixed Cost Component d Operating Labor Maintenance Labor Maintenance Material Admin amp Support Labor 44 64 Natural Gas 0 0 Corrosion Inhibitor 8 929 Activated Carbon 0 2652 Caustic NaOH 0 2172 Reclaimer Waste Disposal 13 26 Electricity 16 29 Auxiliary Power Credit 0 0 Steam elec equiv 20 53 Water 6 683e 02 CO2 Transport 6 082 CO2 Storage 14 46 L Process Type Amine System x Costs are in Constant 2005 dollars 4 Capital Cost ROMER _ Total Cost Amine System O amp M Cost result screen The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the CO Capture technology O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below V
437. lt screen The Selexol CO Capture Diagram result screen displays an icon for the Selexol CO capture unit and values for major flows in and out of it Each result is described briefly below Temperature In Temperature of the syngas entering the CO absorber unit Syngas In Flow rate of the syngas entering the CO absorber unit Solvent Makeup Flow rate of the Selexol solvent added to the regenerator Temperature Out Temperature of the syngas exiting the CO absorber unit Syngas Out Flow rate of the syngas exiting the CO absorber unit CO Product Flow rate of the CO product exiting the regenerator CO Syngas Pressure CO product pressure entering the pipeline Integrated Environmental Control Model User Manual Selexol CO Capture Syngas Results This screen is only available for the IGCC plant type lolx File Edit Yiew Window Help Us Untitled Configure Plant Set Parameters Get Results Air Sulfur co2 Power Block prs d gmt Overall Plant Separation Removal Capture SyngasIn Syngas Out SyngasIn Syngas Out pA OGEE SS h moles kx h moles hr owe ton kr 1 318 4 918 4 1286 1286 2 Hydrogen HD 3 177e 04 3 177e 04 32 09 32 09 3 Methane CHS 1352 1352 1 084 1 084 4 Ethane C2H6 oo o0 0 0 0 0 5 Propane C3H3 oao o o0 0 0 6 Hydrogen Sulfide H25 0 2785 0 2785 4746e 03 4 7460 03 7 Carbonyl Sulfide COS 3 484 9484 0 2848 0 2848 8 Ammonia NHI 3196 3196
438. lt the graphing help file for more detailed descriptions of the graph option buttons The graphing help file is distributed with the IECM software and is accessible from the graph control window see the help button on the lower right of the figure above NOTE Right clicking the graph window will also open the graph control window Importing and Exporting Graphs If a graph window is active you may use the Windows copy function press Ctrl C to copy the graph to the clipboard Both the data and the graph will be placed on the clipboard at the same time Because the clipboard contains both data and graph information it is not certain in which format Windows will paste the graph into an application Windows may paste a Bitmap image a Windows Metafile image or a data list of x y values taken from the graph By default graphics programs will typically paste the graph information and word processing programs will paste the data information To determine how the graph will be pasted use the Paste As function in your target application to paste the graph 398 Working with Graphs Integrated Environmental Control Model User Manual Graph Control x Markers Trends Overlay Eror Bar Background Legend 2D Galley 3D Galley Style Data Titles Axis 30 Fonts Labels System About Printing Export Image Mono Compression D O Color Image Target O Landscape O Clipboard O Eull page File Print Sopy Expor
439. lue Gas Recycle Process Area Costs Boiler Modifications In case of a pre existing PC plant being retrofitted for CO capture the boiler must be modified to suit the new oxyfuel combustion system The cost for these modifications is estimated as a percentage of the cost of the boiler Flue Gas Recycle Fan The cost of the fan required for recycling part of the flue gas is scaled on the basis of the flow rate of the flue gas being recycled Integrated Environmental Control Model User Manual Flue Gas Recycle Ducts Additional ducting is necessary to recycle part of the flue gas in the oxyfuel combustion system The cost of this ducting is assumed to be a function of the flow rate of recycled flue gas Oxygen Heater In addition to the air preheater that exists in a conventional PC plant the oxyfuel combustion system includes an additional heat exchanger called the oxygen heater for better heat integration The cost of this heat exchanger is scaled on the basis of the gross plant size CO Purification System The cost of the CO purification system depends on the desired purity level of the CO product and the total CO product flow rate Direct Contact Cooler The cost of the flue gas cooler is scaled on the basis of the flow rate of the flue gas CO Compression System The multi stage compression unit with inter stage cooling and drying yields the final CO product at the specified pressure about 2000 psig that contains only a
440. m Microsoft A full list of the Microsoft Corporation files installed is provided in the INSTALLR TXT file located on the IECM compact disk CD Microsoft Data Access Components The use of Microsoft Access database files requires the installation of ODBC drivers and support files from Microsoft ODBC is a programming interface that enables applications to access data in database management systems that use Structured Query Language SQL as a data access standard The Microsoft MDAC package is included with the IECM installer program as delivered directly from Microsoft and delivers this important functionality Files are installed into the C Windows System32 directory Microsoft Visual Basic 4 0 Runtime The components of this package are installed from within the IECM installer as delivered by Microsoft They provide Microsoft Visual Basic support files and are Integrated Environmental Control Model User Manual Installing the Model 17 installed into the C Windows System32 directory and the C Program Files Common Microsoft directory Microsoft MFC 4 2 The components of this package are installed from within the IECM installer as delivered by Microsoft They are Microsoft Visual C support files delivered under the Microsoft Foundation Class libraries They are installed into the C Windows System32 directory Files Modified by Install Currently no user files are modified when the IECM software is
441. m the flue gas stream are entered on the Removal Eff input screen lolx Eile Edit Yiew Window Help 151 x Emission y NOx 502 CO2 By Prod Base Plant Constraint fikata Control Control Control Capture Mgmt Removal Efficiency of Mercury Furnace Removal total Spray Dryer oxidized Spray Dryer elemental Spray Dryer particulate Cold Side ESP total w o control Cold Side ESP oxidized Cold Side ESP elemental KRISSE Percent Increase in Speciation In furnace NOx oxidized SNCR oxidized Process Type Activated Carbon Inj Z EENE 2 Cavonin f 3 RetrofitCost 4 CapitalCost Mercury Removal Efficiency input screen Each parameter is described briefly below Integrated Environmental Control Model User Manual Mercury e 175 176 e Mercury Removal Efficiency of Mercury The removal of mercury for each control technology configured is given as a percent of the total entering the control technology The user is given the opportunity to specify the removal separately for each speciation type Control technologies not currently configured are hidden Furnace Removal total Mercury present in ash is removed from the furnace through the removal of bottom ash The speciation is not known so the removal is specified as a total removal The mercury removed in bottom ash is not credited toward the requ
442. maintenance costs screens It provides a consistent basis of reporting for a wider audience of users O amp M costs are expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen The costs are broken down into two categories variable and fixed Variable costs include the costs of reagents chemicals water and other materials consumed during plant operation Fixed costs are associated with labor and overhead charges All operating costs are subject to inflation The base plant considers a more detailed breakdown for the costs associated with the fuel Together they characterize the fuel costs Each parameter is described briefly below As Delivered Coal Cost This is the cost of the delivered coal in dollars per wet ton The value is calculated by the IECM from the particular regional coal selected It does not include any cleaning costs Waste Disposal Cost This is the bottom ash disposal cost for the base plant Water Use This is the water used by the base plant Water Cost This is the water cost as used for the base plant Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is defined as combustion boiler and an air preheater Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per e
443. marily to calculate capital costs The value must be an integer No of Spare CO Compressors This is the total number of spare CO compressors It is used primarily to calculate capital costs The value must be an integer Amine Scrubber Power Requirement This is the equivalent electrical output of thermal steam energy used for reheat plus the actual electrical power required for pumps and booster fans Amine System Capture Inputs 264 e Amine System This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECM Interface Eile Edit Yiew Window Help Configure Plant Sorbent Concentration wt Lean CO2 Loading mol CO2 mol sorb Nominal Sorbent Loss Ib ton CO2 Sorbent Oxidation Loss mol sorb mol acid Liquid to Gas Ratio ratio Ammonia Generation mol NH3 mol sorb alei G meoo kI Gas Phase Pressure Drop psia ID Fan Efficiency valaan aa Regenerator Regeneration Heat Requirement Btu lb CO2 Steam Heat Content Btu lb steam Solvent Pumping Head psia Pump Efficiency Percent Water in Reclaimer Waste Amine System PRIM 4 CO2Storage 5 Retrofit Cost 6 CapitalCost 2O amp MCost Amine System Capture input screen Absorber The absorber is the vessel where the flue gas makes contact with the MEA based sorbent and some of the CO from the flue gas is dissolved in the sorbent The
444. mass flow rate of lime limestone or limestone with dibasic acid injected into the scrubber This is a function of the SO removal efficiency the reagent purity and the reagent stoichiometric all performance input parameters The reagent is assumed to be dry Flue Gas Entering Dryer Temperature In Temperature of the flue gas entering the scrubber This is determined by the flue gas outlet temperature of the module upstream of the scrubber e g a particulate removal technology Flue Gas In Volumetric flow rate of flue gas entering the scrubber based on the flue gas temperature entering the scrubber and atmospheric pressure Fly Ash In Total solids mass flow rate in the flue gas entering the scrubber This is determined by the solids exiting from the module upstream of the scrubber e g a particulate removal technology Mercury In Total mass of mercury entering the scrubber The value is a sum of all the forms of mercury elemental oxidized and particulate Flue Gas Exiting Dryer Temperature Temperature of the flue gas immediately after exiting the scrubber This is a function of saturation temperature and the flue gas component concentrations This temperature is used to determine the flue gas bypass required Temperature Temperature of the flue gas immediately after exiting the induced draft fan This is a function of flue gas temperature exiting the scrubber the flue gas bypass and the temperature rise across ID f
445. mass of SO removed from the flue gas in the collector For more information see also e www netl doe gov publications proceedings 98 98fg hardman pdf e www netl doe gov publications proceedings 98 98fg rubin pdf Integrated Environmental Control Model User Manual Solids Loading Out This is the fabric filter output loading It is an average value based on typical fabric filter units The value is used to determine the particulate removal efficiency Number of Baghouse Units This is the number of baghouse units The value is based on the gross plant size The value must be an integer Each unit contains several compartments It is used to calculate the capital cost of the baghouse Number of Compartments per Unit This parameter specifies the average number of compartments used per baghouse unit It is used to calculate the capital cost of the baghouse Number of Bags per Compartment The number of individual bags per compartment is calculated by comparing the required bag surface area to the bag dimensions and the total number of compartments It is used to calculate the capital cost of the baghouse Bag Length Bag length generally fall into two size categories 30 36 ft or 20 22 ft in length It is based on the fabric filter type and used to calculate the capital cost of the baghouse Bag Diameter Bags are generally between 2 3 and 1 foot in diameter The value is based on the fabric filter type and used to calculate the capital
446. mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Integrated Environmental Control Model User Manual Gasifier 127 Gasifier Syngas Results 7 IEC Interface File Edit View Go Window Help ole Untitled Configure Plant Set Parameters Get Results Major Syngas Components 1583 04 Hydrogen H2 1 430e 04 Methane CH9 Ethane CH Propane C3H8 Hydrogen Sulfide H25 Carbonyl Sulfide COS Ammonia NH3 3 185e 02 Hydrochloric Acid HCN y 0 1061 Carbon Dioxide CO2 134 4 Water Vapor H20 37 07 Nitrogen ND 4 5 244 Argon At Oxygen 02 izis t mel le olo Gasifier Gas Flow result screen Major Syngas Components Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H2 Total mass of hydrogen Methane CH Total mass of methane Ethane C2He Total mass of ethane Propane C3Hs Total mass of propane Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbonyl sulfide Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of hydrochloric acid Carbon Dioxide CO3 Total mass of carbon dioxide Water Vapor H20 Total mass of water vapor Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon
447. materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the pipeline transport system that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor Integrated Environmental Control Model User Manual CO2 Transport System e 365 CO Transport System O amp M Cost Results This screen is available for all plant types 7 IECH Interface File Edit View Go Window Help Configure Plant Set Parameters Get Results Fixed Cost Component zis e Des G ole g alo alee Hed kel la al elke a _ N w A 15 Total O amp M Coss omw Process Type C02 Transport Costs are in Constant 2005 dollars 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost CO Transport System O amp M Cost result screen The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the CO Capture technology O amp M costs are typically expressed on an ave
448. meters or results are displayed on this screen Integrated Environmental Control Model User Manual Overall IGCC Plant 57 Overall IGCC Plant Performance Inputs 7 IECH Interface Fie Edit View Go Window Help 0 US Untitled Configure Plant Set Parameters Get Results Air By Prod Mgmt _ 100 0 Net F ize 7 537 6 100 0 MW output for reference oniy Ambient Air Temperature F 77 00 130 0 77 00 Ambient Air Pressure psia 14 70 15 00 14 70 9 Ambient Air Humidity 1b H20 lb dry air 1 800e 02 z 3 000e 02 1 800e 02 4 2 3 Ic 4 5 6 1 8 See Power Block tab for additional paramefers Process Type overall Plant 2 Performance 5 O amp M Cost Overall IGCC Plant Performance input screen The parameters available on this screen establish the plant availability electrical requirements and ambient conditions for the power plant These parameters have a major impact on the performance and costs of each of the individual technologies Capacity Factor This is an annual average value representing the percent of equivalent full load operation during a year The capacity factor is used to calculate annual average emissions and materials flows Gross Plant Size This is the gross output of the generator in megawatts MW The value does not include auxiliary power requirements The model uses this information to calculate key mass flow rates It is
449. mical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow 206 Cold Side ESP Integrated Environmental Control Model User Manual Fabric Filter The TSPControl Technology Navigation Tab contains screens that design and display flows and costs related to the particulate control technology Shown in the Combustion Boiler plant type configurations Fabric Filter Configuration This screen is only available for the Combustion Boiler plant type lolx Fie Edit Yiew Window Help US Untitled ini eS Configure Plant Set Parameters Get Results Emission NOx 502 CO2 By Prod Base Plant Constraint Control MORMON Control Capture Mgmt Fabric Filter Type Reverse Gas RG Reverse Gas with Sonic RG 5 Shake and Deflate Sh D Pulse jet PJ z 2 ale o B 9 Process Type Fabric Filter z MEM 2 Performance 3RetroftCost f 4
450. mount of taxes paid and deferred State Tax Rate This is the state tax rate It is used to calculate the amount of taxes paid and deferred Integrated Environmental Control Model User Manual Combustion Overall Plant 31 Property Tax Rate The property tax rate or ad valorem is used to calculate the carrying charge Investment Tax Credit This is an immediate reduction in income taxes equal to a percentage of the installed cost of a new capital investment It is zero by default It is used to set the initial balance and the book depreciation Combustion Overall Plant O amp M Inputs 32 e Combustion Overall Plant This screen combines the variable O amp M unit costs from all the model components and places them in one spot These values will also appear in the technology input screens where they are actually used Values changed on this screen will reflect exactly the same change everywhere else they appear O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen File Edit View Go Window Help z eS Configure Plant Set Parameters Get Results amp NOx TSP 2 co2 By Prod Me z mercury Control Control Control Capture Mgmt 8 Title Cale Min Max Default ae Internal COE for Comp Allocations a Menu Menu pe Plant u Internal Electricity Price MWh i 0 0 aA EE TE El
451. mpressor MAC pressurizes atmospheric air to approximately 550 kPA 65 psig but is expressed as a function of the oxygen product required Total ASU Power Requirement This is the electricity used by the air separation unit for internal use A majority of the power is used for the main air compressor and a secondary amount used for the product stream compressor if required It is expressed as a percent of the gross plant capacity Air Separation Retrofit Cost Inputs 86 e Air Separation 7 IECM Interface e File Edit view Window Help By Prod Mgmt Max Default Capital Cost Process Area Air Separation Unit retro new i 10 00 1 000 z mle o P 9 Process Type Jair Separation Costs are in Constant 2000 dollars 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Air Separation Retrofit Cost input screen Capital Cost Process Area Air Separation Unit The retrofit factor is a ratio of the costs of retrofitting an existing facility with an air separation unit versus a new facility using the same equipment Integrated Environmental Control Model User Manual Air Separation Capital Cost Inputs 7 IECM Interface E File Edit View Window Help Sulfur Raka ral CO2 Capture Construction Time General Facilities Capital Engineering amp Home Office Fees Project Contingency Cost
452. n Startup Cost 0 9575 9 Inventory Working Capital 0 3194 10 ll 12 13 14 1s 11 Water Gas Shift Reactor Costs are in Constant 2005 dollars 2 Syngas 2 Capital Cost 4 O amp M Cost 5 Total Cost Zis lt me aeoo ed ced id Kal al an Water Gas Shift Reactor Capital Cost result screen The Water Gas Shift Reactor Capital Cost result screen displays tables for the capital costs Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Water Gas Shift Reactor Process Area Costs High Temperature Reactor This area accounts for the high temperature reactor vessel used for water gas shift The iron based catalyst is designed to be effective at high temperatures 650 1100 F The high temperature reactor has a high reaction rate and converts a large amount of CO into CO3 Low Temperature Reactor This area accounts for the low temperature reactor vessel used for water gas shift The copper based catalyst is designed to be effective at lower temperatures 450 650 F The low temperature reactor has a lower reaction rate but converts a very high percentage of the remaining CO into CO Heat Exchangers The water gas shift process involves substantial cooling because of the exothermic reaction Heat is recovered and temperature control is maintained
453. n 6 02 Save In Oxygen 6 090 Use Chlorine 0 17 Database _ Chlorine 7 000e 02 This Fuel Sulfur 3 25 Sulfur 0 6400 Nitrogen 1 16 Use Default Nitrogen 1 420 Delete Ash 11 0 Ash Properties Ash 9 790 This Fuel Moisture 13 0 Moisture 5 630 Edit Ash Properties View Ash Cost 27 7 Properties Plant Type lt Any gt Fuel Type Coal Process Type Fuel Properties ha Fuel Properties input screen There are two panes on the Fuel Properties input screen one for the composition higher heating value and cost of the Current Fuel the other for properties of the fuels in the Fuel Databases The Current Fuel is the fuel for which the model will conduct its calculations The IECM interface currently supports only one fuel selection per session The Fuel Databases pane displays the properties for other selectable fuels From this screen you may choose a fuel from the model defaults enter a user defined fuel or choose a previously saved user defined fuel Properties of existing fuels may be modified and new fuels may be created and saved to user specified databases The user specified databases can be transferred from one user to another A full suite of buttons have been provided to make the selection and management of the fuel properties easier Both the Current Fuel pane and the Fuel Databases pane display the following information for a fuel Name This is the name of the fuel it may be the
454. n CO removed and the cost per ton avoided based on net plant capacity Since the purpose of adding a CO unit is to reduce the CO emissions per net kWh delivered the cost of CO avoidance is the economic indicator that is widely used in this field Capture Plant e CO2 Emissions Ib kWh This is the amount of CO2 vented to the air for every kilowatt hour of electricity produced in the power plant that is using CO2 Capture Technology e Cost of Electricity MWh The IECM framework calculates the cost of electricity COE for the overall Capture Plant by dividing the total annualized plant cost yr by the net electricity generated kWh yr Reference Plant Integrated Environmental Control Model User Manual Amine System e 283 284 e Amine System CO2 Emissions Ib kWh This is the amount of CO2 vented to the air for every kilowatt hour of electricity produced in the power plant with NO CO2 Capture Cost of Electricity MWh The IECM framework calculates the cost of electricity COE for the overall Reference Plant by dividing the total annualized plant cost yr by the net electricity generated kWh yr Cost of CO Avoided ton This is the economic indicator widely used in the field calculated as the difference between the cost of electricity in the capture plant and the reference plant divided by the difference between the CO2 emissions in the reference plant and the capture plant Cost of CO2 Avoided Co
455. n dioxide in the syngas Water Vapor H20 Flow rate of water vapor in the syngas Nitrogen N2 Flow rate of nitrogen in the syngas Argon Ar Flow rate of argon in the syngas Oxygen O2 Flow rate of oxygen in the syngas Total Total flow rate of the syngas Power Block Flue Gas Results This screen is only available for the Combustion Turbine and IGCC plant types Integrated Environmental Control Model User Manual Power Block 383 7 IECM Interface J File Edit Yiew Window Help Air In Flue Gas Out Major Flue Gas Components b moles hr h moles hr Nitrogen N2 9 505e 04 9 505e 04 Oxygen 02 2 528e 04 1 623e 04 Water Vapor H20 0 0 9055 Carbon Dioxide CO2 0 0 4527 Carbon Monoxide CO 0 0 0 0 Hydrochloric Acid HCD 0 0 0 0 Sulfur Dioxide 802 0 0 0 0 Sulfuric Acid equivalent 503 Nitric Oxide NO Nitrogen Dioxide NO2 Ammonia NH3 Argon Ar zl amp lle le o h o 0 Process Type 1 Gas Turbine bd LL ongan 2 o c Copnsicont 72 cM Con Power Block Flue Gas results screen Major Flue Gas Components Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Di
456. nce Sampling Copyright 1997 Urmila Diwekar Carnegie Mellon University All Rights Reserved Microsoft is a registered trademark Windows Windows 95 Windows 98 Windows NT Windows ME Windows 2000 Windows XP and Visual C are trademarks of Microsoft Corporation Graphics Server is a trademark of Graphics Server Technologies L P Spread is a trademark of FarPoint Technologies Inc Tab Pro is a trademark of FarPoint Technologies Inc Intel and Pentium are trademarks of Intel Corporation 6 e Introduction Integrated Environmental Control Model User Manual Integrated Environmental Control Model User Manual Introduction 7 User Documentation and Help User Manual The User Manual gives further information on both the interface and the underlying model It provides detailed descriptions of plant configurations parameter settings and result screens It also describes technical details behind the model s operation and includes an introduction to uncertainty analysis Technical Manuals Online Help The Technical manuals are detailed engineering descriptions of the technologies and costing assumptions used in the IECM These manuals are not provided by default with the IECM software however they can be downloaded with any web browser from http www iecm online com Online help is provided via a Windows Help File containing the full text of the User Manual Accessing the IECM Help file If you are not running
457. ncluded implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Integrated Environmental Control Model User Manual Hot Side SCR e 169 Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material
458. ndicated in the previous sections there are two fundamental approaches for encoding uncertainty in terms of probability distributions These include statistical estimation techniques and engineering judgments A combination of both methods may be appropriate in many practical situations For example a statistical analysis of measured test data for a new emission control technology may be a starting point for thinking about uncertainties in a hypothetical commercial scale system You must then consider the effect that systematic errors variability or uncertainties about 408 e Appendix A Introduction to Uncertainty Analysis Integrated Environmental Control Model User Manual scaling up the process might have on interpreting test results for commercial scale design applications Statistical Techniques Statistical estimation techniques involve estimating probability distributions from available data The fit of data to a particular probability distribution function can be evaluated using various statistical tests For example the cumulative probability distribution of a set of data may be plotted on probability paper If the data plot as a straight line then the distribution is normal Procedures for fitting probability distribution functions are discussed in many standard texts on probability and are not reviewed here Such procedures can be utilized to obtain distribution functions for many of the power plant parameters in the IECM when
459. ned compounds and the oxidation reaction forming organic acids and liberating ammonia It is assumed that 50 of this MEA loss is due to polymerization and the remaining 50 of the MEA loss is due to oxidation to acids Sorbent Oxidation Loss The sorbent oxidation loss variable is a ratio of the number moles of sorbent that are lost for every mole of acid formed due to oxidation of the sorbent Liquid to Gas Ratio The liquid to gas ration is the ratio of total molar flow rate of the liquid MEA sorbent plus water to the total molar flow rate of flue gas being treated in the absorber Ammonia Generation The oxidation of MEA to organic acids oxalic formic etc also leads to formation of NH3 Each mole of MEA lost in oxidation liberates a mole of ammonia NH3 Gas Phase Pressure Drop This is the pressure drop that the flue gas has to overcome as it passes through a very tall absorber column countercurrent to the sorbent flow ID Fan Efficiency The cooled flue gas is pressurized using a flue gas blower before it enters the absorber This is the efficiency of the fan blower to convert electrical power input into mechanical work output Regenerator The regenerator is the column where the weak intermediate compound carbamate formed between the MEA based sorbent and dissolved CO2 is broken down with the application of heat and CO gets separated from the sorbent to leave reusable sorbent behind In case of unhindered amines like
460. nent oaee oerna deras ach reira Te Eaa EE E N 201 Cold Side ESP Capital Cost ResultSet eaei ereina eiere eaea EE At 201 Dir ct Capital COS Sh ra pra ee casshiin Monette rO E EAE EET 202 Total Capital Costs a ae waned ati Monnens inSain Baia neh ies 203 Cold Side ESP O amp M Cost Results e are eaaa rair ree s aroa Te ra al EER aE ove 203 Variable C s COM pO Na a cade aa ae iOa e eai enna 204 Fixed Cost Compo S e aaaea Earr rae iA Winelands esas 204 Cold Sid ESP Total C st Results asesi iet e eaei eras asa terea eari E ARET 205 Cost Components scsi sects eres eoor atore oo EEEn E Orii araa TeS EETU EEES EIEEE a aes 205 Fabric Filter 207 Fabric Filter Configuration sic neneiia a a e a a a a a eS 207 Fabric Filter Performance IMPUS aa a aS EE aeS 208 Fabric Filter Retrofit INP ts esii aae a e a a a a eiS 209 Capital Cost Process Areas eea e E E E AaS Re ne 210 Fabric Filter Capital Cost INPUtS ipinnu eia EE EET 211 Fabric Filter O amp M Cost INputS nseni nni a E a AN EEEE aS 212 Fabric Hilter Didara a a A a A A R N Ra 214 Flue Gas Entering Filtet aenean a T e A 214 Flue Gas Exiting Filt r srren re N A A AA OE 214 Fabric Filter Performa c sinisini ennn A TA AN 215 Collect d Ply Ashits2 0sficccedl stitial aiid eel nites nein ein 215 Fabric Filter Flue Gas Results srne osei n E a N E T A A TTN 215 Fabric Filter Capital Cost Results 0 0 0 0 cc ceesesessecsseeeeeeseenseeesseecsaeecseeseseeseeaeeesaeesaeesseeenea 216 Fa
461. ng into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Sulfur Removal Hydrolyzer Syngas Results 7 IECM Interface z 10J 342 e Sulfur Removal Eile Edit View Window Help D Configure Plant 2 8 le lole 2 Hydrogen H3 3 Methane CH4 4 Ethane C2H6 i 1 Carbon Monoxide CO 1 825e 04 1 825e 04 255 6 LI cx Set Parameters Get Results By Prod CO2 Capture Power Block Mgmt Stack SyngasIn Syngas Out Syngas In Syngas Out h moles hr hb moles hr ton hr tom hr 255 6 1 416e 04 1 416e 04 1430 14 30 1080 1080 0os660 0 8660 oo oo oo o Blo 5 Propane C3H3 0 0 0 0 0 0 o0 6 Hydrogen Sulfide H25 465 9 4924 7939 8390 7 Carbonyl Sulfide COS 26 88 0 4032 0 8073 1 211e 02 8 Ammonia NH3 3 301 3 301 2 811e 02 2 811e 02 9 Hydrochloric Acid HCD 0 0 0 0 0 0 0 0 10 Carbon Dioxide CO2 5652 5678 124 4 125 0 11 Water Vapor H20 7682 7656 69 22 68 98 12 Nitrogen N2 363 6 363 6 5 092 5 092 13 rgon An 4428 4428 8 844 8 844 14 Oxygen 02 15 0 0 0 0 0 0 0 0 Process Type 2 Hydrolyzer Sulfur Removal Hydrolyzer Syngas result
462. nia salts deposited on the air preheater Electricity Cost of electricity consumption of the hot side SCR This is a function of the gross plant capacity and the SCR energy penalty performance input parameter Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Integrated Environmental Control Model User Manual Hot Side SCR e 171 Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and
463. nput Screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each parameter is described briefly below Water Cost This is the cost of water in dollars per thousand gallons Waste Disposal Cost This is the waste disposal cost for the wet tower Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is a combustion boiler and an air preheater Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Integrated Environmental
464. nsed on particulates in the preheater and removed from the flue gas This parameter specifies the amount of SO removed from the flue gas in the preheater as a function of the coal rank The default value is taken from the removal efficiency reported in the literature references are below This efficiency then determines the mass of SO removed from the flue gas in the collector For more information see also e www netl doe gov publications proceedings 98 98fg hardman pdf e www netl doe gov publications proceedings 98 98f g rubin pdf Hardman R R Stacy et al 1998 Estimating Total Sulfuric Acid Emissions from Coal Flred Power Plants Southern Company Services 98 e Base Plant Integrated Environmental Control Model User Manual Nitrogen Oxide Emission Rate This parameter establishes the level of NO emissions from the boiler The default values reflect the AP 42 EPA emission factors It is a function of boiler firing method and the coal rank The model calculates this value and expresses it in pounds of equivalent NO per ton of coal Percent of NO as NO This parameter establishes the level of nitric oxide NO in the flue gas stream The remainder of the total NO emissions is assumed to be nitrogen dioxide NO2 The default parameters reflect the AP 42 EPA emission factors and are dependent on the fuel type Conc of Carbon in Collected Ash This parameter accounts for retention of carbon in the fly ash and bottom ash The amo
465. nt Performance Inputsisa siihciniatsedatessiiee site ata A E A 95 Base Plant Power Requirements ccccessceceseecsseeceneeeeseeeesaeecsacecsseeessaeecesaeessnees 96 Base Plant Furnace Factors Inputs ccccessssssecccceececcsssneeeceeeceeessnacececeeeeceeeseeeeeeeeeeeeseaaes 97 Base Plant Retrofit Cost Inputs eeeeeesecssceceseceeeeecesceeesseecsseecseeceseaeesseecsaeesseeseseeeenaes 99 Base Plant Capital Cost Inputs sirina ea e a E A ET a aai 100 Base Plant O amp M Cost Inputs wsisissscscstssssccaudsssteshasstehbesscaseslaccnstaadeeasasines aT EEEE EATE Riaan 102 Boiler DiagraM seces innsre nete n adi ei nate esis earl aa 104 Fuel Entering Boiletiscsssncs is a A N A A a e T an 105 Boiler Performance tesenn i on e TT a Sa 105 Air Entering Bolet iesire s n Bil ail a a a a a r a 105 Flue Gas Exiting the ECOonomiZzer esseeeseeereesreerrresrrererereseresererererereseressereseres 105 Bottom Ashs sissies cat dv ieee ee pea E e a a A T 105 Boiler Flue Gas Results j ceciindilicavecets eli wi cinbicin ahi al ails bales 106 Boiler Capital Cost Results 0 ec ceeceeseccesseesssseeessecsseecsseeeesaeecsaeecseeeceeeseaeeesaeessaeessneeese 107 Direct Capital Costs wi sere cai Alsi eae beh ae etek econ 107 Total Capital Costs a vescdiad steiner Biaiiasnisiedl ihe el 108 Boiler O amp M Cost Results cisseccivcivesi avis di chi diss eich vison etisalat ae a 109 Variable Cost Components iieiaei eer E A eea E ES 109
466. nt during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Effective TCR The TCR of the base plant that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor for the base plant Boiler O amp M Cost Results The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the combustion base plant The variable O amp M costs are calculated from the variable costs for fuel water consumption and bottom ash disposal from the furnace The fixed O amp M costs are based on maintenance and labor costs 7 IECM Interface E File Edit view Window Help Get Res
467. nterest Charges AFUDC 4 181 Royalty Fees 0 0 Preproduction Startup Cost 0 8685 Inventory Working Capital o0 1962 ale le lololo na wN Zj tt Sooo z E B S E S ale Process Type Fabric Filter Costs are in Constant 2005 dollars 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost Fabric Filter Capital Cost result screen Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Direct Capital Costs Each process area direct capital cost is a reduced form model based on regression analysis of data collected from several reports and analyses of particulate control technology units They are described in general below The primary factors in the model that effect the capital costs of the cold side ESP are the specific and total collection areas of the T R plate sets and the flue gas flow rate through the ESP The primary model factors that effect the capital costs of the fabric filter are the fabric filter type the air to cloth ratio the number of bags and compartments and the flue gas flow rate through the fabric filter Collector This area covers the material and labor flange to flange for the equipment and labor cost for installation of the entire collection system Ductwork This area includes the material and labor for the
468. ntrol Model User Manual O2 CO2 Recycle e 285 The following reference plant inputs are used to determine the avoided cost of CO avoidance The default value is zero for both parameters requiring the user to supply the actual reference plant values Reference values can be obtained by simulating the same plant configuration minus the CO capture Analysts commonly express the cost of an environmental control system in terms of either the cost per ton of pollutant removed or the cost per ton avoided For an energy intensive system like amine scrubbers there is a big difference between the cost per ton CO removed and the cost per ton CO avoided based on net plant capacity Since the purpose of adding a capture unit is to reduce the CO emissions per net kWh delivered the cost of CO avoidance relative to a reference plant with no CO control is the economic indicator most widely used The reference plant used to compare to the actual plant must be defined as follows CO Emission Rate This is the emission rate for the reference power plant without CO capture Cost of Electricity This is the cost of electricity for the reference power plant without CO capture O 2 CO Recycle Performance Inputs 286 O2 CO2 Recycle This screen is available for Combustion Boiler plant types File Edit View Go Window Help 0 Configure Plant Set Parameters amp 3 Flue Gas Recycled eB Oxygen Content
469. nts are proportional to this value Sampling Methods Input and output variables are related to each other by model definitions defined for each variable These relationships are generally referred to as the decision tree The model uses this decision tree to determine which input variables must be calculated to specify the output variable Only those input variables necessary to specify the output variable value are calculated Since each input variable can be expressed as a non singular distribution a method of sampling the inputs must be determined Several methods are available in the model ranging from a deterministic or single best guess value to a completely random sampling of each input distribution The sampling methods all produce sets of values for the inputs These sets together form the sampling space Deterministic Evaluation Output values can be determined by using the most probable value for each input This method is frequently referred to as the best guess Input variables can be treated deterministically either by specifying only a single value or by selecting the Off option for the Uncertainty Distribution pane This option forces all uncertain parameters to be evaluated deterministically Selecting the Off option forces each uncertainty function used in the decision tree to be evaluated using its expected value This option overrides any particular uncertainty distribution types
470. nty distribution are included in the model when the uncertainty editor is selected the information required and additional notes appear below Distributions that are easiest to use are designated with a dagger Consult a standard statistics reference for additional information None None represents no uncertainty Normal Distributions tNormal mean stddev returns a continuous normal Gaussian probability distribution with the specified mean and the standard deviation stddev tNeghalf_Normal mean stddev returns the lower half of a normal Gaussian probability distribution with the specified mean and the standard deviation stddev tHalf_Normal mean stddev returns the upper half of a normal Gaussian probability distribution with the specified mean and the standard deviation stddev This bell shaped distribution is often assumed in statistical analysis as the basis for unbiased measurement errors The normal distribution has infinite tails however over 99 percent of all values of the normal distribution lie within plus or minus three standard deviations of the mean Thus when used to represent uncertainty in physical quantities which much be greater than zero the standard deviation should not be more than about 20 or 30 percent of the mean Lognormal Distribution Lognormal median gsdev returns a continuous lognormal probability distribution with the specified median and the geometric standard deviation gsdev The
471. number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor 336 Sulfur Removal Integrated Environmental Control Model User Manual Sulfur Removal Diagram i aloxX File Edit Yiew Window Help Temperature In F 101 0 Pressure In psia 572 0 ie Syngas In ton hr 6418 Jn cases with CO2 capture input is from WGS reactor S a Ele aloo Makeup Solvent lb hr 10 01 Makeup Catalyst lb hr Sulfur Out ton hi Process Type RETES ecu i 1 Diagram 2 Capital Cost 3 0 amp M Cost 4 Total Cost Sulfur Removal Diagram result screen Configure Plant Set Parameters Get Results Flue Gas Out ton ht 17 09 CO2 Capture Power Block By Pro
472. o the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable Integrated Environmental Control Model User Manual O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating mainten
473. o 1000 00 Royalty Fees 3 0 5000 00 10 00 0 5000 S2xAAKN amp WH 9 Pre Production Costs 10 Months of Fixed O amp M l i 000 o 120 11 Months of Variable O amp M d j 12 00 12 Misc Capital Cost 7 I 10 00 13 14 Inventory Capital k 10 00 B E s a 0 0 200 0 Costs are in Constant 2007 dollars Air Cooled Condenser Capital Cost Input Screen Each parameter is described briefly below Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is g
474. ocess Type Joverall Plant z 2 Plant Perf 3 Mass In Out 5 Total Cost 6 Cost Summary Overall NGCC Plant Mass In Out results screen Chemical Inputs Solid amp 52 e Overall NGCC Plant Coal Flow rate of coal used in the power plant Oil Flow rate of oil used in the power plant Natural Gas Flow rate of natural gas used in the power plant Petroleum Coke Total mass of petroleum coke used in the power plant Other Fuels Flow rate of other fuels used in the power plant Total Fuels This is the flow rate of fuel entering the power plant This result is highlighted in yellow Lime Limestone Total mass of this reagent used in the power plant on a wet basis Sorbent Total mass of sorbent used in the power plant Ammonia Total mass of ammonia used in the power plant Activated Carbon Flow rate of activated carbon injected in the power plant Other Chemicals Solvents amp Catalyst Flow rate of other chemicals solvents and catalysts used in the power plant Total Chemicals Flow rate of reagent entering the power plant This result is highlighted in yellow Process Water Flow rate of water used in the power plant Liquid Outputs Slag Flow rate of slag from the power plant on a dry basis Ash Disposed Flow rate of ash from the power plant on a dry basis Integrated Environmental Control Model User Manual Scrubber Solids Disposed Flow rate of scrubber treatment solid wastes from the power plant on a dr
475. ochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide SO2 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO2 Total mass of nitrogen dioxide Ammonia NH3 Total mass of Ammonia Argon Ar Total mass of Argon Total Total of the individual components listed above This item is highlighted in yellow Cold Side ESP Capital Cost Results This screen is only available for the Combustion Boiler plant type The Capital Cost result screen displays tables for the direct and indirect capital costs related to the particulate control technology Integrated Environmental Control Model User Manual Cold Side ESP e 201 202 e Cold Side ESP 7 IECH Interface ioj xi File Edit View Go Window Help Configure Plant Set Parameters Get Results 02 CO2 By Prod Control Capture Mgmt Stack Cold Side ESP Process Area Costs a A Ductwork 1 093 General Facilities Capital 0 1465 Fly Ash Handling 3 041 Eng amp Home Office Fees 0 7327 Differential ID Fan 6 87 4e 02 Project Contingency Cost 2 931 Process Contingency Cost 0 0 Interest Charges AFUDC 1 967 Royalty Fees 0 0 Preproduction Startup Cost 0 5640 Inventory Working Capital al 9 232e 02 i Capital Cost Cold Side ESP Plant Costs ts ale le olol na wN Zj tt Sooo z zaleje ale
476. oe ohm aona Process Type Air Separation Costs are in Constant 2000 dollars 3 Copilcost occo AE Air Separation O amp M Cost results screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Variable Cost Component Electricity The cost of electricity consumed by the Air Separation System Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and m
477. ol a amp Technology e Combustion NOx Control E Post Combustion NOx Control Mercury Control e TSP Control gt 02 Control Combined SOx NOx Control K CO2 Capture Base Plant Emission Taxes Process Type Joverall Plant z Costs are in Constant 2003 dollars 2 Plant Pef 3 Mass In Out Z 4 SolidsInOut 5 GasIn Out 6 TotalCost a ANERE Combustion Overall Plant Cost Summary result screen The Cost Summary result screen displays costs associated with the power plant as a whole The costs summarized on this screen are expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each technology row is described briefly below Combustion NO Control The total cost of the In Furnace NO controls used Integrated Environmental Control Model User Manual Combustion Overall Plant 41 42 e Combustion Overall Plant Post Combustion NO Control The total cost of all the Post Combustion NO removal modules used Mercury Control The total cost of all the mercury control modules used TSP Control The total cost of all the conventional particulate removal modules used SO Control The total cost of all the SO conventional removal modules used Combined SO NO The total cost of all the combined SO NO advanced removal modules used Subtotal This is the cost of the conventional and advanced abatement technology modules alone This is t
478. ols This screen is only available for the Combustion Boiler plant type File Edit View Go Window Help Configure Plant Set Parameters Get Results NOx TSP 502 co2 By Prod Control Mercury Control Control Capture Mgmt Stack O amp M Cost O amp M Cost Variable Cost Component M yr Fixed Cost Component M8 yr 0 0 3 417 8 608e 03 Electricity 1 352e 02 Combustion NOx Costs 01307 SNCR Boiler Costs 9 481e 02 _ g g 2 nan al 3 oe e Ep 5 gt R ela ao In Furnace Controls O amp M Cost result screen The O amp M Cost result screen displays tables for the variable and fixed operation and maintenance costs involved with the In Furnace Controls NO control technology O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Fuel The total fuel costs associated with gas reburn are included here Reagent The total reagent costs urea and ammonia used for the SNCR system are included here Water This is the cost of the water used to dilute the urea for the
479. oluble in water moisture injected into the spray dryer evaporates resulting in the mercury remaining in the flue gas The default value is zero Spray Dryer elemental Elemental mercury is assumed to pass through the lime spray dryer It is assumed that elemental mercury is present in the flue gas and is unreactive Percent Increase in Speciation Although NO control technologies do not remove mercury from the flue gas they can change the mercury from one form to another This is particularly true when catalysts are present In this case elemental mercury is converted to oxidized mercury The parameters in this section define the percent increase in oxidized mercury across the control technology In furnace NOx oxidized Low NO burners with or without overfire air and gas reburn can effect the amount of oxidized mercury At present there is insufficient information available to specify a default value The default is set to zero SNCR oxidized An SNCR does not affect the relative amounts of oxidized and elemental mercury The default is set to zero Hot Side SCR oxidized Hot side SCR as a control technology chances elemental mercury to oxidized mercury It is believed that the catalyst is responsible for this shift in speciation The default value is a function of the coal rank and Water Injection Inputs This screen is only available for the Combustion Boiler plant type Inputs for activated carbon and water injecte
480. on Gas Results This screen is available for Combustion Boiler plant types 7 IECH Interface File Edit View Go Window Help US Untitled Configure Plant Set Parameters NOx Control Flue Gas In Major Flue Gas Components b moles hx Captured b moles hr trogen E 22 61 Oxygen 02 454 3 150 7 7 269 Water Vapor H20 1611 oo 14 51 Carbon Dioxide CO 1 959e 04 1 763e 04 431 0 Carbon Monoxide CO 0 0 0 0 4 0 0 Hydrochloric Acid HCD 0 1725 0 0 3 145e 03 Sulfur Dioxide S02 aa oo 0 3759 Sulfuric Acid equivalent 503 0 1060 0 0 4 244e 03 Nitric Oxide NO 16 31 0 0 0 2447 Nitrogen Dioxide NO2 0 8583 0 0 1 974e 02 Ammonia NH3 oo oO oo Argon At 1044 150 7 20 86 tons h Zis me le meloo Sjea jajajaja v n _ cil 4 Process Type FG Recycle amp Purification 7 2 DCC Gas Beemer 4 CapitalCost 5 0 amp MCost 6 TotalCost O gt CO Recycle Flue Gas Purif gas result screen Major Flue Gas Components Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Integrated Environmental Control Model User Manual O2 CO2 Recycle e 295 Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02
481. on capacity of the power plant is not adversely affected The auxiliary boiler comes at an additional cost of capital requirement for the boiler and turbine and the cost of supplemental fuel Also the auxiliary boiler adds to the CO and NO emissions When an auxiliary boiler is added an additional process type will be added to the selection menu at the bottom of the screen Flue Gas Bypass Control This popup selection menu controls whether or not a portion of the inlet flue gas may bypass the scrubber and recombine with the treated flue gas Bypass allows the scrubber to operate at full efficiency while allowing some of the flue gas to go untreated Two choices are available No Bypass and Bypass The no bypass option is the default and forces the entire flue gas to pass through the scrubber The bypass option allows for the possibility of a portion of the flue gas to bypass the scrubber The amount of bypass is controlled by several additional input parameters described below Maximum SO Removal Efficiency This parameters specifies the maximum efficiency possible for the absorber on an annual average basis The value is used as a limit in calculating the actual SO removal efficiency for compliance This is only visible if bypass is specified Overall SO Removal Efficiency This value is the SO removal efficiency required for the entire power plant to meet the SO emission constraint set earlier It is used to determine the actual flue g
482. on factors Boiler Efficiency This is the percentage of fuel input energy transferred to steam in the boiler The model default is to calculate the boiler efficiency using standard algorithms described in the literature The efficiency is a function of energy losses due to inefficient heat transfer across the preheater latent heat of evaporation incomplete combustion radiation losses and unaccounted losses Excess Air for Furnace This is the excess theoretical air used for combustion It is added to the stoichiometric air requirement calculated by the model The value is calculated and based on the fuel type and boiler type Leakage Air at Preheater This is the additional excess air introduced because of leakage into the system at or beyond the air preheater It is based on the stoichiometric air required for combustion The leakage air increases the total gas volume downstream of the air preheater Gas Temperature Exiting Economizer This is the temperature of the flue gas exiting the economizer The temperature is used in the calculation of the flue gas volume and air preheater performance Gas Temperature Exiting Air Preheater This is the temperature of the flue gas exiting the air preheater The temperature is used in the calculation of the flue gas volume and air preheater performance Percent Water in Bottom Ash Sluice Bottom ash collected can be removed from the combustion bolier and disposed by sluicing the bottom ash with w
483. on for the Landfill and values for major flows into it Each result is described briefly below Flue Gas Treatment Inputs Solids mixed with sluice water that are collected in the bottom of the boiler and by the particulate removal technologies are transported to the Pond for treatment The IECM currently provides no additional treatment or consideration of these substances and therefore simply reports the quantities entering the technology Wet FGD Solids Mass flow rate of wet FGD solids Mercury contained in Wet FGD Solids Mass flow rate of mercury present in the Wet FGD solids Wet Fly Ash Mass flow rate of total fly ash solids on a wet basis This value is zero when the fly ash is disposed in a landfill Mercury contained in Fly Ash Mass flow rate of mercury present in the fly ash solids on a wet basis Flue Gas Treatment Totals Wet Total Solids The sum of the wet FGD solids and the fly ash on a wet basis Total Mercury Mass flow rate of mercury present in the combined wet FGD solids and fly ash solids on a wet basis Integrated Environmental Control Model User Manual By Products managemen Fly Ash Disposal oo 21D xi Eile Edit View Window Help k amp Configure Plant Set Parameters amp Air E 502 Preheater Control 7 Control Control S amp Wet Fly Ash ton hr 23 56 Mercury o hi 1 095e 02 el eS R Wet Total Solids ton hr 23 56 Total Mercury lb hr 1 095e 02 Pro
484. ond Interest Rate Real Preferred Stock Return Real Common Stock Return Percent Debt Percent Equity Preferred Stock Percent Equity Common Stock Zis t mler B alelo Federal Tax Rate State Tax Rate Property Tax Rate Investment Tax Credit Process Type overall Plant g 4 Financing E Overall IGCC Plant Financing input screen This screen describes the factors required to determine the carrying charge for all capital investments The carrying charge is defined as the revenue required for the capital investment The total charge can also be expressed as a levelized cost factor or fixed charge factor The fixed charge factor is a function of many items The fixed charge factor can be specified directly or calculated from the other input quantities below it on the financial input screen Each parameter is described briefly below Year Costs Reported This is the year in which all costs are given or displayed both in the input screens and the results A cost index is used by the IECM to scale all costs to the cost year specified by this parameter The cost year is reported on every input and result screen associated with costs throughout the interface Constant or Current Dollars Constant dollar analysis does not include the affect of inflation although real escalation is included Current dollar analysis includes inflation and real escalation This choice allows you to
485. onents Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Gasifier Total Cost Results This screen is only available for the IGCC plant type File Edit View Go Window Help Configure Plant Set Parameters Get Results Memt Percent Total Annual Fixed Cost 13 48 Annual Variable Cost 39 35 Annualized Capital Cost 47 18 Bis el
486. ons to Air Flow rate of particulates emitted to the air from the plant Captured CO gt Flow rate of the captured CO3 Byproduct Ash Sold Flow rate of ash bottom and fly ash sold in commerce as a by product on a dry basis Byproduct Gypsum Sold Flow rate of flue gas treatment solids sold in commerce as a by product on a dry basis Byproduct Sulfur Sold Flow rate of elemental sulfur recovered from flue gas and sold in commerce as a by product on a dry basis Byproduct Sulfuric Acid Sold Total mass of sulfuric acid recovered from the flue gas and sold in commerce as a by product Total Solids amp Liquids This is the total wet solid mass exiting the power plant This result is highlighted in yellow Overall IGCC Plant Gas Emissions Results l01x File Edit View Go Window Help Configure Plant Set Parameters Get Results Air Gasifier Sulfur By Prod Separation Area Removal SOURS jiannn Mgmt Stack Gas Component tons hr Stack Gas Component 2464 Total SOx equivalent S02 Oxygen 02 480 9 Total NOx equivalent NO2 Water Vapor H20 439 1 Carbon Dioxide COZ 48 62 Carbon Monoxide CO 0 0 Hydrochloric Acid HCD 0 1126 Sulfur Dioxide 502 0 1770 Sulfuric Acid equivalent 03 0 0 Nitric Oxide NO 3 301e 02 Nitrogen Dioxide NOD 2 664e 03 Ammonia NH3 Argon An 4 Use Result Tools under View alel G o 9 Ei izl ele menu for alternate units
487. ooling water exiting the wet tower That is equal to the amount of cooling water entering the wet tower based on water mass balance That is the sum of cooling water 14 e Water Systems Integrated Environmental Control Model User Manual through the main steam cycle and amine based carbon capture system if applicable Temperature Out The temperature of reciruclating cooling water exiting the wet tower That is calculated in terms of the inlet cooling water temperature and cooling water temperature drop range Wet Tower Performance Makeup Water The cooling tower operation is maintained by making up fresh water at the same rate as the water losses evaporation blowdown and drift loss from the tower Makeup Underflow This output gives the amount of wastes from cooling makeup water treatment system Evaporation In wet cooling towers water has direct contact with ambient air and cooling is achieved mainly by the evaporation process in which some of the water leaves with the air The evaporation process is the largest source of cooling tower water losses That is estimated based on the mass and energy balance mode Evaporation loss varies with meteorological conditions and displays a seasonal pattern Blowdown Because water evaporated in the cooling tower consists of pure water the concentration of salts or other impurities will increase in the recirculating water To avoid a high concentration and subsequent scaling of the surface w
488. or Combustor This is the excess theoretical air used for combustion It is added to the stoichiometric air requirement calculated by the model This value is based on the required mass flow rate of syngas through the combustor the heat content of the syngas and the flame temperature of the combustor 374 e Power Block Integrated Environmental Control Model User Manual Power Block Steam Cycle Inputs This screen is only available for the Combustion Turbine and IGCC plant types y IECM Interface eX Edt View Window Help US Untitled Set Parameters co By Prod la ollo g Min Max Default Heat Recovery Steam Generator HRSG Outlet Temperature K 150 0 500 0 250 0 Steam Cycle Heat Rate HHV BtwkWh 1 100e 04 9000 AEEA Steam Turbine Total Steam Turbine Output 2 x Power Block Totals Power Requirement Power Block Steam Cycle input screen Heat Recovery Steam Generator HRSG Outlet Temperature This is the desired output temperature from the heat recovery steam generator HRSG Steam Cycle Heat Rate HHV This is the steam cycle heat rate for the heat recovery steam generator Steam Turbine Total Steam Turbine Output This is the net electricity produced by the steam turbine associated with the HRSG steam cycle This value cannot be edited It is provided for reference only Power Block Totals Power Requirement This is the electri
489. or changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0
490. orbent gets heated and the lean regenerated sorbent gets cooled Integrated Environmental Control Model User Manual Circulation Pumps The cost associated with the equipment required to support FGD system operation such as makeup water and instrument air are treated here Sorbent Regenerator This is the column where the weak intermediate compound carbamate formed between the MEA based sorbent and dissolved CO is broken down with the application of heat and CO gets separated from the sorbent to leave reusable sorbent behind In case of unhindered amines like MEA the carbamate formed is stable and it takes large amount of energy to dissociate It also consists of a flash separator where CO is separated from most of the moisture and evaporated sorbent to give a fairly rich CO stream Reboiler The regenerator is connected with a reboiler which is basically a heat exchanger where low pressure steam extracted from the power plant is used to heat the loaded sorbent Steam Extractor In case of coal fired power plants that generate electricity in a steam turbine a part of the LP IP steam has to be diverted to the reboiler for sorbent regeneration Steam extractors are installed to take out steam from the steam turbines Sorbent Reclaimer Presence of acid gas impurities SO2 SO3 NO and HCl in the flue gas leads to formation of heat stable salts in the sorbent stream which can not be dissociated even on application of heat In order
491. ormance Parameter Plant Energy Requirements Turbine Generator Output MW Air Compressor Use MW Turbine Shaft Losses MW Auxiliary Fuel Power Input MBtu hr i Net Turbine Ouiput MW Total Plant Power Input MBtu hr Misc Power Block Use MW Absorption CO2 Capture Use MW Gross Plant Heat Rate HHY Btu kWh Aux Power Produced MW Net Plant Heat Rate HHV Btu kWh Net Electrical Output MW z t 2 mler e oleo e ped cal cal eed jo m Annual Operating Hours hours Annual Power Generation BkWh yr Net Plant Efficiency HHV overall Plant z 2 Plant Perf 3 Mass In Out 5 TotalCost 6 Cost Summary Overall NGCC Plant Performance results screen The Plant Perf result screen displays performance results for the plant as a whole Heat rates and power in and out of the power plant are given Each result is described briefly below Performance Parameter Net Electrical Output This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties Aux Fuel Power Input This is the fuel energy input for the auxiliary natural gas boiler if used with the Amine System This is additional fuel energy used by the plant given on an hourly basis This rate is also referred to as the auxiliary fuel power input Total Plant Power Input This is the total of all the fuel energ
492. ost ResultSet neeaae EAEE EE 189 Variable Cost Components ne nrnna deh inal a a ik 189 Fixed Cost Comiponents henienn aee a ie ea 190 Integrated Environmental Control Model User Manual Contents vii viii e Contents Mercury Total Cost Results renina E ae E E a eE E AE EEE ASES 190 Cost Component me an enaa eens E EE A R E E A 191 Cold Side ESP 193 Cold Side ESP Performance Inputs sseesseeseeeseeeresereeessesrrerrreressrersrereresstessrteseresreserestreee 193 Cold Side ESP Retrofit Cost Inputs ees eeseeesceceseeccnseeesseecsseecsseeceseeeesaeecesaeecseeeeneeeeee 194 Capital Cost Process ALE a sso sate sit erae aea eae sath odes eoe sate eea aenea e 195 Cold Side ESP Capital Cost Inputs eeseeeseecssecesececnseeesseecsaeecsaceceseesesaeeeesaeesseeseneeesee 195 Cold Side ESP O amp M Cost Inputs eeeeeeseecsseeeesseecnseeesaeeceseecsseeceseesessneecsaeesaeesseeesee 197 Cold Side ESP Dia grain 35 csc vigere Sivessdedey coved sesse onus cgep sted eset onus cedegies odes aE EEE Eaa Enese 199 Plue Gas Entering ES Passear eeaeee reao sas eeo eA aane Mea satetedsnegasees 199 Blue Gas Exitin ES Pe heehee eeaeee aea e aaee eap oaee e ea eE ea tense eane 199 ESP Performancen Ger uee aeeoe eanes eea aeaea ee eraen ees Ee eaea Et 200 Collected FIY ASD oe eene a eose eaea ee aaee sats ee a ee ty sites Eeee Nt 200 Cold Sid ESP Flu Gas R sultS scite ents eeens i era aaaea SEE o EEE Eie nei Aas 200 Major Flue Gas Compo
493. ost p enpenga e aatteena raae oean oae tees onttvsyedesdebatetouttesets 160 Capital Cost Process Areas ereh erae dente eea ereo eaa eanes aeoea Eaa EEE a Ene ane 161 Hot Side SCR Capital Cost Inputs eee eesecsseeceseeeceseeesseecsseecsaeecsseecssaaeecsaessaeessneeeeea 162 Hot Side SCR O amp M Cost Inputs cee eeesesesecssceecesseceseeesseecsaeecseeceseeeeseaeecsaeesseeseeeeses 163 Hot Side S CR Dia raa 22sec ae ae ea i rn E Ana ion cai Lane Aun iheith ss 165 Reagent EEEE E E 165 ETE DE E EEE EE A 165 Flue Gas Entering SOR aaea anair aae hot E A EA dies 166 Flu Gas Exiting SCR e init eiaa r aaa i OE E Ea 166 SCR Performances are ase ara o E AEA AEE E OAO aE aaa E AEE K EEES Ea 166 SE So ha R EATE 167 Hot Side SCR Flue Gas Resullts 2 i tees nithesiortais athens Aud E ERAR E EEEa EEES 167 Major Flue Gas Components 3 35 cape chika E R EA 167 Hot Side SCR Capital Cost RESUS arai oanad ereiaro E ra E E E A A cee 168 Hot Side SCR O amp M Cost Rest Sa E a araara a e lactase reat EE IEE a REER 170 Variable Cost Components iecisenciiii i oA a i aan 171 Fixed Cost Components siiin i e a edera er ar i o onn 171 Hot Side SCR Total Cost Results sisicicse nenit rieri anre oenn 172 Cost Components ene nn tee a A apa sda 172 Mercury 175 Mercury Removal Efficiency Inputs 0 0 0 ccc eesesesceceseeecesecseeecseecseecsseecseeeeeceseesssersneeeeee 175 Removal Efficiency of MEeLrcury ceseeesseecsseecsseceeesseesseecsseecseeceseee
494. ost per ton of pollutant removed or avoided For energy intensive CO controls there is a big difference between the cost per ton CO removed and the cost per ton avoided based on net plant capacity Since the purpose of adding a CO unit is to reduce the CO emissions per net kWh delivered the cost of CO avoidance is the economic indicator that is widely used in this field Capture Plant CO Emissions Ib kWh This is the amount of CO vented to the air for every kilowatt hour of electricity produced in the power plant that is using CO Capture Technology Cost of Electricity MWh The IECM framework calculates the cost of electricity COE for the overall Capture Plant by dividing the total annualized plant cost yr by the net electricity generated kWh yr Reference Plant CO Emissions Ib kWh This is the amount of CO vented to the air for every kilowatt hour of electricity produced in the power plant with No CO Capture Cost of Electricity MWh The IECM framework calculates the cost of electricity COE for the overall Reference Plant by dividing the total annualized plant cost yr by the net electricity generated kWh yr Cost of CO Avoided ton This is the economic indicator widely used in the field calculated as the difference between the cost of electricity in the capture plant and the reference plant divided by the difference between the CO emissions in the reference plant and the capture plant
495. ot from top to bottom and left to right as they display on the screen Recycled Flue Gas Entering Preheater Flue gas can be recycled back into the boiler when an O2 CO gt Recycle configuration is specified in Configure Plant This is more commonly known as an oxyfuel configuration Flue gas is not recycled in any other configuration Integrated Environmental Control Model User Manual Air Preheater 135 Recycled Flue Gas Temp Temperature of the recycled flue gas entering the induced draft fan Recycled Flue Gas Volumetric flow rate of the recycled flue gas entering the induced draft fan Atmospheric Air Entering Preheater Ambient Air Temp Temperature of the atmospheric air entering the induced draft fan Ambient Air Volumetric flow rate of air entering the induced draft fan based on the atmospheric air temperature and atmospheric pressure Heated Air Exiting Preheater Heated Oxidant Temp Heated combustion air or recycled flue gas temperature exiting the air preheater This is a complicated function of the heat content and temperatures of the flue gas Heated Oxidant Volumetric flow rate of the combustion air or recycled flue gas exiting the air preheater based on the combustion air temperature and atmospheric pressure Leakage Air Leakage Air Temp Temperature of the atmospheric air leaking across the air preheater into the flue gas This is determined by the leakage parameter on the base plant performan
496. ove This item is highlighted in yellow Sulfur Removal Beavon Stretford Plant Flue Gas Results 7 IECM Interface a Eile Edit View Window Help lol x D REE eS Configure Plant Set Parameters E Air Separation 5 Tail Gas Out Tail Gas Out Major Gas Components h moles hr ton hr a amo sa f 2 Oxygen O2 0 0 0 0 3 Water Vapor H20 226 9 2 045 4 Carbon Dioxide CO2 686 5 15 11 5 Carbon Monoxide CO 0 0 0 0 Hydrochloric Acid HCD 0 0 0 0 Sulfur Dioxide S02 0 1135 3 634e 03 Sulfuric Acid equivalent S03 0 0 0 0 Nitric Oxide NO 1 146e 02 1 720e 04 Nitrogen Dioxide OJ 6 033e 04 1 388e 05 Ammonia NH3 0 0 0 0 Y Argon A 0 0 0 0 Process Type 3 Beavon Stretford Plant X 1 Treated Gas 2 Flue Gas Sulfur Removal Beavon Stretford Plant Flue Gas Results Major Flue Gas Components Nitrogen N2 Total mass of nitrogen Oxygen O2 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid on an SO3equivalency basis Nitric Oxide NO Total mass of nitric oxide Integrated Environmental Control Model User Manual Sulfur Removal 347 Nitrogen Dioxide NO3
497. over chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a fabric filter that has been paid off Power Block O amp M Cost Inputs This screen is only available for the Combustion Turbine and IGCC plant types 7 IECH Interface ioj xi Fie Edit View Go Window Help Us Untitled sioi xi Configure Plant Set Parameters CO2 Capture PALGI Mgmt Units MWh Number of Operating Jobs jobs shift Number of Op erating Shifts shifts day Operating Labor Rate hr Total Maintenance Cost HTPC Maint Cost Allocated to Labor total Administrative amp Support Cost total labor zs t 5e lalelo Process Type Power Block z Costs are in Constant 2005 dollars 1 Gas Turbine
498. ow Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Wet FGD e 241 Spray Dryer The SO2 Control Technology Navigation Tab contains screens that address post combustion air pollution technologies for Sulfur Dioxide The model includes options for a Lime Spray Dryer A spray dryer is sometimes used instead of a wet scrubber because it provides simpler waste disposal and can be installed with lower capital costs These screens are available if the Lime Spray Dryer SO control technology has been selected in Configure Plant for the Combustion Boiler plant type Spray Dryer Configuration This scr
499. own on the bottom of the screen Each result is described briefly below MEA Scrubber Process Area Costs Direct Contact Cooler This area includes the equipment required to cool the flue gas in order to improve absorption of CO into the amine sorbent In case of coal fired power plant applications that have a wet FGD flue gas desulfurization unit upstream of the amine system the wet scrubber helps in substantial cooling of the flue gases and additional cooler may not be required Flue Gas Blower The flue gas has to overcome a substantial pressure drop as it passes through a very tall absorber column countercurrent to the sorbent flow Hence the cooled flue gas has to be pressurized using a blower before it enters the absorber CO2 Absorber Vessel This is the vessel where the flue gas is made to contact with the MEA based sorbent and some of the CO from the flue gas gets dissolved in the sorbent The column may be plate type or a packed one Most of the CO absorbers are packed columns using some kind of polymer based packing to provide large interfacial area Heat Exchangers The CO loaded sorbent needs to be heated in order to strip off CO and regenerate the sorbent On the other hand the regenerated lean sorbent coming out of the regenerator has to be cooled down before it could be circulated back to the absorber column Hence these two sorbent streams are passed through a cross heat exchanger where the rich CO gt loaded s
500. ownloaded to your local computer or network hard drive gt Center for Energy and Environmental Studies Windows Internet Explorer iof x go y JE http www iecm online com index html S x 116 Pir w ae Center for Energy and Environmental Studies A cp Page 9 Tools Welcome to the Integrated Environmental Control Model A tool for calculating the performance emissions and cost of a fossil fueled power plant Developed by Carnegie Mellon University CMU Department of Engineering amp Public Policy EPP With Support from United States Department of Energy s National Energy Technology Laboratory NETL If you have questions or comments please contact us www iecm online com Home Page Downloading the IECM from the internet To download the install software to your computer 1 Open a web browser program e g Internet Explorer or Netscape 2 Inthe Address line of the browser type the following http www iecm online com iecm_dl com You will see the iecm download page Integrated Environmental Control Model User Manual gt Integrated Environmental Control Model Download Windows Internet Explorer ioj xj E E http www iecm online com iecm_dl html li X ff Google Pi w de Integrated Environmental Control Model Download id A 7 y Page G Tools Welcome to the Integrated Environmental Control Model Download Now Downoad TEEM New Fe
501. ox T 02 CO2 By Prod Preheater Control ereury Control Control Capture Memt al Ash Entering Flue Gas 80 00 Mercury Removal Fuel In ton ht Mercury In b hr 7 000 166 7 ee 3 799e 02 Temperature Out deg F Flue Gas Out acfm Fly Ash Out ton hr Mercury Out lb hr Temperature deg F Heated Air acfm 700 0 2 086e 06 9 726 35336 02 497 9 1 656e 06 Dry Bottom Ash ton hr Sluice Water ton hr 0 0 Wet Bottom Ash ton hr 2 432 Process Type Boiler 7 1 Diagram 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost Boiler Diagram result screen Each result is described briefly below in flow order not from top to bottom and left to right as they display on the screen Integrated Environmental Control Model User Manual Fuel Entering Boiler Wet Fuel In Fuel flow rate into the boiler on a wet basis Waste products removed prior to the burners are not considered here Mercury In This is the mass flow rate of total mercury entering the boiler The mass reflects the molecular weight of elemental mercury Boiler Performance Ash Entering Flue Gas Percent of the ash in coal exiting the boiler in the flue gas Mercury Removal Percent of the total mercury in coal removed from the boiler in the bottom ash Air Entering Boiler Temperature Heated air temperature measured at the burners This is generally determined by the combustion air t
502. oxide NO3 Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow 106 e Base Plant Integrated Environmental Control Model User Manual Boiler Capital Cost Results The Capital Cost result screen displays tables for the direct and indirect capital costs related to the Combustion Boiler ioi File Edit View Go Window Help LI MMi Configure Plant Set Parameters Get Results NOx Control Base Plant Process Area Costs Mls Base Plant Plant Costs 128 2 Turbine Island 92 79 General Facilities Capital Coal Handling 43 18 Eng amp Home Office Fees Ash Handling 7 720 Project Contingency Cost Water Treatment 7 833 Process Contingency Cost Auxiliaries 34 05 Interest Charges AFUDC Royalty Fees Preproduction Startup Cost Inventory Working Capital ale le o 2 e o l wg 4 gt a R Boiler Capital Cost result screen Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Direct Capital Costs The direct capital costs described here apply to the base power plant without any of the environmental control options that are separately modeled in the IECM While the purpose of the IECM is to model the cost
503. oxide SO Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO3 Total mass of nitrogen dioxide Ammonia NHs Total mass of ammonia Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Power Block Capital Cost Results This screen is only available for the Combustion Turbine and IGCC plant types 384 e Power Block Integrated Environmental Control Model User Manual 7 IECH Interface Fie Edit Yiew Go Window Help DA Untitled Configure Plant Set Parameters Get Results By Prod CO2 Capture PANA Mgmt Power Block Process Area Costs Power Block Plant Costs ale le jo e o c Heat Recovery Steam Generator Steam Turbine HRSG Feedwater System General Facilities Capital Eng amp Home Office Fees Project Contingency Cost Process Contingency Cost Interest Charges AFUDC Royalty Fees Preproduction Startup Cost Inventory Working Capital w si Zj tt j ja lola Costs are in Constant 2005 dollars LGT Diagram 2ST Diagram 3Syngas f 4FlueGas ROEM 6 O amp MCost 7 TotalCost Power Block Capital Cost results screen This result screen displays tables containing the Power Block Capital Costs Capital costs are typically expressed in either constant or current dollars
504. p home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables
505. p M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a fabric filter that has been paid off O CO Recycle O amp M Cost Inputs This screen is available for Combustion Boiler plant types Integrated Environmental Control Model User Manual O2 CO2 Recycle e 291 292 e O2 CO2 Recycle 7 IECH Interface ioj xi Fie Edit View Go Window Help Configure Plant Set Parameters Get Results Base Plant Mercury Cc apture Title Misc Chemicals Cost ton CO2 Wastewater Treatment Cost ton Electricity Price Base Plant MWh AT 100 0 _ Number of Operating Jobs jobs shift J 30 00 Number of Operating Shifts shifts day 4 y 10 00 Operating Labor Rate hr 5 K
506. pacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the power block that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor Power Block O amp M Cost Results This screen is only available for the Combustion Turbine and IGCC plant types 386 Power Block Integrated Environmental Control Model User Manual 7 IECH Interface File Edit View Go Window Help Configure Plant Set Parameters Get Results By Prod Mgmt Stack Variable Cost Component Fixed Cost Component aeh m 9 0 bmt bmt eee Re Dipi w ioe SA AW A VN e Utility Power Credit Operating Labor Maintenance Labor Maintenance Material Admin amp Support Labor Zj tt Power Block Costs are in Constant 2005 dollars 1 GT Diagram 2 ST Diagram 5 Capital Cost WAU RLNE 7 Total Cost Power Block O amp M Cost results screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Var
507. parameter is described briefly below Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC 162 e Hot Side SCR Integrated Environmental Control Model User Manual General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the o
508. pass remixing and prior to reheating Temperature Out Temperature of the flue gas exiting the scrubber This is a function of flue gas bypass saturation temperature reheater and the flue gas component concentrations Flue Gas Out Volumetric flow rate of the flue gas exiting the scrubber after the reheater based on the flue gas temperature exiting the scrubber and atmospheric pressure Fly Ash Out Total solids mass flow rate in the flue gas exiting the scrubber after the reheater This is a function of the ash removal and flue gas bypass input parameters Mercury Out Total mass of mercury exiting the scrubber after the reheater The value is a sum of all the forms of mercury elemental oxidized and particulate FGD Performance Ash Removal Actual particulate removal efficiency in the scrubber This is set by the scrubber ash removal input parameter SO2 Removal Actual removal efficiency of SO in the scrubber This is a function of the maximum removal efficiency scrubber performance input parameter and the emission constraint for SO emission constraints input parameter It is possible that the scrubber may over or under comply with the emission constraint SO3 Removal Percent of SO in the flue gas removed from the scrubber The SO is assumed to combine with H O and leave with the ash solids or sluice water as a sulfate in the form of H SO Mercury Removal Percent of the total mercury removed from the scrubber
509. pe of coal ash properties Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Integrated Environmental Control Model User Manual Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Cold Side ESP Total Cost Results This screen is only available for
510. ped separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Integrated Environmental Control Model User Manual Cold Side ESP Diagram This screen is only available for the Combustion Boiler plant type The Diagram result screen displays an icon for the particulate control technology selected and values for major flows in and out of it Ee 101 x Eile Edit View Window Help Configure Plant Set Parameters Get Results Air NOx 502 CO2 By Prod Stack Preheater Control 1 Control Capture Mgmt me Temperature In deg F 1750 Temperature Out deg F 1750 Flue Gas In acfim 1 392e 06 Flue Gas Out acfm 1 346e 06 Fly Ash In ton hr 26 87 Fly Ash Out ton hr 6 6312 02 Mercury In lb hr 3 633e 02 Mercury Out lb hr 3 533e 03 _ _ s alel le oplo o E z i Ash Removal 303 Removal Mercury Removal Dry Ash ton hi Sluice Water ton hr 0 0 Wet Ash ton hr Process Type Cold Side ESP g Me 2 Flue Gas 2 Capital Cost 4 O amp M Cost 5 Total Cost Cold Side ESP Diagram Each result is described briefly below Flue Gas Entering ESP Temperature In Temperature of the flue gas entering the particulate control technology
511. perating Absorbers This is the number of operating scrubber towers The number is determined by the absorber capacity and is used to calculate the capital costs The value must be an integer Number of Spare Absorbers This is the total number of spare absorber vessels It is used primarily to calculate capital costs The value must be an integer Liquid to Gas Ratio The design of spray towers for high efficiency is achieved by using high liquid to gas L G ratios The calculated value is a function of the reagent type the removal efficiency and stoichiometry It determines the power requirement and capital cost Reagent Stoichiometry This is the moles of calcium per mole of sulfur removed from the absorber The stoichiometry is calculated as a function of the reagent type It is used to determine the liquid to gas ratio reagent usage reagent waste and capital cost Reagent Purity This is the percent of the reagent that is lime CaO or limestone CaCO The calculated value is a function of the reagent type This parameter determines the waste solids produced and the reagent needed to remove the necessary SQ Reagent Moisture Content This is the moisture content of the reagent The remaining reagent impurities are assumed to be inert substances such as silicon dioxide sand This parameter is used to determine the waste solids produced Total Pressure Drop across FGD This is the total pressure drop across the FGD vessel prior
512. perating Shifts shifts day Operating Labor Rate br t mlel aleo Total Maintenance Cost TPC Maint Cost Allocated to Labor total 12 Administrative amp Support Cost total labor 13 14 15 16 17 18 Process Type fi Water Gas Shift Reactor X Costs are in Constant 2005 dollars 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Water Gas Shift Reactor O amp M Cost input screen Inputs for O amp M costs are entered on the Water Gas Shift Reactor O amp M Cost input screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen High Temperature Catalyst Cost This is the unit cost of the iron based high temperature catalyst Low Temperature Catalyst Cost This is the unit cost of the copper based low temperature catalyst Water Cost This is unit cost of water used to drive the water gas shift reaction Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is defined as the air separation unit gasifier and the power block Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent op
513. perator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the spray dryer that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor Integrated Environmental Control Model User Manual Sulfur Removal e 339 Sulfur Removal O amp M Cost Results 340 e Sulfur Removal File Edit View Go Window Help Configure Plant Set Parameters Get Results By Prod CO2 Capture Power Block Stack O amp M Cost M yr Fixed Cost Component Makeup Selexol Solvent 0 1548 Operating Labor Makeup Claus Catalyst 2 992e 03 Maintenance Labor Makeup Beavon Stretford Catalyst 365e 03 Maintenance Material Sulfur Byproduct Credit 1 568 Admin amp Support Labor Disposal Cost 2 537e 02 Selexol Electricity 2 003 Claus Electricity 0 1743 Beavon Stretford Electricity 0 5304 Variable Cost Component J zs t alel aleo S2AAn amp wr
514. perator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to cover chemicals water consumables and solid disposal charges in start up assuming 100 load This excludes any fuels e Misc Capital Costs This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new
515. perature The composition may be changed by the user The location of this syngas composition is after the gasification but prior to the low temperature cooling and water quench Hence the steam content of the syngas is typically in the 10 15 by volume range This screen is only available for the IGCC plant type Integrated Environmental Control Model User Manual 7 IECH Interface Fie Edit View Go Window Help Set Parameters Get Results By Prod CO2 Capture Power Block Memt Sulfur Removal Stack Max Raw Syngas Composition Carbon Monoxide CO Hydrogen H Methane CH9 Ethane C2H6 Propane C3H8 Hydrogen Sulfide H25 Carbonyl Sulfide COS Ammonia NH3 Hydrochloric Acid HCD Carbon Dioxide C02 Moisture H20 a Nitrogen N2 Argon An Total vol 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 T ESQ ES ES US ES ES ES IN IS IS ISIS ISS Z e 2 mel o PI o Ou 3 RetrofitCost 4 CapitalCost 5 O amp MCost Gasifier Gas Flow result screen Raw Syngas Composition Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H2 Total mass of hydrogen Methane CH Total mass of methane Ethane C2Hg Total mass of methane Propane C3Hs Total mass of methane Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total ma
516. pes to be 100 Fuel Cost Input The cost of the cleaned coal transportation costs and other miscellaneous for coal and the auxiliary natural gas costs are accessed on the Cost input screen Note that coal parameters are not displayed for the Combustion Turbine plant type Integrated Environmental Control Model User Manual Fuel e 79 7 IECH Interface File Edit View Go Window Help NOx 02 co2 Control Control Capture 4 000 Aux Natural Gas Costs A 3 e R Natural Gas Cosi 10 00 Fuel Cost input screen Each parameter is described briefly below Coal Costs Coal is the primary fuel for the combustion plant type The costs associated with the coal have been simplified and contain only the total as fired cost Total Delivered Cost as fired This is the total cost of delivered coal on a wet ton basis in dollars per ton It is assumed to contain any costs of cleaning and transportation The total cost in units of ton is the same value as shown on the fuel properties screen Total Delivered Cost as fired This is also provided in units of MBtu This value cannot be edited It is based on the value given above in units of ton Aux Natural Gas Costs Natural gas is an auxiliary fuel used as an option for the combustion NOx control and the amine CO capture configurations Natural Gas Cost This is also provided in units
517. pollution control equipment is reported in the middle portion of the second column The number displayed varies as a function of the components configured in the power plant Net Electrical Output This is the net plant capacity which is the gross plant capacity plus any auxiliary electrical output minus the losses due to plant equipment and pollution equipment energy penalties This is the same value used in the first column Integrated Environmental Control Model User Manual Combustion Overall Plant 35 Combustion Overall Plant Mass In Out Ha a File Edit View Go Window Help Configure Plant Set Parameters Get Results Solid amp Liquid Outputs Bottom Ash Disposed Oi i Fly Ash Disposed Natural Gas i Scrubber Solids Disposed Particulate Emissions to Air Captured CO2 Lime Limestone i Byproduct Ash Sold Sorbent j Byproduct Gypsum Sold Ammonia i Byproduct Sulfur Sold Urea i Byproduct Sulfuric Acid Sold Dibasic Acid Activated Carbon Blo a P le G olo See Tab Process Type overall Plant z 2 Plant Perf a ERUETI 4 Solids In Out 5 GasIn Out 6 TotalCost f7 Cost Summary Combustion Overall Plant Mass In Out result screen The Mass In Out result screen displays the flow rates of fuels and chemicals into the plant and solid and liquid flow rates out of the plant Each result is described briefly below Input Flow Rates Coal Total mass of co
518. ponent Sisaria ete a a E E T a aat 138 In Furnace Controls 141 In Furnace Controls Configuration ccccceescecsscecesececeseeesseecsaeesscecseeceseeeessaeesseeseaeeesee 141 In Furnace Controls Performance Input ceesecessceesseeceeseesneecsseecesaeecsaeecseeecesaeeeeaeers 143 Combustion NO Controls cccc0eeeseseeeeeceeesesseessssesseseseessssssseeeceeeeessestseeeees 144 SNGER NO Control aroan Gistinnaciesscteshe dati viens Meise ESRA ESEA 144 In Furnace Controls Capital Cost ie tiie oisstarheaticitas techie EAEE eerie dae 145 Base Capital Costs e a a E a EE a a E a EE ARST 145 Retrofit Capital Cost Factors reeniro eran i r a ES 146 Total Capita Costs stai aaea esaa a e mati N OA 146 In Furnace Controls O amp M CoSt i ccisicissscesiessseendsassvsassesctecdesscesviesscssvduseceopssesecaseapesnsodsseorsey 146 Variable O amp M Costs jinicnintcuinienininatbenini iy itanistaiatee ait 147 Fixed O amp M CoOsteiveiiesiet cosseioedteanet dit vedicaepaset en be dettpa E apie hide e e 147 In Furnace Controls Diagram eeeescessscessseeecsseceseeesscecesseecsaeecseeessssecnseeesaeessaeeseeeeses 148 Fuel Entering Boiler 232 s 22030s3 na anne etedeviaee dei e aa ries 148 Ai Entering Boiler ssc iecctetiint desi daly da heii lad oad 148 Flue Gas Exiting Convective Zone ccescceseecssecesaeecssecseecseecsseeeesaeessaeeeenes 149 Flue Gas Exiting the ECcOnOmiIZeD cceesceeeseeceseeecess
519. por condenses into the liquid phase Flue Gas Conditioning Water Injected Water added to the flue gas to reduce the temperature No water is injected if water injection is not specified in the configuration or the inlet temperature is within the approach to saturation relative to the acid dew point Carbon Injected Total activated carbon mass flow rate injected into the flue gas NOTE Carbon injected into the flue gas is collected downstream in the particulate control device e g the cold side ESP Mercury Flue Gas Results This screen is only available for the Combustion Boiler plant type The Flue Gas result screen displays a table of quantities of flue gas components entering and exiting the flue gas conditioning area For each component quantities are given in both moles and mass per hour 7 IECM Interface Eile Edit View Window Help D E eS Set Parameters Get Results Ai TEA T5F 02 cO2 By Prod ae Madde Control Control Capture Mgmt 3 Flue Gas In Flue Gas Out Flue Gas In Flue Gas Out h moles hr Ih moles hr ton hr tonhr 1 266e 05 1 266e 05 1773 1773 Oxygen 02 9402 3402 1504 150 4 Water Vapor H20 1 361e 04 1 361e 04 122 7 122 7 Carbon Dioxide CO2 2 050e 04 2 050e 04 4514 451 4 Carbon Monoxide CO 0 0 0 0 0 0 0 0 Hydrochloric Acid HC 5 643 5 643 0 1029 0 1029 Sulfur Dioxide 802 214 2 214 2 6 862 6 862 Sulfuric Acid equivalent 03 0 8639 0 8639 3 458e 02 3 458e 02
520. pose the collected flue gas waste solids This does not consider by product gypsum sold in commerce Electricity Cost of power consumption of the scrubber This is a function of the gross plant capacity and the scrubber energy penalty performance input parameter Water Cost of water for reagent sluice in the scrubber This is a function of the liquid to gas ratio performance input parameter for the wet FGD The cost is a function of the flue gas flow rate and the slurry recycle ratio performance input parameter for the spray dryer Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It
521. power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Base Plant The Base Plant Technology Navigation Tab screens display and define the performance and costs directly associated with the combustion power plant particularly the boiler Pre combustion and post combustion control technologies are not considered part of the Base Plant The screens described in this chapter all apply to the Combustion Boiler plant type Base Plant Performance Inputs Inputs for the major flow rates and concentrations of the gas and solids streams are entered on the Performance input screen 7 IECH Interface Fie Edit View Go Window Help US Untitled Configure Plant TSP co2 By Prod Control Capture Mgmt Gas Temp Exiting Economizer Gas Temp Exiting Air Preheater Percent Water in Bottom Ash Sluice izi t me e aeo Base Plant Power Requirements Coal Pulverizer Steam Cycle Pumps
522. pplied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Integrated Environmental Control Model User Manual Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the spray dryer that is used in determining the total power plant cost The effective TCR is d
523. presents the amount of makeup water used for sluicing fly ash that is entrained in the flue gas and removed by air pollution control system equipment such as ESP There may no need of makeup water to sluice fly ash as the blowdown from the wet tower and bottom ash pond overflow can be reused as sluice water FGD Makeup The variable presents the amount of makeup water needed to replace the evaporated water in the reagent sluice circulation stream CCS Makeup The variable presents the amount of makeup water needed to replace the loss from contact cooler evaporation dilute the makeup MEA and supplement the reclaimer loss when amine based capture system is used Water Consumption Results This screen is only available for pulverized coal power plants This screen summarizes water consumption across the entire plant Major outputs are briefly described below 34 e Water Systems Integrated Environmental Control Model User Manual IECM Interface 6 1 1 ek iz R mlel le al 2 Water Consumption Sd 1 Diagram Water Consumption Result Screen Water Consumption This variable presents the total amount of water consumed across the entire plant including associated environmental control technologies FGD Evaporation This variable presents the amount of evaporation water in FGD when it is loaded Wet Tower Evap This variable presents the amount of evaporation and drift losses in the wet tower when the wet cooling tower
524. pture Power Block GasIn Gas Out GasIn Gas Out Major se Componenis h moles hr h moles hr tonhr towhr i 2 Hydrogen H2 3 Methane CH4 4 Ethane C2H6 Propane C3H8 Hydrogen Sulfide H25 4825 24 13 8 222 0 4111 Carbonyl Sulfide COS 0 1330 0 1330 3 996e 03 3 996e 03 Ammonia NH3 0 0 0 0 0 0 0 0 Hydrochloric Acid HCD 0 0 0 0 0 0 0 0 10 Carbon Dioxide CO2 0 0 0 0 0 0 0 0 11 Water Vapor H20 0 0 458 4 0 0 4 130 12 Nitrogen ND 0 0 861 8 0 0 12 07 13 Argon Ar 0 0 0 0 0 0 0 0 14 Oxygen 02 0 0 1 526e 05 0 0 2 441e 07 15 Process Type 4 Claus Plant he ho LAr N 2 Treated Gas Sulfur Removal Claus Plant Treated Gas results screen z R B e lalelo Major Syngas Components Carbon Monoxide CO Total mass of carbon monoxide Hydrogen H2 Total mass of hydrogen Methane CH Total mass of methane Ethane C2H6 Total mass of ethane Propane C3Hg Total mass of propane Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbonyl sulfide Integrated Environmental Control Model User Manual Sulfur Removal e 345 Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of hydrochloric acid Carbon Dioxide CO2 Total mass of carbon dioxide Water Vapor H20 Total mass of water vapor Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Oxygen O2 Total mass of oxygen
525. quired TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a fabric filter that has been paid off CO Transport System O amp M Cost Inputs This screen is available for all plant types File Edit View Go Window Help z eS Configure Plant Set Parameters Get Results CO2 Eegist ed tracy Control Capture 8 Title Min Max amp 1 BoosterPumpOperatingCost_ PFC 1 500 oo 100 0 2 B aa _ e 3 Fixed O amp M Cost Smiter 4989 0 0 3 219e 04 4 E 5 s 7 7 8 9 ll a0 ll 12 13 Process Type coz Transport Costs are in Constant 2005 dollars 1 Config 3 Retrofit Cost 4 Capital Cost 5 O amp M Cost CO Transport System O amp M Cost input screen 360 e CO2 Transport System Integrated Environmental Control Model User Manual Inputs for operation and maintenance are entered on the O amp M Cost input O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each parameter is described briefly below Booster Pump Operating Cost This is the cost of operating a booster pump as a percent of the process facilities capital Fixed O amp M Cost These are the operating and maintenance fixed costs including all maintenance materials and all la
526. quirements and ambient conditions for the power plant These parameters have a major impact on the performance and costs of each of the individual technologies Capacity Factor This is an annual average value representing the percent of equivalent full load operation during a year The capacity factor is used to calculate annual average emissions and materials flows Gross Electrical Output This is the gross output of the generator in megawatts MWg The value does not include auxiliary power requirements The model uses this information to calculate key mass flow rates The value here is shown for reference only The value is controlled primarily by the number of gas turbines selected from the Power Block tab Net Electrical Output This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties The value cannot be changed and is shown for reference only Ambient Air Temperature This is the inlet temperature of the ambient combustion air prior to entering the preheater The model presumes an annual average temperature Inlet air temperature affects the boiler energy balance and efficiency It provides a reference point for the calculation of pressure throughout the system Currently the model cannot have temperatures below 77F Ambient Air Pressure This is the absolute pressure of the air inlet stream to the boiler The air pressure is used to conver
527. r Manual In Furnace Controls 147 SNCR Boiler ModificationsVariable O amp M Costs This is the total fixed O amp M cost for the SNCR equipment alone This input is not shown if one of the SNCR options is not selected In Furnace Controls Diagram This screen is only available for the Combustion Boiler plant type 7 IECH Interface Fie Edit View Go Window Help t mlel aleo Untitled Configure Plant Stoic mol NH3 mol NOx SNCR Reagent tons hr Wet Coal In tons hr Mercury In lb hr Mercury 1 126 1 260 No Overfire Ait No Reburn 166 6 R 3 797e 02 Convective Zone Temperature F Flue Gas acfm Fly Ash tons h Mercury lb hr 700 0 2 090e 06 9 722 3 5310 02 vernennen Process Type ERECTA X 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost 1 Diagram In Furnace Controls Diagram Set Parameters Control Get Results 502 coz Capture Temperature Out F Flue Gas Out acfm Fly Ash Out tons hr Mercury Out lb hr Ammonia Slip ppmw Temperature F Heated Air acfim Boiler NOx Removal SNCR NOx Removal By Prod Mgmt Stack 700 0 2 090e 06 9 722 3 531e 02 17 56 499 6 1 662e 06 The Diagram result screen displays an icon for the In Furnace Controls NO technology selected and values for major flows in and out of it Fuel Entering Boiler Wet Coal In Fuel flow
528. r Systems 7 IECM Interface 6 1 1 File Edit View Go Window Help D la olaa Le al e gt R Le Untitled Configure Plant Set Parameters o Get Results Mgmt Title i Calc Min Max Default Wet Cooling Tower Ambient Air Temp Dry Bulb Avg 15 00 100 0 77 00 Sir Wet Bulb Temperature Avg 15 00 100 0 alc Cooling Water Inlet Temperature 50 00 1200 90 00 Cooling Water Temperature Drop 10 00 30 00 calc Cycles of Concentration 2 000 20 00 4 000 Tower Drift Loss 1 oo 01000 1 000e 3 Auxiliary Cooling Load 2 v 0 0 20 00 calc Tower Overdesign Factor total load E 0 0 20 00 0 0 1 Recirculating Water 2 Primary Steam Cycle 18 Power Requirement Process Type we LConig PREECE 3 RetrofitCost 4 CapitalCost 5 O amp M Cost i Wet Cooling Tower Performance Input Screen Ambient Air Temp Dry Bulb Avg This refers basically to the ambient air temperature measured by a thermometer This input specifies annual average ambient temperature Air Wet Bulb Temperature Avg This refers to the temperature of air that is cooled adiabatically to saturation at a constant pressure by evaporation of water into it That is calculated in terms of ambient dry bulb temperature and humidity That is the lowest temperature that can be reached by evaporating water into the air Cooling Water Inlet Temperature This is the temperatur
529. r reheat plus the actual electrical output power required for pumps and booster fans Wet FGD Additives Inputs This screen is only available for the Combustion Boiler plant type If a limestone reagent with additives is selected from the Config input screen the screen below will be displayed y IECM Interface File Edit View Go Window Help 0 US Untitled Configure Plant Set Parameters NOx Base Plant Mercury Control Title Units Unc Value Chloride Removal Efficiency i 90 00 Dibasic Acid Concentration ppmw 1000 Dibasic Acid Makeup tb ton S02 rem 10 00 Zis lt mler alelo 13 14 15 pol 17 18 Process Type wet FGD EWN 4 RetrofitCost S CapitalCost 6 O amp M Cost Wet FGD Additives input screen for limestone and lime reagents Integrated Environmental Control Model User Manual Wet FGD e 227 The parameters are described briefly below Chloride Removal Efficiency Chlorides in the flue gas inlet stream are removed by the lime limestone slurry This parameter determines the amount of chlorides removed Dibasic Acid Concentration Dibasic acid DBA is added to limestone to reduce the liquid to gas ratio enhancing the removal of SO This is the concentration of DBA in the limestone slurry Dibasic Acid Makeup DBA is not completely recovered in the reagent feedback loop This parameter is used to determine the makeup
530. rage annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Booster Pump Operating Cost This is the total capital cost of a booster pump Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow 366 e CO2 Transport System Integrated Environmental Control Model User Manual CO Transport System Total Cost Results This screen is available for all plant types 7 IECH Interface Fie Edit View Go Window Help Configure Plant Set Parameters Get Results By Prod Mgmt Stack Variable Cost Component Fixed Cost Component Booster Pump Operat
531. rain CO2 Capacity _ 1b moles hr 1 500e 04 1 3 000e 04 1 500e 04 Number of Operating Absorbers integer 3 Menu calc Number of Spare Absorbers integer 0 be Menu 0 Thermal Energy Credit mwg 3 870 i 10 00 Blo t a ale loeo Process Type fi Water Gas Shift Reactor 1 Performance 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Water Gas Shift Reactor Performance input screen Water Gas Shift Reactor Unit CO to CO Conversion Efficiency Most of the CO in the raw syngas is converted into CO through the Water Gas Shift reaction CO is removed from the shifted syngas through a physical absorption unit This variable is the percentage of CO that is converted to CO in the reaction COS to H2S Conversion Efficiency COS is difficult to remove in the Selexol unit so a polishing unit is added to convert COS to H2S This is the conversion efficiency of the polishing unit Steam Added This parameter determines the amount of water added to the shift reactor in converting CO to CO2 The moles of steam added is proportional to the moles of CO converted Integrated Environmental Control Model User Manual Water Gas Shift Reactor 319 Maximum Train CO Capacity The maximum production rate of CO is specified here It is used to determine the number of operating trains required Number of Operating Trains This is the total number of operating trains It
532. rated Environmental Control Model User Manual Fuel e 77 ave as ZX Saven retiem deade Save as type iEcM Fuel Database fdb gt Cancel Fuels Windows Save As screen Fuel Mercury Input The concentration of mercury in the as fired coal and speciation of mercury after combustion are entered on the Mercury input screen lolxi File Edit view Window Help US Untitled Configure Plant NOx TSP 502 Control Control Control Mercury in Coal elemental A 2 000 Mercury in Oil elemental 0 1000 Mercury in Natural Gas elemental 0 1 000e 02 Mercury Speciation Elemental Oxidized Particulate z R lala P o zgeen _ N w _ A tn a a 18 Process Type Fue Properties Fuel Mercury input screen Each parameter is described briefly below Concentration on a Dry Basis Trace elements found in fuels are typically measured and reported as a mass concentration given on a dry basis The IECM uses this concentration in conjunction with the fuel flow rate and fuel moisture to determine the mass flow rate Currently Mercury is the only trace species tracked in the IECM Mercury in Coal elemental This input parameter specifies the mass concentration of total mercury in the coal given on a dry basis The mercury concentration should be given on an elemental
533. rating scrubber towers The number is determined by the absorber capacity and is used to calculate the capital costs The value must be an integer Number of Spare Absorbers This is the total number of spare absorber vessels It is used primarily to calculate capital costs The value must be an integer Reagent Stoichiometry This is the moles of calcium per mole of sulfur into the absorber The stoichiometry is calculated as a function of the required SO removal efficiency inlet flue gas temperature inlet sulfur concentration and approach to saturation temperature CaO Content of Lime This is the percent of reagent that is pure lime CaO This parameter determines the waste solids produced and the reagent mass requirements given the stoichiometry needed for SO removal H20 Content of Lime This is the moisture content of the lime CaO The remaining reagent impurities are assumed to be inert substances such as silicon dioxide sand This parameter is used to determine the waste solids produced Total Pressure Drop Across FGD This is the total pressure drop across the spray dryer vessel prior to the reheater This is used in the calculations of the power requirements or energy penalty and thermodynamic properties of the flue gas Approach to Saturation Temperature This defines the gas temperature exiting the absorber The approach is the increment over the water saturation temperature at the exit pressure As the approach to
534. ratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 ca
535. re Plant Set Parameters NOx 02 co By Prod FICS iets Control Control Capture Mgmt Stack Min Max 10 00 General Facilities Capital 40 00 Engineering amp Home Office Fees ji i 50 00 Project Contingency Cost i 100 0 Process Contingency Cost s 100 0 Royalty Fees A K 10 00 Pre Production Costs Months of Fixed O amp M Months of Variable O amp M Misc Capital Cost z e le R Ele le mjelo Inventory Capital TCR Recovery Factor Process Type Fabric Filter Config 7 Revo Cost _ Wee Fabric Filter Capital Cost input screen The necessary capital cost input parameters associated with the fabric filter control technology are shown on this input screen no distinction is made between the various types of fabric filtersEach parameter is described briefly below Indirect Capital Costs Costs that are indirectly applied to the technology are based on the process facilities cost Each of the cost factors below is expressed as a percentage of the process facilities cost and is entered on this screen Each parameter is described briefly below Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes
536. re and other impurities e g N2 at acceptable levels Auxiliary Natural Gas Boiler The cost of the natural gas boiler is estimated on the basis of the steam flow rate generated from the auxiliary boiler Auxiliary Steam Turbine The regeneration heat is provided in the form of low pressure LP steam extracted from the steam turbine in case of coal fired power plants and combined cycle gas plants through the Integrated Environmental Control Model User Manual Amine System 277 278 Amine System reboiler a heat exchanger In case of simple cycle natural gas fired power plants a heat recovery unit maybe required Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow MEA Scrubber Plant Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor cove
537. re technology is compressed and dried using a multi stage compressor with inter stage cooling Number of Compressors The number of compressors is a user specified number The value is used to determine the capital cost for sequestration Product Pressure The CO product may have to be carried over long distances Hence it is necessary to compress and liquefy it to very high pressures so that it may be delivered to the required destination in liquid form and as far as possible without recompression facilities en route The critical pressure for CO is about 1070 psig CO Compressor Efficiency This is the effective efficiency of the compressors used to compress CO to the desired pressure Transport amp Storage Storage Method The default option for CO disposal is underground geological storage e EOR Enhanced Oil Recovery e ECBM Enhanced Coal Bed Methane e Geologic Geological Reservoir e Ocean Selexol CO Capture Retrofit Cost Inputs This screen is only available for the IGCC plant type Integrated Environmental Control Model User Manual Selexol CO2 Capture 305 306 Selexol CO2 Capture Fo ole Ea ne Ren Configure Plant Set Parameters Get Results By Prod Power Block Mgnt _ Capital Cost Process Area Absorbers retro new Power Recovery Turbines retro new Slump Tanks retro new Recycle Compressors retro new Flash Tanks retro new Selexol Pumps retro new Reftig
538. re train A train consists of a bottom dump railroad car unloading hopper vibrating feeders conveyors belt scale magnetic separator sampling system deal coal storage stacker reclaimer as well as some type of dust suppression system Slurry preparation trains typically have one to five operating trains with one spare train The typical train consists of vibrating feeders conveyors belt scale rod mills storage tanks and positive displacement pimps to feed the gasifiers All of the equipment for both the coal handling and the slurry feed are commercially available The direct cost model for the coal handling is based upon the overall flow to the plant rather than on a per train basis Gasifier Area The GE gasification section of an IGCC plant contains gasifier gas cooling slag handling and ash handling sections For IGCC plants of 400 MW to 1100 MW typically 4 to 8 operating gasification trains are used along with one spare train Low Temperature Gas Cooling This is the cost associated with the Low Temperature Gas Cooling process area The low temperature gas cooling section includes a series of three shell and tube exchangers Integrated Environmental Control Model User Manual Gasifier 129 130 Gasifier The number of operating trains are estimated based on the total syngas mass flow rate and the range of syngas flow rates per train used Process Condensate Treatment The treated process condensate is used as make up to
539. rect Contact Cooler Integrated Environmental Control Model User Manual Amine System 273 Flue Gas Exiting Amine System Temperature Out Temperature of the flue gas exiting the amine scrubber system Flue Gas Out Volumetric flow rate of the flue gas exiting the amine scrubber Fly Ash Out Total solids mass flow rate in the flue gas exiting the amine scrubber Mercury Out Total mass of mercury exiting the amine scrubber The value is a sum of all the forms of mercury elemental oxidized and particulate Amine System Performance NH Generation The flow rate of ammonia by product produced in the amine scrubbing process CO Removal Actual removal efficiency of CO in the amine scrubber Sorbent Circ The flow rate of the sorbent through the amine scrubber system CO Product Actual amount of CO produced as a result of the amine scrubbing CO Pressure Compressed CO product pressure The product stream is compressed and sent through the pipeline system to the configured sequestration system Collected Solids Reclaimer Waste Total solids mass flow rate of solids removed from the amine scrubber Amine System Flue Gas Results This screen is only available for the Combustion Boiler and Combustion Turbine plant types 274 Amine System Integrated Environmental Control Model User Manual y IECM Interface File Edit Yiew Window Help Set Parameters Flue Gas In Flue Gas Out Flue Gas In Flue Gas Ou
540. reen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each parameter is described briefly below Variable O amp M Costs Urea Cost This is the cost of urea used for any of the SNCR options This input will only display if SNCR or LNB amp SNCR is selected in the In Furnace Controls pull down menu Ammonia Cost This is the cost of ammonia used for any of the SNCR options This input will only display if SNCR or LNB amp SNCR is selected in the In Furnace Controls pull down menu Natural Gas Cost This is the cost of natural gas used for the Gas Reburn option This input will only display if Gas Reburn is selected Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is defined as combustion boiler and an air preheater Fixed O amp M Cost Fixed O amp M costs are given as a total cost rather than itemized costs broken down by individual maintenance and labor costs The results are given as a percent of the total capital cost Combustion Modifications This is the total fixed operating and maintenance cost for boiler NO modifications made in the combustion zone LNB OFA natural gas reburn This parameter is not shown if one of these options is not selected Integrated Environmental Control Model Use
541. ribed briefly below Direct Capital Costs Condenser Structure This area deals with the cost of air cooled condenser equipments erection and installation of the air cooled condensers at the site The cost of the ACC equipments is estimated as a function of initial temperature difference between inlet steam and air based on the cost data estimated by Electric Power Research Institute The erection accounted for approximately 30 of the sum of the equipment and erection cost which is equivalent to about 43 of the ACC equipment cost Scream Duct Support This area deals with the cost of steam duct support and column foundations Electrical amp Control Equipment This area deals with the cost of fan pump motor wiring and controls etc Auxiliary Cooling That deals with the cost of auxiliary cooling including separate fin fan unit or others Clearing System That deals with the cost of clearing finned tube surfaces Integrated Environmental Control Model User Manual Water Systems e 29 Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly That highly depends on the initial temperature difference between inlet steam and air This result is highlighted in yellow Total Capital Costs Process Facilities Cap
542. ricity and is calculated as a function of the utility cost of the base plant The base plant for the Combustion Turbine model is assumed to be the natural gas supply power block and stack This value is calculated and provided for reference purposes only unless User Specified is selected in the pop up in the previous line As Delivered Coal Cost This is the cost of the coal as delivered Natural Gas Cost This is the cost of natural gas in dollars per thousand standard cubic feet Water Cost This is the cost of water in dollars per thousand gallons Limestone Cost This is the cost of limestone in dollars per ton Lime Cost This is the cost of lime in dollars per ton Ammonia Cost This is the cost of ammonia in dollars per ton Urea Cost This is the cost of natural gas in dollars per ton MEA Cost This is the cost of MEA in dollars per ton Activated Carbon Cost This is the cost of activated carbon in dollars per ton Integrated Environmental Control Model User Manual Caustic NaOH Cost This is the cost of caustic NaOH gas in dollars per ton Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Overall NGCC Plant Emis Taxes Inputs This screen allows users to specify emission taxes or credits as part of the overall plant cost economics Taxes or credits are typically provided in either constant or current dollars
543. ring the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This resu
544. rocessing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Total Capital Costs Process Facilities Capital See definition above This result is highlighted in yellow General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spe
545. rod Capture Mgmt Stack Variable Cost Component oe Fixed Cost Component Steam 0 1023 Solid Waste Disposal 1 380 Electricity 3 763 Water 1 604e 02 Operating Labor Maintenance Labor n Maintenance Material w Admin amp Support Labor ne zs t alel aleo ela alaaa n 6 aD Process Type wet FGD z Costs are in Constant 2005 dollars 2 Flue Gas 4 Capital Cost 5 O amp M Cost 6 Total Cost Wet FGD O amp M Cost result screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Reagent The total mass flow rate of lime or limestone injected into the scrubber on a wet basis This is a function of the SO concentration in the flue gas and the reagent stoichiometric performance input value Steam Annual cost of steam used for direct or reheat use in the scrubber This is a function of the steam heat rate reheat energy requirement and gross plant capacity Integrated Environmental Control Model User Manual Wet FGD e 239 Solid Waste Disposal Total cost to dis
546. rol Model User Manual Wet FGD e 225 226 e Wet FGD Maximum SO Removal Efficiency This parameters specifies the maximum efficiency possible for the absorber on an annual average basis The value is used as a limit in calculating the actual SO removal efficiency for compliance Scrubber SO Removal Efficiency This is the annual average SO removal efficiency achieved in the absorber The calculated value assumes compliance with the SO emission limit specified earlier if possible The efficiency is used to determine the liquid to gas ratio and emissions This input is highlighted in blue Scrubber SO Removal Efficiency The default value is taken from the removal efficiency reported in the literature references are below This efficiency then determines the mass of SO removed from the flue gas in the collector For more information see also e www netl doe gov publications proceedings 98 98fg hardman pdf e www netl doe gov publications proceedings 98 98fg rubin pdf Particulate Removal Efficiency This is the percent removal of particulate matter entering the FGD system from the upstream particulate collector Particulate collectors are designed to comply with the specified particulate emission limit This is additional particulate removal Absorber Capacity This is the percent of the flue gas treated by each operating absorber This value is used to determine the number of operating absorbers and the capital costs Number of O
547. rom low to high values and the effect on a model output parameter is observed Meanwhile all other model parameters are held at their nominal values In practical problems with many input variables which may be uncertain the combinatorial explosion of possible sensitivity scenarios e g one variable high another low and so on becomes unmanageable Furthermore sensitivity analysis provides no insight into the likelihood of obtaining any particular result A more robust approach is incorporated in the IECM to represent uncertainties in model parameters using probability distributions Using probabilistic simulation techniques uncertainties in any number of model input parameters can be propagated through the model simultaneously to determine their combined effect on model outputs The result of a probabilistic simulation includes both the possible range of values for model output parameters and information about the likelihood of obtaining various results You may have seen probabilistic analysis referred to elsewhere as range estimating or risk assessment The development of ranges and probability distributions for model input parameters can be based either on statistical data analysis and or engineering judgments The approaches to developing probability distributions for model parameters are similar in may ways to the approach you might take to pick a single best guess number for deterministic point estimate an
548. rsrreessrerrerssee 367 Stack 369 Stack Dia oran ses st cok ives RE G och rs sev ohne svbya eentuee en ceh ont sees REAREA E DN 369 Flue Gas Outre seb shat oer he Riku ave Sea uate Mention teak eaten i aie 369 Fl e Gas EmissioM ois hb oss See ote ot ae leek ee A ek ee A ee Oe 369 Mercury Fini ssi on eaae Steck ra Aint eek A wets eek nated ae aan eee he 370 Mercury Exitine Stack 2 00 26 0 shh oe aii ee eee ea a a e 370 Stack Flue Gas Results 29 0st ach ee eget Ae ee elm tee ee eee tee 370 Major Flue Gas Component aee a e e N A a a A eR 371 Stack Emission Taxes Result sic iscscsisstosnsdsiesievaatansschtatesddatazesatacedeia iene Eaa 372 Tax o EMISSIONS noiis a e lores aahc E aai 372 Power Block 373 Power Block Gas Turbine Inputs cceeseeeseecssceeceseecnseeesaeecsseessaeecsseeeeseseecsaeesneeseneeeeee 373 Gras Turbinie Generator resene resien e p Ree pE e Te a EEEa oaee 373 Ait COMPLE SSOD I i esineen ates orae eeaeee iad O EE e KEEA E Ea NeR Ss 374 Combustor aor aeae enp enee eene eo aee eere oee ES ea n 374 Power Block Stearn Cycle Inputs kenossa eraasi roa E A EARE ar ves 375 Heat Recovery Steam Generator eee ee eseeceesseceeeseeecesseeecessseeecessaeeseeeesaaees 375 Steam LUD o ori apes sh a Ea EE EE dae dyss AEE ESEE Ee EEES eee dass TANE 375 Power Block Total Siesa nie aaea a Anais RE T 375 Power Block Emission Factors caiser epe rear orais aA e E AES SETERS EE EPn i 375 Emission Factors Input Parameters
549. s ccccccssssssccccscccecccccccccssseeseseecsscseseeneecesseess 53 Overall NGCC Plant Total Cost Results 2 0 0 0 cccccccccceccccceseeceseseccccescceceeccseeeccesaecseeeeseeeaes 54 Overall NGCC Plant Cost Summary Results eee eeeeeeceesseeeeseeeceseeeeesseeeseeeesaeees 55 Overall IGCC Plant 57 Overall IGCE Plant Dia grams 2s Me cuds na a a a a A A AE O dies 57 Overall IGCC Plant Performance Inputs cecccceeeecseceeeeesceeeeeeceeeeneeeceseeeeeseneeeeeeeeneees 58 Overall IGCC Plant Constraints Inputs ccecesccceeeeccceeceneceeeeeeeceeenaceeceseneeeesseseeeesaeeeess 59 Overall IGCC Plant Financing Inputs cccceceescceeseeeceeeesnceceeeeeeeseneeecseneeeeeesseneeessneeeess 59 Overall IGCC Plant O amp M Cost Inputs 2000 0 cece ceeeeccceeeeeseseeeeeeeceeeesenaeeeeeeeeeeeesaeeaaeeeeeeeeeaaes 61 Overall IGCC Plant Stack Emis Taxes Inputs cccccceesseccceeeneceeeeeeeeeesneeeeeseeeeeeeneaeens 63 Overall IGCC Plant Performance Results ccccccssssssecccccsscesseeeccccsseeeseseessccssseseceessuees 64 Performatice Parameter seses veidcesteiaieis condos eaeeee ee weud ee etueeade ss uccbav case bo verd ol eee eanees 64 Plant Power Requirements cesccesssecesseeeceeecsseecsseecesseecsaeecsseessssaeeeseeesatecsaeers 65 Overall IGCC Plant Mass In Out Resullts cccccccccceeccccesecccseccececeeecceseeeccsesecceeaceeaeeseeeaes 66 Plant Mpita a T diene hile eine h aia aahiicknht
550. s The C Program Files IECM_CS intdb directory contains the database files used by the IECM interface These contain default data used in the interface program The following files are installed by the installation program Intdesc mdb Microsoft Access database file It contains all the descriptions for the IECM interface screens Model_Default_fules mdb Microsoft Access database file It contains the model default coal information Session Database Files The C Program Files IECM_CS sessdb directory contains the database files created by the IECM interface All user data associated with sessions are stored here These files are not created by the installation program rather they are created by the IECM Interface at runtime if they are not available This means that user data cannot be overwritten by the installation program System Files Several files are installed into the windows system directory These system files are common to many Windows applications All of these files are created and distributed freely through Microsoft Corporation using their installer packages These system files are unique to the other IECM components listed above because they are hard wired into the system registry file In order to maintain consistency with the operating system and stability with the IECM interface these special system files must be stored in the windows system directory and installed with software installers directly fro
551. s listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Integrated Environmental Control Model User Manual Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Water Gas Shift Reactor Total Cost Results File Edit View Go Window Help Us Untitled Bei ki Configure Plant Set Parameters Get Results By Prod Mgmt Po
552. s 6 15 support file LTDIS13N DLL Graphics Server for Windows 6 15 support file sTEFX13N DLL Graphics Server for Windows 6 15 support file TF IL13N DLL Graphics Server for Windows 6 15 support file LTKRN13N DLL Graphics Server for Windows 6 15 support file MFC71 DLL Microsoft Foundation Class support file for Visual Studio NET MFC71U DLL Microsoft Foundation Class support file for Visual Studio NET MSVCR71 DLL Microsoft Visual C runtime library HISTORY TXT History of the IECM software including features installed and planned IECMILIB DLL IECM interface support file It handles all database uncertainty and model access IECMINT EXE IECM program file for the interface IECMINT MDB Microsoft Access 97 template database file LHS DLL IECM interface support file It handles all uncertainty sampling LHS_C DLL IECM interface support file It handles all uncertainty sampling LICENSE TXT IECM license agreement 16 o Installing the Model Integrated Environmental Control Model User Manual MODEL DLL IECM interface model support file It contains all the technology performance and cost modules SPR32d60 d11 Spread 6 0 support file Tab32d30 d11 Tab Pro 3 1 support file UNWISE32 EXE Uninstaller program This requires an installer log created during installation Interface File
553. s Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during construction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other
554. s h e fai gt g R Plant Inlet tons h I No Post Comb NOx Control r No Combustion NOx Control I FOD Makeup tons h CCS Makeup tons hr 47 05 Process Tee ITE a 1 Diagram ff Makeup Water Result Screen Plant Inlet this variable presents the total amount of makeup water required by the plant for boiler cooling system bottom ash sluice fly ash sluice FGD and carbon capture system if applicable Boiler Makeup This variable presents the amount of makeup water for the main steam cycle to supplement boiler blowdown and Integrated Environmental Control Model User Manual Water Systems e 33 miscellaneous steam losses which mainly depends on the boiler blowdown rate Cooling Makeup This variable presents the amount of makeup water for the cooling system There is no makeup water required for once through and air cooled condenser systems For the wet cooling tower the makeup water is required to supplement the evaporation blowdown and drift losses Bot Ash Sluice This variable presents the amount of makeup water used for sluicing bottom ash that is collected at the bottom of the boiler In a wet sluicing system bottom ash is sluiced with water and transported to a bottom ash pond where the ash settles in the pond There may no need of makeup water to sluice bottom ash as the blowdown from the wet tower and bottom ash pond overflow can be reused as sluice water CE ESP Sluice This variable
555. s must be sized to deal with the increased flue gas pressure drop resulting from the additional ductwork and the SCR reactor Structural Support The costs of this area are related primarily to the structural support required for the SCR reactor housing ductwork and air preheater Misc Equipment This area includes the capital costs incurred for ash handling addition water treatment addition and flow modeling for a hot side SCR system Hot Side SCR Capital Cost Inputs This screen is only available for the Combustion Boiler plant type File Edit View Go Window Help D eS Configure Plant Set Parameters Get Results Base Plant Mercury l co 8 Title tA 1 10 00 2 General Facilities Capital i 50 00 E 3 Engineering amp Home Office Fees _ i 50 00 4 Project Contingency Cost i 100 0 ey Process Contingency Cost 100 0 6 Royalty Fees ii 0 10 00 5 t 8 Pre Production Costs 9 Months of Fixed O amp M R 10 Months of Variable O amp M Misc Capital Cost Inventory Capital 18 TCR Recovery Factor Process Type Hot Side SCR 1 Config 2 Perf cont 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Hot Side SCR Capital Cost input screen Inputs for the capital costs of the Hot Side SCR NO control technology are entered on the Capital Cost screen for the Hot Side SCR and the Capital Cost input screen for In Furnace Controls Each
556. s on Emissions are entered by the user in dollars per ton Tax on Emissions Sulfur Dioxide S03 The cost as a result of user entered data to the plant of emitting sulfur dioxide in dollars per ton Nitrogen Oxide equiv NO2 The cost as a result of user entered data to the plant of emitting nitrogen oxide in dollars per ton Carbon Dioxide CO3 The cost as a result of user entered data to the plant of emitting carbon dioxide in dollars per ton Total Emission Taxes This is the sum of the emission taxes displayed above It is highlighted in yellow 372 e Stack Integrated Environmental Control Model User Manual Power Block The power block technology area includes all the equipment necessary to convert the potential and kinetic energy of natural gas or syngas fuels into steam and electricity The process equipment is divided into several areas the gas turbine generator the air compressor the combustor the steam turbine and the heat recovery steam generator These are all available in the Combustion Turbine and IGCC plant types Power Block Gas Turbine Inputs This screen is only available for the Combustion Turbine and IGCC plant types 7 IECM Interface File Edit Yiew Go Window Help US Untitled Configure Plant Set Parameters zioixi Get Results ock sri Stack 403 8 Fuel Gas Moisture Content Turbine Inlet Temperature 33 00 2420 Turbine Back Pressure 2 000 Adiabati
557. s resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up These are typically applied to the O amp M costs over a specified period of time months The two time periods for fixed and variable Integrated Environmental Control Model User Manual O amp M costs are described below with the addition of a miscellaneous capital cost factor e Months of Fixed O amp M Time period of fixed operating costs used for preproduction to cover training testing major changes in equipment and inefficiencies in start up This includes operating maintenance administrative and support labor It also considers maintenance materials e Months of Variable O amp M Time period of variable operating costs used for preproduction to c
558. s screen Major Syngas Components Carbon Monoxide CO Total mass of carbon monoxide Integrated Environmental Control Model User Manual Hydrogen H2 Total mass of hydrogen Methane CH Total mass of methane Ethane C2He Total mass of ethane Propane C3Hsg Total mass of propane Hydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbonyl sulfide Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of hydrochloric acid Carbon Dioxide CO2 Total mass of carbon dioxide Water Vapor H20 Total mass of water vapor Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Oxygen O2 Total mass of oxygen Total Total of the individual components listed above This item is highlighted in yellow Sulfur Removal Selexol Sulfur System Syngas Results 1012 File Edit View Window Help LI ix Configure Plant Set Parameters Get Results By Prod CO2 Capture Power Block Mgmt Stack SyngasIn Syngas Out SyngasIn Syngas Out b moles hr h moles hr ton hr ton hr 2 8 lale pial 9126 9126 1278 1278 2 Hydrogen HD 3150e 04 3150e 04 31 81 31 81 3 Methane CH9 108 0 1080 os660 0 8660 4 Ethane C2H6 C oo oo oo oo Propane C3H9 0 0 0 0 0 0 0 0 Hydrogen Sulfide H25 4924 93847 8390 0 1678 Carbonyl Sulfide COS 0 4032 0 2701 1 211e 02 8 113e 03 Ammonia NH3 3 301
559. seeeseecsseecsseeseseeeesaeeceseneneeeee 319 Water Gas Shift Reactor Retrofit Cost Inputs 0c ceeceeeceeeseeeeceneeeseeceseeeesaeessaeessneeeesnaee 320 Capital Cost Process Area ehipto e neoane e ene ae erii eae anes 321 Water Gas Shift Reactor Capital Cost Inputs eeseeeseseseeesesereserreserssresrrrsrrssrrssressressreereee 321 Water Gas Shift Reactor O amp M Cost Inputs sesseeseeeseeeseeeseseresssserrrsrrrsrersrrssrrsereseresesrersee 323 Water Gas Shift Reactor Diagram 00 ceesceeseecesnceeseseesneeceseeceseeeesaeecsaeecsssaeeeseeesaeeesaeers 324 Water Gas Shift Reactor Syngas Results eeceeesecssecsseeceeeeeesseecsacecsseeessaeeesaeeceesaeessaes 325 Major Syngas Components ceseceeseecsseeessseeceeecsseeceseeeeseeeesaeecsneesesaeeneeeesaes 325 Water Gas Shift Reactor Capital Cost Results ces eesceescccesseeesssecsseeceseeeesaeeesaeesseeenseaes 326 Water Gas Shift Reactor Process Area Costs ccsscesesecsseceseeeceeseessaeeseesseeeees 326 Water Gas Shift Reactor Plant Costs ceeeeeeseesseecssececeeeeeseeeesseecseessneeeesaeeees 327 Water Gas Shift Reactor O amp M Cost Results eeeceesccesscecssneeccsseesseessseeeesaeeeseessneeeeesaes 328 Variable Cost Comp poneha ere ar eas ois asad anid eerie 328 Fixed Cost Components csi a raaraa etisalat nth nda 328 Water Gas Shift Reactor Total Cost Results ceseescecsseccesnececseeeseecsseeessaeessaeessneeeessaes 329 Cost COMPONENE s
560. ser to supply the actual reference plant values Reference values can be obtained by simulating the same plant configuration minus the CO capture Analysts commonly express the cost of an environmental control system in terms of either the cost per ton of pollutant removed or the cost per ton avoided For an energy intensive system like amine scrubbers there is a big difference between the cost per ton CO removed and the cost per ton CO avoided based on net plant capacity Since the purpose of adding a capture unit is to reduce the CO emissions per net kWh delivered the cost of CO avoidance relative to a reference plant with no CO control is the economic indicator most widely used The reference plant parameters required are CO Emission Rate This is the emission rate for the reference power plant without CO capture Cost of Electricity This is the cost of electricity for the reference power plant without CO capture Auxiliary Boiler Configuration This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECM Interface File Edit View Window Help Configure Plant Excess Air Nitrogen Oxide Emission Rate 1b NO2 MCF Percent of NOxasNO _ ae e Steam Turbine Efficiency zi R me le loeo Process Type aux Boiler System 1 Performance Aux Boiler System Performance input screen
561. ses other than power used for the air compressor Net Turbine Output This if the net power generated by the turbine This is the gross output of the turbine minus the power required by the air compressor and any miscellaneous losses Misc Power Block Use This is the power required to operate pumps and motors associated with the power block area Absorption CO Capture Use If a CO Capture system is in use this is the power required to operate the system Aux Power Produced If an auxiliary natural gas boiler is used to provide steam and power this is the additional power that it produces Net Electrical Output This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties Integrated Environmental Control Model User Manual Overall NGCC Plant e 51 Overall NGCC Plant Mass In Out Results 7 IECM Interface k File Edit Yiew Go Window Help Set Parameters Solid amp Liquid Ouiputs oal Slag Oi Ash Disposed Natural Gas f 74 31 i Scrubber Solids Disposed Petroleum Coke i Particulate Emissions to Air izis ele Other Fuels Captured CO2 By Product Ash Sold By Product Gypsum Sold Lime Limestone By Product Sulfur Sold Sorbent i By Product Sulfuric Acid Sold Ammonia Activated Carbon 12 13 Other Chemicals Solvents amp Catalyst A See Tab 15 Process Water Pr
562. sport System Capital Cost input screen Inputs for capital costs are entered on the Capital Cost input screen Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company These fees typically range from 7 15 Project Contingency Cost This is factor covering the cost of additional equipment or other costs resulting from a more detailed design Higher contingency factors will be applied to simplified or preliminary designs and lower factors to detailed or finalized designs Process Contingency Cost This quantifies the design uncertainty and cost of a commercial scale system This is generally applied on an area by area basis Higher contingency factors are applied to new regeneration systems tested at a pilot plant and lower factors to full size or commercial systems Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Pre Production Costs These costs consid
563. ss area accounts for the heat exchangers used Steam generated in the heat exchangers is sent to the steam cycle Water Gas Shift Reactor Capital Cost Inputs File Edit View Go Window Help Configure Plant Set Parameters Get Results By Prod Mgmt Title Min Max 10 00 General Facilities Capital 50 00 Engineering amp Home Office Fees 50 00 Project Contingency Cost 100 0 Process Contingency Cost i 100 0 Royalty Fees H 10 00 Pre Production Costs Months of Fixed O amp M y 12 00 Months of Variable O amp M o 12 00 Misc Capital Cost 10 00 zis t a mle e aolo Inventory Capital 1 10 00 TCR Recovery Factor 100 0 Process Type fi Water Gas Shift Reactor 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Water Gas Shift Reactor Capital Cost input screen Inputs for capital costs are entered on the Capital Cost input screen Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capita
564. ss of carbonyl sulfide Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of hydrochloric acid Carbon Dioxide CO2 Total mass of carbon dioxide Moisture H20 Total mass of water vapor Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Total Total of the individual components listed above This item is highlighted in yellow Gasifier Retrofit Cost Inputs This screen is only available for the IGCC plant type Integrated Environmental Control Model User Manual Gasifier e 121 122 e Gasifier 7 IECH Interface ioj xi zs t alel alelo Fie Edit View Go Window Help Us Untitled ot x Configure Plant Set Parameters Get Results Capital Cost Process Area Coal Handling retro new Gasifier Area retro new Low Temperature Gas Cooling retro new Process Condensate Treatment retro new ama re oms omt omt omt omt am oms aS a REG RETSY naaman 2 Syngas Out 2 Retrofit Cost 4 Capital Cost 5 O amp M Cost Gasifier Retrofit Cost input screen Capital Cost Process Area Coal Handling Coal handling involves unloading coal from a train storing the coal moving the coal to the grinding mills and feeding the gasifier with positive displacement pumps A typical coal handling section contains one operating train and no spare train A train consists of a
565. ssed later however user specified values for control technology performance may cause the plant to over comply or under comply with the emission constraints specified in this screen Each parameter is described briefly below Sulfur Dioxide Emission Constraint The emission constraint is defined by the 1979 revised NSPS The calculated value is determined by the potential emission of the raw coal minus the amount of sulfur retained in the ash streams The emission limit is dependent on the fuel type and is used to determine the removal efficiency of SO control systems Nitrogen Oxide Emission Constraint The combined emissions of NO and NO of present power plants are constrained by NSPS Integrated Environmental Control Model User Manual Combustion Overall Plant 29 standards The limit is a function of the coal rank and fuel type and is used to determine the removal efficiency of NO control systems Particulate Emission Constraint The emission constraint of the total suspended particulates is defined by the NSPS standards of 1978 The limit is a function of the fuel type and is used to determine the removal efficiency of particulate control systems Total Mercury Removal Constraint The emission constraint of total after the economizer Mercury removed in the furnace due to bottom ash removal is not considered in this constraint The limit determines the removal efficiency of the particulate control systems Total CO Removal Cons
566. st adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens The following are the Capital Cost Process Areas for the CO Transport System Material Cost This includes the cost of line pipe pipe coatings and cathodic protection Labor Costs This covers the cost of labor during pipeline construction Right of way Cost This is the cost of obtaining
567. st input screen Capital Cost Process Area The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens The following are the Capital Cost Process Areas for the Flue Gas Recycle portion of the plant Boiler Modifications In case of a pre existing PC plant being retrofitted for CO capture
568. st is a function of the sorbent flow rate Sorbent Recycle This capital cost area represents the materials and equipment necessary to recycle ash and activated carbon from the particulate collector back into the duct injection point The purpose is to create a equilibrium state where the carbon is reintroduced to improve performance Equipment includes hoppers blowers transport piping and a control system The direct capital cost is a function of the recycle rate of ash and spent sorbent NOTE Sorbent recycling is a feature to be added in a future version of the IECM Additional Ductwork This capital cost area represents materials and equipment for ductwork necessary beyond the other process areas Extra ductwork may be required for difficult retrofit installations NOTE Future versions of the IECM will include parameters to determine a capital cost for this area The current version assumes no additional ductwork Sorbent Disposal This capital cost area represents materials and equipment required to house and dispose the collected sorbent Equipment includes hoppers blowers transport piping and a control system This is in excess of existing hoppers tanks and piping used for existing particulate collectors The direct capital cost is determined by the incremental increase in collected solids in the particulate collector CEMS Upgrade This capital cost area represents materials and equipment required to install a continuous emiss
569. st of Electricity cap Cost of Electricity ref CO2 emissions ref CO2 emissions cap Integrated Environmental Control Model User Manual O CO gt Recycle The O2 COz Recycle is a post combustion technology used for CO capture It is more frequently referred to as oxyfuel combustion Two systems are associated with this technology Air Separation and Flue Gas Recycle The following sections describe the performance and result screens for each of these systems The O COz Recycle option is available in the IECM in the Combustion Boiler plant type configuration Please refer to the air separation chapter for help with the oxidant feed input parameters and results O 2 CO Recycle Configuration This screen is available for Combustion Boiler plant types 7 IECH Interface Fie Edit View Go Window Help US Untitled Configure Plant Set Parameters Get Results NOx 2 By Prod Control Mgmt Back Reference Plant inputs for Avoidance Cost Cale CO2 Emission Rate Cost of Electricity izis e x B oleo Process Type Fe Recycle amp Purification z 1 Config 2 CO2 Storage 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost 0O2 CO Recycle Flue Gas Configuration input screen Is this a Retrofit Unit The user may decide whether the unit is added to a new or existing plant Reference Plant Integrated Environmental Co
570. stion NOx Control 0 0 0 0 Technology alp le o B 9 0 m Fa iig Blo t Ble C A wh o o o o Emission Taxes o 5 o o o o o o o E Joverall Plant v Costs are in Constant 2005 dollars 2 Plant Perf 5 Totaicost_ A Overall NGCC Plant Total Cost results screen The Total Cost result screen displays a table which totals the annual fixed variable operations maintenance and capital costs associated with the power plant as a whole Each technology row is described briefly below Technology CO Capture The total cost of all the CO Capture modules used Power Block The total cost of the power block without consideration of any abatement technologies The Power Block contains the air compressor gas turbine steam turbine and heat recovery steam generator areas 54 e Overall NGCC Plant Integrated Environmental Control Model User Manual Post Combustion NO Control The total cost of all the Post Combustion NO removal modules used Subtotal This is the cost of the conventional and advanced abatement technology modules alone This is the total abatement cost The subtotal is highlighted in yellow Emission Taxes This is the sum of the user assessed taxes on the plant emissions of SO NO and COs Total This is the total cost of the entire power plant This result is highlighted in yellow Each cost category column is des
571. stions sug bserv ns or criti garding the softw or umentatior ease send us a note University opment Team Affiliatic 414 e Appendix B Technical Support Integrated Environmental Control Model User Manual Glossary of Terms Integrated Environmental Control Model User Manual Glossary of Terms 415 Index A Absorber 411 D Development software 4 E Emission Constraints 167 U Uncertainty 409 Uncertainty Distributions 404 407 Integrated Environmental Control Model User Manual Index 417
572. struction and is based on an interest rate equal to the before tax weighted cost of capital This interest is compounded on an annual basis end of year during the construction period for all funds spent during the year or previous years Royalty Fees Royalty charges may apply to some portions of generating units incorporating new proprietary technologies Preproduction Startup Cost These costs consider the operator training equipment checkout major changes in unit equipment extra maintenance and inefficient use of fuel or other materials during start up Inventory Working Capital The raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts Total Capital Requirement TCR Money that is placed capitalized on the books of the utility on the service date TCR includes all the items above This result is highlighted in yellow Effective TCR The TCR of the spray dryer that is used in determining the total power plant cost The effective TCR is determined by the TCR Recovery Factor 92 e Air Separation Integrated Environmental Control Model User Manual Air Separation O amp M Cost Results 7 IECM Interface E File Edit view Window Help D Fixed Cost Component Operating Labor Maintenance Labor In Maintenance Material Admin amp Support Labor zi 2 P amp
573. system is loaded CCS Evaporation This variable presents the amount of evaporation loss in direct contact cooler when the amine based capture system is loaded Integrated Environmental Control Model User Manual Water Systems e 35 Integrated Environmental Control Model User Manual Carnegie Mellon University Note This User Documentation applies to Version 5 2 2 and was last updated in 2007 Version 6 2 incorporates some additional modifications that should be easily understood but are not fully documented in this volume This manual was produced using ComponentOne Doc To Help Contents Disclaimer 1 Acknowledgements 2 Introduction 3 The Integrated Environmental Control Model ccceescesseeeeseceeeeeeeseecseessceceseeessaeeeeeees 3 PULPOS Gs ss aiticis AIRE ee SEAS ee Be a a Ie 3 Syst m Requirements nusi Airtel ain ah ti ira eect ts edie 3 Uncertainty Features n sich ann in bribe eat ain bie A ee 4 Software Used in Development ecceseccsscecesseecessecsneecesceessaeecsaeecsaeeecesaeessseesatessaeesseeenea 4 Disclaimer of Warranties and Limitation of Liabilities lee eeeeesseeeceseeeeseeeneeeesseeesneers 5 Copyright Notic Sizaniaikurtiedcin iti nar ian dine pean bi TTT T eine de 5 User Documentation and Help 9 User Mantial cctop a r cate ei een nares alos tee ee eee 9 Technical Manitals tsi ss tiniest heaiteig er a teil e a ara A ei dated 9 Online Helps ntesi a nlite ig nila ees isle a e
574. t Mercury O amp M Cost result screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Activated Carbon This is the activated carbon cost for flue gas conditioning Water This is the water cost for flue gas conditioning Additional Waste Disposal This is the solid disposal cost per year for the flue gas conditioning Only the removal of carbon from the particulate device is considered here Integrated Environmental Control Model User Manual Mercury e 189 Electricity This is the power utilization cost per year for the flue gas conditioning Total Variable Costs This is the sum of all the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts p
575. t D moles hr Ih moles hr ton hr tonhr Nitrogen N2 1 266e 05 1 266e 05 1773 1773 Oxygen 02 9379 9379 150 1 150 1 Water Vapor H20 2413 2413 21 74 21 74 Carbon Dioxide CO2 2 050e 04 2050 4510 45 10 Carbon Monoxide CO 0 0 0 0 0 0 0 0 Hydrochloric Acid HCD 5 643 0 2821 01029 5 144e 03 Sulfur Dioxide S02 41 12 0 2066 1 317 6 586e 03 Sulfuric Acid equivalent 03 1 468e 02 7 338e 05 5 875e 04 2 937e 06 Nitric Oxide NO 10 99 10 99 01649 0 1649 Nitrogen Dioxide VO 0 5783 0 4338 1 330e 02 9 979e 03 Ammonia NH3 0 7392 1451 6 294e 03 1 236 Argon Ad 0 0 07500 00 1 498e 02 Major Flue Gas Components Process Type Amine System e E o co LOM Toulon G Cost Fariors Amine System Flue Gas result screen Major Flue Gas Components Each result is described briefly below Nitrogen N2 Total mass of nitrogen Oxygen 02 Total mass of oxygen Water Vapor H20 Total mass of water vapor Carbon Dioxide CO2 Total mass of carbon dioxide Carbon Monoxide CO Total mass of carbon monoxide Hydrochloric Acid HCI Total mass of hydrochloric acid Sulfur Dioxide S02 Total mass of sulfur dioxide Sulfuric Acid equivalent SO3 Total mass of sulfuric acid Nitric Oxide NO Total mass of nitric oxide Nitrogen Dioxide NO2 Total mass of nitrogen dioxide Ammonia NH3 Total mass of ammonia Argon Ar Total mass of argon Total
576. t input screen Many of the calculated quantities on the Performance screen are determined by the reference parameters described below Reference Parameters The first set of reference parameters is primarily used to determine the actual space velocity The values are used with actual operating conditions through a series of correction factors in the IECM If you set the actual space velocity displayed on the Performance screen this set of input parameters is not used by the IECM and does not have to be set Space Velocity This is the reference space velocity for a high dust system It is used to calculate the actual space velocity Catalyst Replacement Interval This is the reference operating life in hours associated with the reference space velocity for the high dust catalyst It is used to calculate the actual space velocity Ammonia Slip Ammonia slip accounts for the ammonia passing through the reactor unchanged and further downstream The value is based on an 80 percent or lower NO removal efficiency It is used in calculating the ammonia stoichiometry and actual space velocity Temperature This is the operating temperature associated with the reference space velocity It is used to determine the actual space velocity NO Removal Efficiency This is the NO removal efficiency associated with the reference design specifications for the SCR system It is used to determine the actual space velocity NO Concentration This is t
577. t Therefore a power law relationship based on flue gas flow rate is used This is based on cost and flow rate data from Fluor Daniel Inc The cost assumes one absorber vessel per train The cost is a function of the volumetric flow rate of the flue gas and the flue gas temperature Heat Exchangers The CO loaded sorbent must be heated in order to strip off CO and regenerate the sorbent In addition the regenerated sorbent must be cooled down before it can be recirculated back to the absorber column Heat exchangers are used to accomplish these two tasks This area is a function of the sorbent flow rate Circulation Pumps Circulation pumps are required to take the sorbent introduced at atmospheric pressure and lift it to the top of the absorber column This area is a function of the sorbent flow rate Sorbent Regenerator The regenerator or stripper is a column where the weak intermediate compound carbamate is broken down by the application of heat The result is the release of CO in concentrated form and return of the recovered sorbent back to the absorber This process is accomplished by the application of heat using a heat Integrated Environmental Control Model User Manual exchanger and low pressure steam MEA requires substantial heat to dissociate the carbamate Therefore a flash separator is also required where the CO is separated from the moisture and evaporated sorbent to produce a concentrated CO stream This area is
578. t labor and maintenance materials used for plant startup e Variable Operating Cost Time period of variable operating costs at full capacity chemicals water and other consumables and waste disposal changes used for plant startup Full capacity estimates of the variable operating costs will assume operations at 100 load e Misc Capital Cost This is a percent of total plant investment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for an activated carbon and water injection system that has been paid off 182 e Mercury Integrated Environmental Control Model User Manual Mercury O amp M Cost Inputs This screen is only available for the Combustion Boiler plant type File Edit View Go Window Help T Untitled Mi x Configure Plant Set Parameters Get Results 502 coz By Prod Title Units Activated Carbon Cost w shippi ton Mgmt Disposal Cost ton Electricity Price Base Plant MWh Value 1322 13 86 41 12 Unc
579. t Map File Graph Template to sds Fe Ref Strings Browse Name oe le Cancel d Apply Now le Help Pi The System tab in the graph control window allows data to be imported and saved in any method Full control of importing and exporting is accomplished through the System tab in the graph control window as shown in the figure above For more detailed information please consult the graph window help file Graph Window Help Help Topics Graph control Contents Index Find Click a topic and then click Display Or click another tab such as Index QA How to a Enter the property pages 2D Gallery page 3D Gallery page 3D page B Axis page Background page Bound data page Data page Error Bar page Fonts page Labels page Legend page Markers page IJ BIBI i Gose j le Print il l Cancel Detailed Help File Window Detailed graph help is available by clicking the button on the graph window Clicking this button brings up the help file as shown in the figure above This detailed help is not reproduced here Integrated Environmental Control Model User Manual Working with Graphs e 399 Running a Probabilistic Analysis Uncertainty Analysis As noted in the introduction a unique feature of the IECM is its ability to analyze uncertainties probabilistically You may assign probability distributions to any input parameter including calcu
580. t Side SCR Performance Inputs This screen is only available for the Combustion Boiler plant type 156 e Hot Side SCR Integrated Environmental Control Model User Manual y IECM Interface File Edit View Window Help Ber Configure Plant Set Parameters Get Results TSP 502 2 By Prod ntrol Control Control Capture Mgmt Title Maximum NOx Removal Efficiency Particulate Removal Efficiency Number of SCR Trains Number of Spare SCR Trains ale le ole o o Number of Catalyst Layers Dummy Layers number Menu Menu Initial Layers number 3 Menu Menu Reserve Layers mmber o gt Menu mMenu z wg eja alaman Catalyst Replacement Interval hours 1 000e 04 100 0 4 000e 04 Catalyst Space Velocity 1hr 5198 100 0 8000 Ammonia Stoichiometry mol N mol NOx 0 5320 oo 4 000 Steam to Ammonia Ratio mol H20 mol NH3 19 00 0 0 50 00 Total Pressure Drop Across SCR in H20 gauge 9 000 0 0 20 00 Oxidation of 02 to 503 vol 0 5636 i 100 0 Hot Side SCR Power Requirement MWg 2 0524 oo 1000 Process Type Hot Side SCR z h LConigs WPM 3 Perf cont 4 RetrofitCost 5 Capital Cost Hot Side SCR Performance input screen Inputs for the performance of the Hot Side SCR NO control technology are entered on the on the Performance input screen Each parameter is described briefly below Actual NOx Removal Efficiency The actual removal efficiency is
581. t flue gas molar flow rates to volume flow rates The default value is 14 7 psia Integrated Environmental Control Model User Manual Ambient Air Humidity This is the water content of the inlet combustion air This value is used in calculating the total water vapor content of the flue gas stream The value is referred to as the specific humidity ratio expressed as a ratio of the water mass to the dry air mass The default value is 0 018 Overall NGCC Plant Constraints Inputs The Constraints input parameters define the emission constraints as they apply to the gases emitted from the power plant Constraints for sulfur dioxide nitrogen dioxides particulates and mercury are not needed due to the cleaner emissions from NGCC plants File Edit View Go Window Help B Untitled Mim E Configure Plant Set Parameters Get Results Power Block NOx Control CO2 Capture Mgmt Total CO2 Removal Constraint Bi Lele 2 me e apon Process Type Overall Plant J 2 Constraints 5 O amp M Cost Overall NGCC Plant Emission Constraints input screen The emission constraints determine the removal efficiencies of control systems that capture CQ The level of capture is set to comply with the specified emission constraints As discussed later however user specified values for control technology performance may cause the plant to over comply or under comply w
582. t is described briefly below Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Selexol CO Capture Cost Factors Results This screen is only available for the IGCC plant type 316 Selexol CO2 Capture Integrated Environmental Control Model User Manual y IECM Interface E File Edit View Window Help Get Results By Prod Power Block Mgmt Costof CO2 Avoided Capture Plant CO2 Emissions Ibs kWh Cost of Electricity G MWh Fixed Charge Factor fraction z 8 e oela Reference Plant CO2 Emissions lbs kWh Cost of Electricity M Wh _9 Cost of CO2 Avoided ton
583. t of money that must be collected from customers to compensate a utility for all expenditures in capital goods and services The revenue requirement is equal to the carrying charges plus expenses The revenue required is given on both an annualized and a net power output basis Integrated Environmental Control Model User Manual Overall IGCC Plant The input parameter screens described in the following sections are available when the IGCC is selected as the plant type from the New Session pull down menu These screens apply to the power plant as a whole not to specific technologies Overall IGCC Plant Diagram 7 IECM Interface File Edit View Go Window Help Set Parameters Get Results Air Gasifier Sulfur By Prod Fuel Separati P Removal CO2 Capture Power Block Mgmt IGCC Sour Shift CO2 Config Gasification Options t Gasifier GE Oxygen blown Gas Cleanup Cold gas CO2 Capture Sour Shift Selexol Pic Post Combustion Controls i e g NOx Control None Blo t mle loeo lo Solids Management Slag Landfill Sulfur Sulfur Plant 1 Diagram 2 Plant Perf 5 Total Cost 6 Cost Summary Overall IGCC Plant Diagram screen The Overall IGCC Plant Diagram appears in the Configure Plant Set Parameters and in the Get Results program area The screen displays the plant configuration settings on the left side of the page and a diagram of the configured plant on the right of the page No input para
584. t per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Integrated Environmental Control Model User Manual Mercury 183 Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Mercury Diagram This screen is only available for the Combustion Boiler plant type The Diagram result screen displays an icon for the water and carbon injection systems both part of the overall mercury control option and values for major flows in and out of it 7 IECM Interface E oj x Eile Edit View Window Help Set Parameters TSP Control Carbon Injected ton hr 2 752 Temperature In deg F 300 0 Temperature Out deg F 281 0 Flue Gas In acfm 1 575e 06 Flue Gas Out
585. t type Integrated Environmental Control Model User Manual Spray Dryer e 247 248 e Spray Dryer Fo ole Pa ne RE Configure Plant Set Parameters Get Results CO2 By Prod Base Plant Mercury Capture Mgmt Stack Title Min Max 10 00 General Facilities Capital i 50 00 Engineering amp Home Office Fees i 60 00 Project Contingency Cost 100 0 Process Contingency Cost fl 100 0 Royalty Fees i 10 00 _ CeAANKH amp wn Pre Production Costs Months of Fixed O amp M Months of Variable O amp M 12 Misc Capital Cost 13 14 Inventory Capital 15 16 17 zs t S mle moo 18 TCR Recovery Factor Process Type Spray Dryer z 1 Config 3 Retrofit Cost 4 Capital Cost 5 O amp M Cost Spray Dryer Capital Cost input screen Inputs for capital costs are entered on the Capital Cost input screen Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly The cost typically ranges from 5 20 Engineering amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid t
586. tained in Fly Ash Mass flow rate of mercury present in the fly ash solids on a wet basis Bottom Ash Pond Totals Wet Total Solids The sum of the fly ash and bottom ash solids on a wet basis Total Mercury Mass flow rate of mercury present in the combined bottom ash and fly ash solids on a wet basis By Products Management Flue Gas Treatment Diagram The By Product Management Technology Navigation Tab screens displays the flow rates of solid and liquid substances collected which require management disposal or recovery There are three By Product Management areas Bottom Ash Pond Flue Gas Treatment and Fly Ash Disposal If CO capture has Integrated Environmental Control Model User Manual By Product Management e 351 352 e By Product Management been configured for the plant by the user then a Geological Reservoir is also available These are accessed by the Process Type drop down menu Each management technology has only one Result Navigation Tab Diagram 7 IECM Interface File Edit view Window Help Us Untitled Configure Plant Set Parameters Wet Fly Ash tonb 00 Mercury lb hr Lay Wet FGD Solids tonb 17 42 Mercury lb hs 2 304e 02 z 2 8 le o e o 0 Wet Total Solids ton hr 17 42 Total Mercury lb hr 2 304e 02 Process Type IMEE E pa 1 Diagram By Products Management Bottom Ash Pond Diagram result screen The Flue Gas Treatment Diagram result screen displays an ic
587. tal oxidized and particulate ESP Performance Ash Removal Ash removal efficiency of the particulate control technology This is a function of the ash emission constraint and the inlet ash mass flow rate SO Removal Percent of SO in the flue gas removed from the particulate control technology The SO is assumed to combine with H O and leave with the ash solids as a sulfate in the form of H SO Mercury Removal Percent of the total mercury removed from the particulate control technology The value reflects a weighted average based on the particular species of mercury present elemental oxidized and particulate Collected Fly Ash Dry Ash Total mass flow rate of the solids removed from the ESP This is a function of the solids content in the flue gas and the particulate removal efficiency of the ESP The value is given on a dry basis Sluice Water Water added to the dry fly ash This water is added for transportation purposes Wet Ash Total mass flow rate of the solids removed for waste management This includes dry fly ash and sluice water The value is given on a wet basis Cold Side ESP Flue Gas Results This screen is only available for the Combustion Boiler plant type The Flue Gas result screen displays a table of quantities of flue gas components entering and exiting the Particulate Control Technology For each component quantities are given in both moles and mass per hour 200 Cold Side ESP Integrated
588. tal Cost result screen Cost Component The Total Cost result screen displays a table which totals the annual fixed variable operations maintenance and capital costs Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual Cost The total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow Integrated Environmental Control Model User Manual Spray Dryer e 257 Amine System The amine CO scrubber is a post combustion capture technology It is only used in the Combustion Boiler and Combustion Turbine plant type configurations Amine System Confi
589. te in the flue gas exiting the air preheater This is a function of the percent ash entering the flue gas furnace emissions input parameter and the ash content of the fuel Mercury Out Total mass of mercury exiting the air preheater in the flue gas The value is a sum of all the forms of mercury elemental oxidized and particulate Air Preheater Flue Gas Results This screen is only available for the Combustion Boiler plant type iojxi File Edit Yiew Go Window Help Configure Plant Set Parameters Flue GasIn Air Leak b moles hr b moles hr h moles hr 1 Mogna OOO 1oseros 1 7 t18 04 1 264005 Oxygen 02 4814 4591 9405 Water Vapor H20 1 342e 04 631 4 1 405e 04 Major Flue Gas Components Carbon Dioxide CO2 2049e 04 0 0 2 049e 04 Carbon Monoxide CO 0 0 0 0 0 0 Hydrochloric Acid HCH 5 640 0 0 5 640 Sulfur Dioxide 02 229 00 212 9 Sulfuric Acid equivalent S03 2 933 0 0 1 467 0 1174 Nitric Oxide NO 10 98 0 0 10 98 0 1648 Nitrogen Dioxide NOD 05781 o0 0 5781 1 330e 02 Ammonia NH3 0 2962 0 0 0 2962 2522e 03 T2 Argon An 1292 204 6 1497 25 82 a eC al B a 3l gt ra R Air Preheater Flue Gas result screen Major Flue Gas Components The Flue Gas result screen displays a table of quantities of flue gas components entering and exiting the air preheater For each component entering and exiting in flue gas values
590. tenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Integrated Environmental Control Model User Manual Water Systems e 27 Air Cooled Condenser Diagram 28 e Water Systems This screen is available for all plant type The Diagram result screen displays an icon for the Air Cooled Condenser selected and values for major flows in and out of it and its size 7 JECM Interface File Edit view Go Window Help is Untitled Configure Plant i Set Parameters Number of Cells 53 00 Footprint Area sq f 6 289e 4 Steam In tons hr Steam Temperature CF Initial Temp Diff CF Air Cooled Condenser ACC Process Type TEETE SGM 2 CopitlCost 3 O amp M Cost 4 Total Cost Air Cooled Condenser Diagram Each result is described briefly below Number of Cells Number of cells in the dry cooling system Each cell has eight heat exchanger bundles in the default The heat exchanger bundle consists of two row staggered plat finned flat tubes Footprint Area The plot area of the dry cooling system That is a function of initial temperature difference between inlet steam and air and ambient pressure Steam In The total mass flow rate of the exhaust steam That depends on the plant size and steam cycle heat rate Steam Temperature The temperature of exhaust steam entering the air cooled condensers That is empirically es
591. the scrubber The value reflects a weighted average based on the particular species of mercury present elemental oxidized and particulate Collected Solids Dry Solids Total solids mass flow rate of solids removed from the scrubber This is a function of the solids content in the flue gas and the particulate removal efficiency of the scrubber The solids are assumed to be dry Spray Dryer Flue Gas Results 252 e Spray Dryer This screen is only available for the Combustion Boiler plant type Eile Edit View Window Help Q e Get Results Air co2 By Prod H 1 u Capture Mgmt Stack 3 Flue Gas In Flue Gas Out Flue Gas In Flue Gas Out h moles hr h moles hr ton hr towhr Major Flue Gas Components 1 266e 05 1 266e 05 1773 1773 Oxygen 02 9409 9379 150 5 150 1 Water Vapor H20 1 406e 04 2 413e 04 126 7 217 4 Carbon Dioxide COJ 2 050e 04 2 050e 04 451 0 451 0 Carbon Monoxide CO 0 0 0 0 0 0 0 0 Hydrochloric Acid HCD 5 643 5 643 0 1029 0 1029 Sulfur Dioxide SOD 213 0 4112 6823 1 317 Sulfuric Acid equivalent 03 1 468 0 1468 5 875e 02 5 875e 03 Nitric Oxide NO 10 99 10 99 0 1643 0 1649 Nitrogen Dioxide NO2 0 5783 0 5783 1 330e 02 1 330e 02 Ammonia NH3 0 7392 0 7392 6 294e 03 6 294e 03 Argon At 0 0 0 0 0 0 0 0 t T Process Type Spray Dryer Z ruca AEE Spray Dryer Flue Gas result s
592. the IECM from the internet To install the software to from the internet directly onto your computer 1 Open a web browser program e g Internet Explorer or Netscape 2 Inthe Address line of the browser type the following http www iecm online com iecm_dl html You will see the iecm download page Integrated Environmental Control Model User Manual gt Integrated Environmental Control Model Download Windows Internet Explorer ioj xj E E http www iecm online com iecm_dl html li X ff Google Pi w de Integrated Environmental Control Model Download id A 7 y Page G Tools 2 Welcome to the Integrated Environmental Control Model Download Now Downoad TEEM New Features ailed mod pipeline es added of measure Bugs Fixed 1 Interation problem in NGCC with amin www iecm online com Download Page 3 Click on the blue button labeled Download IECM A dialog box will appear File Download Security Warning x Do you want to run or save this file Name IECM_520 exe Type Application 30 9MB From www iecm online com Bun Save i While files from the Internet can be useful this file type can A potentially harm your computer If you do not trust the source do not tun or save this software What s the risk File download dialog box run the program directly 4 Click on the_Run button The installer program will download to a temporary location on your
593. the additional pressure drop electricity to operate pumps and compressors and equivalent energy for steam consumed It is expressed as a percent of the gross plant capacity Hot Side SCR Performance Continued This screen is only available for the Combustion Boiler plant type 158 e Hot Side SCR Integrated Environmental Control Model User Manual CT nix File Edit View Window Help EEE x Configure Plant Set Parameters Get Results TSP 502 2 By Prod ntrol Control Control Capture Mgmt Title i Min Max Space Velocity 8000 Catalyst Replacement Interval 1 000e 04 Ammonia Slip None Temperature 1300 NOx Removal Efficiency 95 00 NOx Concentration 5000 ale le jolelo o ig Za Reference Catalyst Activity Minimum Activity 0 5000 o 1 000 0 5000 Reference Time 1 000e 04 2 500e 04 1 000e 04 Activity at Reference Time 0 8500 1 000 0 8500 Ammonia Deposition on Preheater 5 000 i 25 00 000 Ammonia Deposition on Fly Ash 50 00 100 0 50 00 Ammonia in High Conc Wash W mg l 310 0 i 1000 310 0 Ammonia in Low Conc Wash Wa mg l 40 00 i 100 0 40 00 18 Ammonia Removed from Wash W 67 00 i 100 0 67 00 Process Type Hot Side SCR ial h LConig f 2Pefomance PRPC Retrofit Cost 5 Capital Cost Hot Side SCR Perf cont input screen The Hot Side SCR system has additional inputs for performance entered on the Perf Con
594. the base plant where the base plant is defined as an air separation unit gasifier and the power block Number of Operating Jobs This is the total number of operating jobs that are required to operate the plant per eight hour shift Number of Operating Shifts This is the total number of equivalent operating shifts in the plant per day The number takes into consideration paid time off and weekend work 3 shifts day 7 days 5 day week 52 weeks 52 weeks 6 weeks PTO 4 75 equiv Shifts day Operating Labor Rate The hourly cost of labor is specified in the base plant O amp M cost screen The same value is used throughout the other technologies Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates can be developed separately for each process area Maint Cost Allocated to Labor Maintenance cost allocated to labor as a percentage of the total maintenance cost Administrative amp Support Cost This is the percent of the total operating and maintenance labor associated with administrative and support labor Integrated Environmental Control Model User Manual Gasifier 125 Gasifier Diagram 126 o Gasifier This screen is only available for the IGCC plant type 7 IECH Interface ioj xj File Edit View Go Window Help E Configure Plant Set Parameters Get Results a Air Separation Power Block 4 a Quench Water X Cold Gas
595. the current session If the box is checked the fuel will be available to all new sessions regardless of the primary fuel type they use This filter will be more important when oil fuels are made available in the IECM The Fuel Databases pane displays two additional items that verify whether or not a particular fuel is restricted to particular plant types or for primary fuel types Either a particular plant type and fuel type will be specified or the word lt All gt will be displayed Selecting a Fuel The Current Fuel pane displays the fuel that is in use by the model The Fuel Databases pane initially displays the first default fuel in the model s default database To make the fuel that is displayed in the Fuel Database pane the fuel to be used by the model press the Use this Fuel button The fuel will then be displayed in the Current Fuel pane To view the ash properties press the View Ash Properties button in the Fuels Database the ash properties are displayed and the button that was pressed labeled View Ash Properties has changed to View Fuel Properties This button toggles between View Ash Properties and View Fuel Properties To find other fuels Select a Different Fuel in the Open Database Select the pull down menu on the text box labeled Fuel The list of fuels in the database is displayed another fuel can be chosen Select a Different Open Database Select the pull down menu on the text box labeled Source The list of o
596. the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general factor across an entire process area rather than as a specific uncertainty for the particular cost on the capital or O amp M input screens Any uncertainty applied to a process area through the retrofit cost factor compounds any uncertainties specified later in the capital and O amp M cost input parameter screens Integrated Environmental Control Model User Manual Water Systems e 9 7 IECM Interface 6 1 1 Eek File Edit View Go Window Help Bi EE Untitled DER Configure Plant Set Parameters y Get Results Mgmt Title i i Max Default Capital Cost Process Area Cooling Tower Structure retro new 10 00 1 000 Circulation Pumps retro new i 10 00 1 000 Auxiliary Systems retro new 10 00 1 000 Piping tetro new i 10 00 1 000 Makeup Water System retro new i 10 00 1 000 Component Cooling Water System retro new I 10 00 1 000 Foundation amp Structures retro new i 10 00 1 000 la Le al e gt R Costs are in Constant 2007 dollars LConfig f 2Perfommance WE f 4 Capital Cost 5 O amp M Cost il Wet Cooling Tower Retrofit Cost Input Screen
597. ther open databases is displayed Open Another Fuel Database When pressed the button labeled Open Database will display the Windows Open screen All files with fdb extension will be displayed fdb is the default extension for the Fuel Databases files Select a file and press the Open button Modifying a Fuel The fuel values that are displayed in the Current Fuel pane may be modified Put the cursor into the cell containing the value of the property to be edited and enter the new value To edit the ash properties of the current fuel press the Edit Ash Properties button in the Current Fuel pane the ash properties are displayed and the button that was pressed labeled Edit Ash Properties has changed to Edit Fuel Properties This button toggles between Edit Ash Properties and Edit Fuel Properties The ash properties may be edited in the same way as the fuel Integrated Environmental Control Model User Manual properties Place the cursor in the value of the property to be modified and enter the new value The model will run using the fuel that is displayed in the Current Fuel pane Saving a Modified Fuel A fuel that has been modified may be saved to any user specified fuel database except the default database model_default_fuels mdb Use the Save in Database button to save the modified fuel displayed in the Current Fuel pane to the database that is displayed in the Source text box If the default database model_default_fuels mdb is disp
598. this process area Base Plant Capital Cost Inputs 100 Base Plant Inputs for the capital costs of the Combustion Boiler base plant itself are entered on the Capital Cost input screen Integrated Environmental Control Model User Manual TT alolx File Edit view Window Help EEE oo ox Configure Plant Set Parameters Get Results Default 3 000 3 000 10 00 i 10 00 Engineering amp Home Office Fees 6 500 6 500 Project Contingency Cost 11 67 i 11 67 Proces Contingency Cost 0 3000 i 0 3000 Royalty Fees i 7 000e02 7 000e 02 a Elp le lololo Pre Production Costs Fixed Operating Cost 1 000 1 000 Variable Operating Cost 1 000 1 000 Misc Capital Cost 2 000 J 2 000 Inventory Capital 6 000e 02 i 6 000e 02 18 TCR Recovery Factor 100 0 0 0 100 0 Process Type Base Plant z Costs are in Constant 2000 dollars 3 Retrofit Cost 4 Capital Cost 5 O amp M Cost Base Plant Capital Cost input screen The necessary capital cost input parameters associated with the base plant are on this input screen The capital cost parameters and terminology used in the IECM are based on the methodologies developed by the Electric Power Research Institute EPRI They have prepared a Technical Assessment Guide TAG in order to provide a consistent basis for reporting cost and revenues associated with the electr
599. timated in terms of the steam turbine back pressure Initial Temp Diff That is the temperature difference between inlet steam and steam of the dry cooling system This variable significantly affects the performance and cost of the dry cooling system Integrated Environmental Control Model User Manual Air Cooled Condenser Capital Cost Results This screen is available for all plant types The Capital Cost result screen displays tables for the direct and indirect capital costs related to the Air Cooled Condenser technology 7 IECM Interface File Edit view Go Window Help is Untitled Configure Plant Air Cooled Condenser Process Area Costs Condenser Structure J Sream Duct Support Set Parameters Capital Cost Qs 67 02 0 4221 Capital Cost Air Cooled Conde Plant Costs 0 ondenser os Ms General Facilities Capital Electrical amp Control Equipment 2 078 Eng amp Home Office Fees Auxiliary Cooling 6 814 Project Contingency Cost Clearing System 0 5766 Process Contingency Cost Interest Charges AFUDC 2AAn wn Daana WN Royalty Fees Preproduction Startup Cost Inventory Working Capital Air Cooled Condenser Capital Cost Result Screen Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is desc
600. ting temperature 30 F by refrigeration This process PFC is a function of the solvent flow rate and the temperature difference CO Compressors The CO from the flash tanks is compressed to high pressure gt 1000psia for storage using a multi stage inter stage cooling compressor This process area PFC is a function of the compressor horse power Final Product Compressors Compressed CO from the CO compressors must be further compressed to the final product pressure This process area PFC is a function of the compressor horse power Heat Exchangers Gas gas heat exchangers are used to extract heat from the syngas This process PFC is a function of the heat load of the exchangers and the temperature difference across them Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Selexol CO2 Capture Plant Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead
601. tion process is not very effective at capturing COS so the removal efficiency default is very low CO Removal Efficiency This is removal efficiency of CO for the sulfur recovery system This system is optimized to capture sulfur bearing components of a syngas but maintains an affinity for CO2 The CO2 removed is eventually vented to the atmosphere from the Beavon Stretford technology Max Syngas Capacity per Train This is the maximum flow rate of one Selexol based sulfur recovery vessel It is used to determine the number of absorber vessels required to treat the syngas Number of Operating Absorbers This is the number of absorbers required to treat the entire syngas stream It is used primarily to determine the cost of the sulfur control area Power Requirement This is the equivalent electrical output of thermal steam energy used for reheat plus the actual electrical output power required It is calculated as a function of the syngas flow rate Claus Plant Sulfur Recovery Efficiency This is the recovery efficiency of the Claus Plant in converting H3S to elemental sulfur Max Sulfur Capacity per Train This is the maximum capacity of elemental sulfur from one Claus train Number of Operating Absorbers The number of trains is estimated from the recovered sulfur mass flow rate and the allowable range of recovered sulfur mass flow rate per train Power Requirement This is the equivalent electrical output of thermal steam
602. to the reheater This is used in the calculations of the power requirements or energy penalty and thermodynamic properties of the flue gas Integrated Environmental Control Model User Manual Temperature Rise Across ID Fan An induced draft ID fan is assumed to be located upstream of the FGD system The fan raises the temperature of the flue gas due to dissipation of electro mechanical Gas Temperature Exiting Scrubber A thermodynamic equation is used to calculate this equilibrium flue gas temperature exiting the scrubber The gas is assumed to be saturated with water at the exiting temperature and pressure The value determines the water evaporated in the scrubber Gas Temperature Exiting Reheater This is the desired temperature of flue gas after the reheater It is assumed to be equal to the stack gas exit temperature If scrubber bypass is employed reheat requirements are reduced or eliminated It determines the reheat energy required Entrained Water Past Demister This is a liquid water entrained in the flue gas leaving the demister expressed as a percentage of the total water evaporated in the absorber Oxidation of CaSO to CaSO This parameter determines the mixture of chemical species calcium sulfite and calcium sulfate in the solid waste stream The default values depend on the selection of forced or natural oxidation Wet FGD Power Requirement This is the equivalent electrical output of thermal steam energy used fo
603. total annual cost is the sum of the total annual O amp M cost and annualized capital cost items above This result is highlighted in yellow 154 e In Furnace Controls Integrated Environmental Control Model User Manual Hot Side SCR The NOx Control Technology Navigation Tab contains screens that address combustion or post combustion air pollution technologies for Nitrogen Oxides in the Combustion Boiler plant type configurations If you have selected a Hot Side SCR there will be six input screens and therefore six Input Navigation Tabs If you have selected In Furnace Controls there will be four input screens and therefore four Input Navigation Tabs These input screens are only available if a Hot Side SCR has been selected under Post Combustion Controls in the Configure Plant program area If you have selected both In Furnace Controls and a Hot Side SCR for NO control you may switch between the two sets of screens that configure these technologies by using the Process Type pull down menu at the bottom of the screen Process Type Hot Side SCR bd In Furnace Controls Hot Side SCR The Process Type pull down menu Hot Side SCR Configuration This screen is only available for the Combustion Boiler plant type Integrated Environmental Control Model User Manual Hot Side SCR e 155 y IECM Interface File Edit View Window Help Ei untitled i ioj x Configure Plant Set Parameters Get Results TSP 02 coz By
604. tput of the generator s in megawatts MWg The value does not include auxiliary power requirements The model uses this information to calculate key mass flow rates The value here is shown for reference only The value can be changed for a combustion plant by navigating to the Base Plant Performance Inputs page 95 screen Net Electrical Output This is the net plant capacity which is the gross plant capacity minus the losses due to plant equipment and pollution equipment energy penalties The value cannot be changed and is shown for reference only Ambient Air Temperature This is the inlet temperature of the ambient combustion air prior to entering the preheater The model presumes an annual average temperature Inlet air temperature affects the boiler energy balance and efficiency It provides a reference point for the calculation of pressure throughout the system Currently the model cannot have temperatures below 77 F Ambient Air Pressure This is the absolute pressure of the air inlet stream to the boiler The air pressure is used to convert flue gas molar flow rates to volume flow rates Integrated Environmental Control Model User Manual Ambient Air Humidity This is the water content of the inlet combustion air This value is used in calculating the total water vapor content of the flue gas stream The value is referred to as the specific humidity ratio expressed as a ratio of the water mass to the dry air mass Combust
605. trade name or a unique identifier supplied by the user Rank The rank of a coal refers to the degree of coalification endured by the organic matter It is estimated by measuring the moisture content specific energy reflectance of vitrinite or volatile matter these are known as rank parameters Source The model provides the values for default fuel properties these can be used as is or modified and used Modified fuels maybe stored in a new database or an existing database Source displays the database file from which the data was retrieved or indicates that the data has been enetered by the user Fuel Properties The property value spreadsheet is used to display the heating value and content of carbon hydrogen oxygen chlorine sulfur nitrogen ash and moisture are specified on a weight percent basis for coal fuels The data can be edited only in the Current Coal pane The fuel composition is used in a combustion equation to calculate the flue gas composition in the furnace The heating value is Integrated Environmental Control Model User Manual used to calculate the mass flow rate of fuel Property data also determines the fuel rank bituminous subbituminous or lignite This in turn determines the default values of several boiler parameters The editable fuel properties are Heating Value This is the higher heating value of the fuel in Btu lb Carbon The weight percent of carbon in the fuel on a wet basis Hydrog
606. traint The emission constraint applies to all the air emission sources in the power plant primary or secondary The default value is based on recent discussions and is not based on any currently enforced law Combustion Overall Plant Financing Inputs Inputs for the financing costs of the base plant itself are entered on the Financing input screen Or specify all the following Inflation Rate Plant or Project Book Life Real Bond Interest Rate Real Preferred Stock Return Real Common Stock Return Percent Debt Percent Equity Preferred Stock Percent Equity C ommon Sto cl Federal Tax Rate State Tax Rate Property Tax Rate Investment Tax Credit Process Type overall Plant AE 50EMCot 6 Enis Tares Overall Plant Financing input screen This screen describes the factors required to determine the carrying charge for all capital investments The carrying charge is defined as the revenue required for the capital investment The total charge can also be expressed as a levelized cost factor or fixed charge factor The fixed charge factor is a function of many items The fixed charge factor can be specified directly or calculated from the other input quantities below it on the financial input screen Each parameter is described briefly below Year Costs Reported This is the year in which all costs are given or displayed both in the input screens
607. trol Model User Manual In Furnace Controls 149 and reburn It does not include the removal efficiency of an SNCR system SNCR NOx Removal This is the removal efficiency of the SNCR system alone It does not take into consideration any other NO reduction prior to the SNCR In Furnace Controls Flue Gas Results 150 o In Furnace Controls This screen is only available for the Combustion Boiler plant type 7 IECH Interface Fie Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results TSP 502 coz By Prod Mercury Control Control Capture Mgmt eied Combustion Combustion Convective Major Flue Gas Components Zone In Zone Out Zone Out b moles hr h moles hr Ib moles hr Nitrogen ND 1 082e 05 1 082e 05 1 083e 05 Oxygen 0D 4810 4819 4816 Water Vapor H20 1 297e 04 1 297e 04 1 298e 04 Carbon Dioxide COZ 2 048e 04 2 048e 04 2 049e 04 Carbon Monoxide CO i 0 0 0 0 Hydrochloric Acid HCN i 5 640 5 640 Sulfur Dioxide S502 2144 214 1 Sulfuric Acid equivalent 303 5 1 727 1 727 6 913e 02 6 913e 02 Nitric Oxide NO 36 43 21 97 0 7744 0 5316 10 Nitrogen Dioxide NoD 1 865 1 156 6 249e 02 4 290e 02 11 Ammonia NH3 i 0 0 2 600 0 0 0 0 12 Argon AD 1292 1292 25 82 26 82 13 14 15 sl Process Type n Furnace Controls 2 Flue Gas 3 Capital Cost 4 O amp M Cost 5 Total Cost zs t mlel aleo oa alajaja wln
608. ts shifts day Operating Labor Rate Shr zj ele 2 alej e olo 1 Total Maintenance Cost TPC Maint Cost Allocated to Labor total Administrative amp Support Cost total labor Spray Dryer Costs are in Constant 2005 dollars 1 Config 3 Retrofit Cost 4 Capital Cost 5 O amp M Cost Spray Dryer O amp M Cost input screen Integrated Environmental Control Model User Manual Spray Dryer e 249 Inputs for operation and maintenance are entered on the O amp M Cost input tab O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each parameter is described briefly below Bulk Reagent Storage Time This is the number of days of bulk storage of reagent This factor is used to determine the inventory capital cost Lime Cost This is the cost of Lime for the Wet FGD or Lime Spray Dryer system Waste Disposal Cost This is the sludge disposal cost for the FGD system Electricity Price Base Plant This is the price of electricity and is calculated as a function of the utility cost of the base plant where the base plant is for the Combustion Boiler Model is a combustion boiler and an air preheater Total Maintenance Cost This is the annual maintenance cost as a percentage of the total plant cost Maintenance cost estimates
609. ts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Integrated Environmental Control Model User Manual Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Amine System Total Cost Results This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECH Interface ioj xi Fie Edit View Go Window Help Us Untitled Configure Plant Set Parameters Get Results NOx TSP 02 SOM By Prod Control Control Control p aptur e Mgmt Stack Percent Total 3 670 2 Annual Variable
610. tural Support retro new Misc Equipment retro new Zi e me ooo bt pmt pet Opet Opet pe et et AAAA aa n la kal aie Lad an 18 Process Type Hot Side SCR 1 Config 2 Perf cont 4 Retrofit Cost 5 Capital Cost 6 O amp M Cost Hot Side SCR Retrofit Cost input screen The Hot Side SCR system has inputs for the capital costs of modifications to process areas necessary to implement the technology entered on the Retrofit Cost input screen The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC The retrofit cost factor provided for each of the process areas can be used as a tool for adjusting the anticipated costs and uncertainties across the process area separate from the other areas Uncertainty can be applied to the retrofit cost factor for each process area in each technology Thus uncertainty can be applied as a general f
611. ture Amine System this option puts an amine scrubber at the end of the flue gas train Other locations may be available in the future CO Adsorption this option is grayed out and may be available in the future O2 Transport Membrane this option is grayed out and may be available in the future Cryogenics this option is grayed out and may be available in the future Integrated Environmental Control Model User Manual Configure Plant 21 Solids Management Flyash Disposal This configuration setting determines how flyash is disposed Fly ash collected from a particulate removal system is typically combined with other solid waste streams if other waste streams exist The waste disposal option has little effect on the rest of the IECM The choices are No Mixing for no flyash mixing This option disposes the flyash separately e Mixed w FGD Wastes to dispose flyash with FGD wastes This option can only be selected if a wet FGD is configured under the SO Control option e Mixed w Bottom Ash to dispose flyash with bottom ash e g in the pond Configuring the Combustion Turbine Plant 22 e Configure Plant The following configuration options are available when the Combustion Turbine is selected as the plant type from the New Session pull down menu 7 IEC Interface ioj x File Edt View Go Window Help my Untitled Configure Plant Set Parameters Get Results No Devices NGCC Base Configuration
612. u allows you to select an additional variable This option is currently unavailable Integrated Environmental Control Model User Manual Variable Chooser Please choose a variable to display on the X axis Ok E Set Parameters Overall Plant Cancel Fuel Base Plant amp Base Plant Performance Gross Electrical Output Unit Type Steam Cycle Heat Rate HHY Boiler Firing Type Boiler Efficiency Excess Air For Furnace Leakage Air at Preheater Gas Temp Exiting Economizer Gas Temp Exiting Air Preheater Percent Water in Bottom Ash Sluice Coal Pulverizer Steam Cycle Pumps Forced Draft Fans Cooling System Miscellaneous Furn Factors All the IECM variables are available through the Choose buttons Clicking the Choose button immediately to the right of the axis drop down menus in the graph chooser window opens the variable chooser window as shown above All the input variables listed in the IECM are included in this window The variables are nested according to input or result variable technology type and technology sub option These match the navigation tabs used in the IECM Every variable is present in the same pattern as the IECM screens themselves Select a variable and click Ok to place the variable in the X axis drop down list The variable chosen will be added to the drop down menu For best results select a variable that has a probabilistic function defined in other words the v
613. ual CO2 Transport System 367 Stack Stack Diagram y IECM Interface File Edit view Window Help US Untitled Configure Plant Set Parameters Air Separation By Prod CO2 Capture Power Block PSN Overall Plant Elus Gas Out Temperature Out CF 250 0 Flue Gas Out acfin 2 163e 06 Flue Gas Out ton hr 3590 BAS Equiv SO2db MBtuy 01268 Equiv NO2 b MBt 2101e 02 _ CO2 b MBtu 199 6 Ash lb MBtu 4 000e 03 zls 8 le oleole Primary Flue Gas ton hr Other Flue Gas ton hr Process Type Stack v Stack Diagram The Diagram result screen displays an icon for the stack and values for major flows out of it Each result is described briefly below Flue Gas Out Temperature Out Temperature of the flue gas exiting the stack Flue Gas Out Volumetric flow rate of flue gas exiting the stack based on the flue gas temperature exiting the stack and atmospheric pressure Fly Ash Out Mass flow rate of solids in the flue gas exiting the stack Flue Gas Emission CO This is the number of pounds of CO vented to the air for every MBtu Integrated Environmental Control Model User Manual Stack e 369 Equivalent SO This is the number of pounds of Equivalent SO vented to the air for every MBtu Equivalent NO This is the number of pounds of Equivalent NO2 vented to the air for every MBtu Particulate This is the number of pounds of Particulate vented to the air for e
614. ual cost of waste disposal for this process It does not include the CO product stream disposal cost Electricity The cost of electricity consumed by the CO Selexol system CO Transport The CO captured at the power plant site has to be carried to the appropriate storage disposal site Transport of CO to a storage 314 e Selexol CO2 Capture Integrated Environmental Control Model User Manual site is assumed to be via pipeline This is the annual cost of maintaining those pipelines CO Storage Disposal Once the CO is captured it needs to be securely stored sequestered This annual cost is based upon the storage option chosen Total Variable Costs This is the sum of the variable O amp M costs listed above This result is highlighted in yellow Fixed Cost Components Fixed operating costs are essentially independent of actual capacity factor number of hours of operation or amount of kilowatts produced All the costs are subject to inflation Operating Labor Operating labor cost is based on the operating labor rate the number of personnel required to operate the plant per eight hour shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance l
615. ults Air Nox uy TSP 02 CO2 By Prod Stack Preheater Control ercury Control Control Capture Mgmt a Fixed Cost Component Operating Labor Maintenance Labor Maintenance Material Admin amp Support Labor wef le e ale J f Process Type Boiler 7 Costs are in Constant 2000 dollars 2 Flue Gas 2 Capital Cost 4 O amp M Cos 5 Total Cost The Boiler O amp M Cost result screen O amp M costs are typically expressed on an average annual basis and are provided in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Variable Cost Components Variable operating costs and consumables are directly proportional to the amount of kilowatts produced and are referred to as incremental costs All the costs are subject to inflation Fuel The total cost of as fired fuel Minemouth cost coal cleaning costs and transportation costs are all included Water The total cost of water consumed by the base plant for direct or reheat use Disposal The total cost of bottom ash disposal The value is given on a wet ash basis This does not consider by product ash sold in commerce Utility Power Credit Power consumed by abatement technologies result in lower net power produced and lost revenue The IECM charges each technology for the internal use of electricity and treats the charge as a Int
616. unt of carbon in the collected ash streams is typically known It is used to calculate the total unburned carbon in coal boiler efficiency and flue gas composition Percent of Burned Carbon as CO This parameter accounts for any incomplete combustion in the furnace and is used to calculate boiler efficiency and flue gas composition The remainder is assumed to be CO or unburned carbon Base Plant Retrofit Cost Inputs Inputs for the capital costs of modifications to process areas of the base plant itself are entered on the Retrofit Cost input screen lolx File Edit Yiew Window Help Capital Cost Process Area Steam Generator retro new i E 8 Units db e retro new Coal Handling retro new Ash Handling retro new Water Treatment retro new Awdliaries retro new Process Type Base Plant z Costs are in Constant 2000 dollars ern 4 Capital ost Base Plant Retrofit Cost input screen The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Integrated Environmental Control Model User Manual Base Plant 99 Direct capital costs for each process area are calculated in the IECM These ca
617. ur shift and the average number of shifts per day over 40 hours per week and 52 weeks Maintenance Labor The maintenance labor is determined as a fraction of the total maintenance cost Maintenance Material The cost of maintenance material is the remainder of the total maintenance cost considering the fraction associated with maintenance labor Admin amp Support Labor The administrative and support labor is the only overhead charge It is taken as a fraction of the total operating and maintenance labor costs Total Fixed Costs This is the sum of all the fixed O amp M costs listed above This result is highlighted in yellow Total O amp M Costs This is the sum of the total variable and total fixed O amp M costs It is used to determine the base plant total revenue requirement This result is highlighted in yellow Spray Dryer Total Cost Results This screen is only available for the Combustion Boiler plant type 256 e Spray Dryer Integrated Environmental Control Model User Manual File Edit View Go Window Help Configure Plant Set Parameters Get Results CO2 By Prod Capture Mgmt Stack Cost Component Percent Total ae eloj Annual Fixed Cost x J 25 26 Annual Variable Cost E 31 77 E Annualized Capital Cost i i 42 97 Ze tt Spray Dryer z Costs are in Constant 2005 dollars 3 Capital Cost 4 O amp M Cost 5 Total Cost Spray Dryer To
618. ure In Temperature of the heated and saturated syngas entering the combustor Pressure In This is the pressure of the heated and saturated syngas as it enters the combustor Syngas In This is the mass flow rate of the heated and saturated syngas to the combustor Flue Gas Exiting Gas Turbine Temperature Out Temperature of the flue gas exiting the gas turbine Flue Gas Out Volumetric flow rate of the flue gas exiting the gas turbine Power Block Steam Diagram Integrated Environmental Control Model User Manual This screen is only available for the Combustion Turbine and IGCC plant types Power Block e 381 7 IECM Interface Eile Edit View Go Window Help Configure Plant Set Parameters Get Results mem By Prod ock Mgmt Stack zls t R mlp le oeol Cooling Water Power Block LOT Dagan Cae E OEM Cost 1 Toul Cost A Power Block HRSG Steam Diagram results screen Flue Gas Exiting Steam Generator Temperature Out Temperature of the flue gas exiting the HRSG system Flue Gas Out Volumetric flow rate of the flue gas exiting the HRSG Flue Gas Entering Steam Generator Temperature In Temperature of the flue gas entering the HRSG Flue Gas In Volumetric flow rate of flue gas entering the HRSG Power Block Syngas Results This screen is only available for the Combustion Turbine and IGCC plant types 382 e Power Block Integrated Environmental Control Model User Manual 7 IECM Interface Ei
619. ure of the syngas exiting GE Entrained Flow Reactor Total Water or Steam Input This is the ratio of water to carbon in the coal slurry Integrated Environmental Control Model User Manual Gasifier e 119 Oxygen Input from ASU The GE gasifier requires a constant value for the oxygen O2 in the oxidant to carbon C in coal ratio Total Carbon Loss This the percent of carbon in the fuel that is lost Sulfur Loss to Solids This is the percent of the sulfur in coal that is lost in the slag Coal Ash in Raw Syngas This is the percent of ash in the coal that is in the syngas Percent Water in Slag Sluice This is the percent of the slag sluice that is water Number of Operating Trains This is the total number of operating trains It is used primarily to calculate capital costs The value must be an integer Number of Spare Trains This is the total number of spare trains It is used primarily to calculate capital costs The value must be an integer Raw Gas Cleanup Area Fly Ash Removal Efficiency This is the percentage of the ash which is removed by the raw gas cleanup process Power Requirement This is the equivalent electrical output of thermal steam energy used for reheat plus the actual electrical output power required Gasifier Syngas Inputs 120 o Gasifier The syngas generated by the gasifier is calculated as a function of the coal water and oxidant input flow rates the carbon loss and the gasifier tem
620. urface area of one T R set of plates It is used to determine the total number of T R sets needed and the capital costs Percent Water in ESP Discharge This is the water content of the collected fly ash Fly ash disposed with bottom ash is assumed to be sluiced with water and dry otherwise The occluded water in wet fly ash is difficult to remove resulting in a rather high water content when the fly ash is mixed with bottom ash Cold Side ESP Power Requirement The default calculation is based on the T R set power consumption with estimates for auxiliary power requirements and electro mechanical efficiencies of fan motors The T R set power consumption is a function of removal efficiency Cold Side ESP Retrofit Cost Inputs 194 o Cold Side ESP This screen is only available for the Combustion Boiler plant type Inputs for the capital costs of modifications to process areas to implement the Particulate control technology are entered on the Retrofit Cost input screen The retrofit cost factor of each process is a multiplicative cost adjustment which considers the cost of retrofitted capital equipment relative to similar equipment installed in a new plant These factors affect the capital costs directly and the operating and maintenance costs indirectly Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the dir
621. ust be sized to deal with the increased flue gas pressure drop resulting from the additional ductwork and the SCR reactor The costs are a function of the flue gas flow rate and pressure drop across the SCR Structural Support The costs of this area are related primarily to the structural support required for the SCR reactor housing ductwork and air preheater The costs are a function of the reactor housing costs duct costs and air preheater modification costs above Misc Equipment This area includes the capital costs incurred for ash handling addition water treatment addition and flow modeling for a hot side SCR system The costs are a function of the gross plant capacity Initial Catalyst The cost of the initial catalyst charge is included in the total direct cost because it is such a large and integral part of the SCR system The costs are a function of the initial catalyst charge Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Total Capital Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are i
622. ustion Turbine plant types 7 IECM Interface Edit View Window Help amp untitled a n P o o g 146 0 1 288e 06 Fly Ash Out ton hr 3 361e 02 Mercury Out lb hr 1 515e 03 MEA Makeup Ib hr 3769 Water ton hr 4397 Sorbent Circ ton hr 6549 CO2 Product ton hr ed Temperature In F 132 0 Flue Gas In acfm 1 397e 06 Fly Ash In ton hr 6 722e 02 Mercury In lb hr 1 515e 03 Process Tyee SST a 1 Diagen c L Reclaimer Waste lb hr 6521 Amine System Diagram Reagent MEA Makeup The mass flow rate of fresh MEA needed to replace the amount used in the process Water This is the flow rate of water that is used to mix with the MEA Makeup Flue Gas Entering Amine System Temperature In Temperature of the flue gas entering the amine system area prior to any processing This is determined by the flue gas outlet temperature of the process area upstream Flue Gas In Volumetric flow rate of flue gas entering the amine system Fly Ash In Total solids mass flow rate in the flue gas entering the Amine System This is determined by the solids exiting from the module upstream Mercury In Total mass of mercury entering the amine system The value is a sum of all the forms of mercury elemental oxidized and particulate Temperature Temperature of the flue gas entering the amine scrubber system Water This is the flow rate of water into the Di
623. v isiectiss rarest Wapdissdesesseasiea as IEEE EE OKEE NESA TeS r OTa vapisdsetedish eves 330 Sulfur Removal 331 Sulfur Removal Performance Inputs ceeeesecesseeeessceceeeceseeceseeeesaeecsaeecsaeesesaeseeeeesaes 331 Hydrolyzer or Shift Reactor cee eeeeeesseeesseeeceeeceseeceseeeesseeesaeecseessesaeeneeeesaes 332 Sulfur R emoval Unit isc ian aa a E TA E E aei 332 Claus Plant onne aiin aaa A EA EEE AE E ETE AET 332 Tailgas Treatment ninnisin tir E hacks E E a a eaa 332 Sulfur Removal Retrofit Cost Inputs seeeseeeseeereeseeeseteerestrsrtssressreseresereseresseressresesereseee 333 Capital Cost Process Areaisicetstshciicsties aici a eresneascitialan uathea bie aadiiee 333 Sulfur Removal Capital Cost Inputs 00 eeceeeeeeeecesseeeesnceceeecseecsseeeesaeecsaeecseaesesaeeneeeesaes 334 Sulfur Removal O amp M Cost Inputs 0 0 ceseeeccesssecesseeceseecscecsseecssaeeesaeecsaeeecsseeeeseeseeeeesaes 335 Sulfur Removal Dia gta sieni a aT i stasis TE AEE E G RANE 337 Sulfur Removal Capital Cost Results ceeeesescssseecssscecseecesceseseeeesaeecsaeecseeeeeseesnaeeesaes 338 Sulfur Removal Process Area Costs csscccsssccssseeessceeceseesseeceseeessaeecseessneeesenaes 338 Sulfur Removal Plant Costs ceescesscecsscessseeceesseeseessseecsseecsseecsseeecesaeesaeessaeees 339 Sulfur Removal O amp M Cost Results ceeceescesssecesneeeceeecsscecsseecsseeeesaeecsaeecssseeeeseessaeessaes 340 Variable Cost COMPOMENL
624. vailable for cyclone boilers LNB amp OFA Low NO burners see above with overfire air is another combustion NO reduction method Overfire air is an enhancement to LNB to reduce NO formation by further separating the air injection locations An addition of approximately 10 NO is reduced by the addition of OFA A portion of the secondary air used by LNB is diverted to injection ports located above the primary combustion zone reducing available oxygen in the primary combustion zone Overfire air in the IECM refers to separated OFA for both wall and tangential fired boilers This option is not supported for cyclone boilers Integrated Environmental Control Model User Manual Gas Reburn Gas reburn is a post combustion NO reduction method Gas reburn substitutes up to one fourth of the heat input of coal with natural gas reducing the NO up to 60 as a function of the amount of reburn The natural gas is injected above the primary combustion zone to create a reducing zone Reburn has been shown to be effective for wall and tangential fired boilers and more recently for cyclone boilers SNCR Selective non catalytic reduction is a post combustion NO reduction method This process removes NO from flue gas by injecting one of two nitrogen based reagents ammonia or urea in the presence of oxygen to form nitrogen and water vapor Optimum removal is achieved in a temperature window of 1600 2000 F Although the technology is very simple th
625. ver expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a fabric filter that has been paid off Air Separation O amp M Cost Inputs 88 e Air Separation I ox File Edit View Window Help x Configure Plant Set Parameters Get Results Title Electricity Price Base Plant MWh 100 0 Number of Operating Jobs jobs shift Hl 30 00 Number of Operating Shifts shifts day A 10 00 alp e oao Operating Labor Rate hr 100 0 Total Maintenance Cost TPC y 10 00 Maint Cost Allocated to Labor total 100 0 9 Administrative amp Support Cost total labor A 100 0 Process Type Jair Separation gt Costs are in Constant 2000 dollars 2 Retrofit Cost 3 Capital Cost 4 O amp M Cost Air Separation O amp M Cost input screen Inputs for O amp M costs are entered on the Air Separation O amp M Cost input screen O amp M costs are typically expressed on an average annual basis and are provided
626. very MBtu Mercury Emission Elemental This is the number of pounds of Elemental Mercury vented to the air for every MBtu Oxidized This is the number of pounds of Oxidized Mercury vented to the air for every MBtu Total This is the number of pounds of Total Mercury vented to the air for every MBtu Mercury Exiting Stack Elemental Mercury Mass flow rate of elemental mercury Hg in the flue gas exiting the stack Oxidized Mercury Mass flow rate of oxidized mercury Hg in the flue gas exiting the stack Total Mercury Mass flow rate of total mercury in the flue gas exiting the stack elemental oxidized and particulate Stack Flue Gas Results The FlueGas result screen displays a table of quantities of flue gas components exiting the stack For each component quantities are given in both moles and mass per hour 370 Stack Integrated Environmental Control Model User Manual TT aldlx File Edit Yiew Window Help LIM cx Configure Plant Set Parameters Get Results By Prod CO2 Capture Power Block Raat Migs Power Block Total Flue Major Flue Gas Components Area h moles hr h moles hr EETA Nitrogen ND i 1 665e 05 1 674e 05 2332 Oxygen 02 i 2 889e 04 2 889e 04 I 462 3 Water Vapor H20 x 3 089e 04 3 134e 04 y 278 3 Carbon Dioxide CO2 i 2 159e 04 2 238e 04 z 475 0 Carbon Monoxide CO i j j 0 0 Hydrochloric Acid HCD i i j 1 0 0 Sulfur Dioxide S02 i ag 1 116e 02
627. vestment sum of TPC and AFUDC to cover expected changes to equipment to bring the system up to full capacity Inventory Capital Percent of the total direct capital for raw material supply based on 100 capacity during a 60 day period These materials are considered storage The inventory capital includes fuels consumables by products and spare parts This is typically 0 5 TCR Recovery Factor The actual total capital required TCR as a percent of the TCR in a new power plant This value is 100 for a new installation and may be set as low as 0 for a wet cooling tower that has been paid off Wet Cooling Tower O amp M Cost Inputs This screen is available for all plant types 12 e Water Systems Integrated Environmental Control Model User Manual 7 ECM Interface Eile Edit view Go Window Help Untitled Ea Configure Plant Set Parameters Get Results l A e o Title Units ved Waste Disposal Cost ton Electricity Price Base Plant MWh Number of Operating J obs jobs shift Number of Operating Shifts 5 shifts day Operating Labor Rate hr 2AAKN ew B E s a 9 Total Maintenance Cost TPC 10 Maint Cost AllocatedtoLabor total 11 Administrative amp Support Cost total labor 12 13 14 15 16 17 18 Costs are in Constant 2007 dollars 1 Config 3 Retrofit Cost 4 Capital Cost 5 0 amp MCost ff Wet Cooling Tower O amp M Cost I
628. ween the plant site and the sequestration site Net Pipeline Elevation Change Plant gt Injection The pipeline may traverse hilly terrain this is the overall elevation change from plant site to injection site Integrated Environmental Control Model User Manual CO2 Transport System e 355 Number of Booster Stations The cost of CO transport may be lowered by adding booster stations for longer pipeline lengths This is the number of those stations that are to be modeled Compressor Pump Driver This is the type of motor that drives the compressor or pump electric diesel or natural gas Booster Pump Efficiency This is the efficiency of the pump and accounts for all frictional losses Design Pipeline Flow plant cap This is the flow of liquid CO that the pipeline has been designed to handle as a percent of the total that the plant is capable of producing Actual Pipeline Flow This is the amount of liquid CO that flows through the pipeline in tons per year Inlet Pressure power plant The inlet pressure is shown here for reference only and may be modified in the parameters for the CO capture device e g amine scrubber selexol scrubber Min Outlet Pressure storage site This the minimum outlet pressure of the CO at the storage site Average Ground Temperature This is the average temperature of the ground where the pipeline will traverse Pipe Material Roughness The roughness measure is the average size of
629. wer technology 16 e Water Systems Integrated Environmental Control Model User Manual 7 IECM Interface Eile Edit Yiew Go Window Help wie Untitled Configure Plant f Set Parameters Get Results Wet Cooling Tower Process Area Costs are aa Wet Cooling Tower Plant Costs Cooling Tower Structure J 8 716 Circulation Pumps 2 249 Auxiliary Systems 0 2812 Eng amp Home Office Fees Piping 8 154 Project Contingency Cost 1 2 General Facilities Capital 3 4 Makeup Water System 1 125 5 Process Contingency Cost 6 7 8 Cooling Water System 1 687 Interest Charges AFUDC Foundation amp Structures 6 185 Royalty Fees Preproduction Startup Cost 9 Inventory Working Capital 10 ll 12 13 14 15 1 2 3 4 S 6 7 8 Costs are in Constant 2007 dollars Wet Cooling Tower Capital Cost Result Screen Capital costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Direct Capital Costs Cooling Tower Structure This area deals with the cost for the cooling tower and installation Circulation Pumps This area deals with the cost for the circulating cooling water pumps Auxiliary Systems This area deals with the cost for a closed loop process that utilizes a higher quality water to remove heat from ancillary equipments and transfers that h
630. wer Block Stack aeh elol Annual Variable Cost Annualized Capital Cost Zj tt 1 Water Gas Shift Reactor x Costs are in Constant 2005 dollars 2 Syngas 3 Capital Cost 4 O amp M Cost 5 Total Cost Water Gas Shift Reactor Total Cost result screen The Total Cost result screen displays a table which totals the annual fixed variable operations and maintenance and capital costs associated with the Water Gas Shift Reactor Unit Total costs are typically expressed in either constant or current dollars for a specified year as shown on the bottom of the screen Each result is described briefly below Integrated Environmental Control Model User Manual Water Gas Shift Reactor 329 Cost Component Annual Fixed Cost The operating and maintenance fixed costs are given as an annual total This number includes all maintenance materials and all labor costs Annual Variable Cost The operating and maintenance variables costs are given as an annual total This includes all reagent chemical steam and power costs Total Annual O amp M Cost This is the sum of the annual fixed and variable operating and maintenance costs above This result is highlighted in yellow Annualized Capital Cost This is the total capital cost expressed on an annualized basis taking into consideration the levelized carrying charge factor or fixed charge factor over the entire book life Total Levelized Annual
631. xygen The minimum number of operating trains is two Process Facilities Capital The process facilities capital is the total constructed cost of all on site processing and generating units listed above including all direct and indirect construction costs All sales Integrated Environmental Control Model User Manual Air Separation e 91 taxes and freight costs are included where applicable implicitly This result is highlighted in yellow Air Separation Plant Costs Process Facilities Capital see definition above General Facilities Capital The general facilities include construction costs of roads office buildings shops laboratories etc Sales taxes and freight costs are included implicitly Eng amp Home Office Fees The engineering amp home office fees are a percent of total direct capital cost This is an overhead fee paid to the architect engineering company Project Contingency Cost Capital cost contingency factor covering the cost of additional equipment or other costs that would result from a more detailed design of a definitive project at the actual site Process Contingency Cost Capital cost contingency factor applied to a new technology in an effort to quantify the uncertainty in the technical performance and cost of the commercial scale equipment Interest Charges AFUDC Allowance for funds used during construction also referred to as interest during construction is the time value of the money used during con
632. y click the Ok button at the bottom of the graph chooser window m Graph of Particulate Collector Capita 2 5 Conf 10 20 0 000 EAA AAA AASA AAAA ASEE EAR RRR E EERE EERE EEE 10 00 10 50 M Untitled Mean 10 51 Graph window using all default conditions The graph window is a very powerful and versatile tool for viewing data results The variables selected earlier are represented on the axes Graph option buttons are provided above the graph allowing you to change the appearance and style of the variables being graphed These are described in a separate help document distributed with the IECM mon Eea alele Integrated Environmental Control Model User Manual Working with Graphs e 397 Graph Control Labels System About Markers ceeds Trends Overlay Error Bar Background Legend 3D Gallery Style Data Titles Axis 30 Fonts e B Ls Polar Bubble Ml had Line Area el High Low Candlestick Box Whisker Time Series Cancel Apply Nove Help Graph controls can be accessed from any button on the graph window or any tab from within the graph control window itself The two methods are synonymous Each button at the top of the graph window opens the same graph control window but with a particular tab selected The figure above shows the row of buttons in the graph window and the graph control window that opens when one of the buttons is clicked Consu
633. y basis Particulate Emissions to Air Solids that remain in the flue gas and exit the plant are reported on a mass basis Captured CO Flow rate of the captured CO Byproduct Ash Sold Flow rate of ash bottom and fly ash sold in commerce as a by product on a dry basis Byproduct Gypsum Sold Flow rate of flue gas treatment solids sold in commerce as a by product on a dry basis Byproduct Sulfur Sold Flow rate of elemental sulfur recovered from flue gas and sold in commerce as a by product on a dry basis Byproduct Sulfuric Acid Sold Total mass of sulfuric acid recovered from the flue gas and sold in commerce as a by product Total This is the total wet solid mass exiting the power plant This result is highlighted in yellow Overall NGCC Plant Gas Emissions Results zmizi File Edit Yiew Go Window Help Configure Plant Set Parameters Get Results Fuel Power Block NOx Control CO2 Capture ka Flow Rate tons hr Total SOx equivalent SO2 0 0 Oxygen 02 Total NOx equivalent NOZ 5 101e 02 Water Vapor H20 Carbon Dioxide COZ Carbon Monoxide CO Hydrochloric Acid HCD Sulfur Dioxide 502 Sulfuric Acid equivalent 503 0 0 Nitric Oxide NO 3 201e 02 Nitrogen Dioxide NO2 1 937e 03 Ammonia NH3 7 887e 04 Argon Ar 0 0 Use Result Tools under View menu for alfernate units Stack Gas Component Stack Gas Component z e e amp mlp ooo
634. y used by the plant given on an hourly basis maximum capacity This rate is also referred to as the total plant power input Gross Plant Heat Rate HHV This is the gross heat rate of the entire plant Net Plant Heat Rate HHV This is the net heat rate of the entire plant including aux power produced which includes the effect of plant equipment and pollution control equipment Annual Operating Hours This is the number of hours per year that the plant is in operation If a plant runs 24 hours per day seven days per week with no outages the calculation is 24 hours 365 days or 8 760 hours year 50 e Overall NGCC Plant Integrated Environmental Control Model User Manual Annual Power Generation This is the net annual power production of the plant The capacity factor and all energy credits or penalties are used in determining its value Net Plant Efficiency HHV This is the net efficiency of the entire plant Plant Power Requirements A second group of results provide a breakdown of the internal power consumption for the individual technology areas These are all given in units of megawatts Individual plant sub components will only be displayed when they are configured in the Configure Plant section of the model Turbine Generator Output This is the power generated by the turbine Air Compressor Use The power required to operate the air compressor Turbine Shaft Losses This value accounts for any turbine electricity los
635. ydrogen Sulfide H2S Total mass of hydrogen sulfide Carbonyl Sulfide COS Total mass of carbonyl sulfide Ammonia NHs Total mass of ammonia Hydrochloric Acid HCI Total mass of hydrochloric acid Water Vapor H20 Total mass of water vapor Carbon Dioxide CO3 Total mass of carbon dioxide Nitrogen N2 Total mass of nitrogen Argon Ar Total mass of argon Oxygen O2 Total mass of oxygen Total Total of the individual components listed above This item is highlighted in yellow Integrated Environmental Control Model User Manual Auxiliary Boiler e 115 Auxiliary Boiler Flue Gas Results 116 e Auxiliary Boiler This screen is only available for the Combustion Boiler and Combustion Turbine plant types 7 IECM Interface Eile Edit View Go Window Help US Untitled Configure Plant Set Parameters NOx Control TSP Mercury Control Flue Gas Out b moles hr _ tons hr Nitrogen ND 6 030e 04 704 6 Oxygen 02 990 1 15 84 Water Vapor H20 1 194e 04 107 5 Carbon Dioxide CO2 6408 Carbon Monoxide CO Hydrochloric Acid HCD Sulfur Dioxide 502 Sulfuric Acid equivalent 503 Nitric Oxide NO 10 Nitrogen Dioxide NO2 Ammonia NH3 Argon An Major Flue Gas Components Z e R D e le lalelo Auxiliary Boiler System Flue Gas result screen Major Flue Gas Components Natural gas fired in the auxiliary boiler produces
636. year Direct Capital Costs Direct capital costs for each process area are calculated in the IECM These calculations are reduced form equations derived from more sophisticated models and reports The sum of the direct capital costs associated with each process area is defined as the process facilities capital PFC This is the basis for all other capital cost parameters The process facilities capital for the technology is the total constructed cost of all on site processing and generating units including all direct and indirect construction costs All sales taxes and freight costs are included where applicable implicitly These direct capital costs are generally calculated by the IECM and not presented directly on input screens However when important input variables are required for these calculations they are listed at the top of the input screen Integrated Environmental Control Model User Manual Mercury 181 Indirect Capital Costs Costs that are indirectly applied to the technology are based on the process facilities cost Each of the cost factors below is expressed as a percentage of the process facilities cost and is entered on this screen Each parameter is described briefly below Construction Time This is the idealized construction period in years It is used to determine the allowance for funds used during construction AFUDC General Facilities Capital GFC The general facilities include construction costs of roads o
637. yees makes any warranty express or implied or assumes any legal liability or responsibility for the accuracy completeness or usefulness of any information apparatus product or process disclosed or represents that its use would not infringe privately owned rights Reference herein to any specific commercial product process or service by trade name trademark manufacturer or otherwise does not necessarily constitute or imply its endorsement recommendation or favoring by the United States Government or any agency thereof The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof Integrated Environmental Control Model User Manual Disclaimer 1 Acknowledgements This report is an account of research sponsored by the U S Department of Energy s National Energy Technology Center DOE NETL under Contract No DE AC21 92MC29094 2 e Acknowledgements Integrated Environmental Control Model User Manual Introduction The Integrated Environmental Control Model Purpose This Integrated Environmental Control Model with Carbon Sequestration TECM cs and Interface were developed for the U S Department of Energy s National Energy Technology Laboratory NETL formerly known as the Federal Energy Technology Center FETC under contracts No DE AC22 92PC91346 and DE AC21 92MC29094 The product of this work is a desktop computer model that allows
638. ysis A Technical Example A second example focuses on a performance parameter for an advanced pollution control system This parameter has an important effect on system performance and cost The example focuses on an assessment of uncertainty in the performance of an innovative emission control system for coal fired power plants In this system a chemical sorbent circulates between a fluidized bed reactor where SO in the flue gas is removed by chemical reaction with the sorbent and a regenerator in which SO is evolved in a reaction of the sulfated sorbent with methane There is no commercial experience with this system the largest test unit has been sized to handle 100 scfm of flue gas Furthermore the test units have used batch rather than continuous regeneration One of the key parameters affecting the performance and cost of this system is the regeneration efficiency which is defined as the fraction of the spent sorbent which is converted for reuse In small scale tests in which the regeneration efficiency has been estimated the efficiency was found to be roughly 30 to 50 percent In a more recent test the regeneration efficiency was not measured due to instrumentation difficulties however it may have been lower than the previously obtained values Regeneration residence times were typically greater than 30 minutes A detailed modeling study of the regenerator estimated that a properly sized and designed unit coupled with heat

IECM User Manual - Carnegie Mellon University

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