ÿWPCv ¹ç )™^Ò $ Æoa\:Á«õ»‘Ûò«tæ‚5ÛZÁ JQXºvpb¢ÞÝP–H¹ëô/¿éŽÊó:öX“Ú½·X$ÿƒýNblœ*‘wMÜ\»† á‹tô¹×Þ6ã~“¨Ha¶$ð1{¯½]ÙBõÀ¡Z¥rFÅ6f˜ÿÃQuð¤6x‡ÅÑá5!®* ‚näÜAƒbÑMá±ÉŠÛ¥§åç9) <A¢PË©¿°¬Vnºgé2ð¶£òõO,"|Š!: `¬[’T"0ëîÅÈÒõR¶[mÕQn­ÕTÐöÌ”ŒsºiÀÃF,ĪŽþ3× EKhÝ=Poð@í”›náRdÆ#[ç~®ÜÜè!£z¹¢Üe¨à Cà±ÌüÎŒâ Y^PøuŸ}®,o6K#­† Õi¢«X5CJhº£'v²[âLEb{Å„#ž‹`›”@Æ¢KœwK^IÞ“6ë8É®Ä^8ËÛá©Ãp´'Ͱ2¸‰Ö•( E­ýTzýÑBñÝ2û˜}¤°Þ&ƒÚs´«”a˜áT5áÎ1ÃJEg…¢Â¤âqlÃØûà»eúåäêò‡xî§h‡E¡#Êy 9`ýoAjûemU Bö %8–> 0Ô 0”q 0Œ 0T‘ U!Nå Æ3 UNù B GdnXt 0rÌ>fTw@V4–aª 0޾fLÆNÆÆÚ 1u a A©)ÆÒ˜ C  D3ºUNí^ ; 1UGUNœê#!ì 0c Np mr4‰M½fÁaÃf×aÙfíaï B *M- 1U11M†MŠ AMŽÆÛ 0Ž¡ 0K/ D+zM¥M©M­M±MµM¹M½MÁMÅMÉMÍ BÑMîMò 0NöMDMHMLMPMTMXXXXXXXXXXXXXXXXXXXXXXXXXXXX C\ô\  `*Times New RomanTTô' Ï 'MEMORANDUM Sue McKee0Sue McKee .   H0%ÿÿ4heading 1heading 1Ô&  ÔÓ  ÓÔ  ÔÔ  ÔòòóóÔ  ÔÔ  ÔÔ'  Ôhÿÿ:Default ParaDefault Paragraph FontÔ  ÔÔ  ÔÔ  ÔÔ  Ô`ÿÿ:footnote reffootnote referenceÔ  ÔÔ  ÔÔ  ÔÔ  Ô(ÿÿ$__Ô  ÔÔ  ÔÔ  ÔÔ  Ô(ÖÃ9 Z ‹6Times New Roman Regular‚Level 1Level 2Level 3Level 4Level 5(ÈhH  Z ‹6Times New Roman Regular d3|xŒ«ô\  `*Times New RomanTTôôCô\  PŽ6QôPô\  `*Times New RomanTTXXPô\  PŽ6QXP(J¹$¡¡Ô€XkMXôôÔÔ€XkMXXXkMÔÓ  Ó Ñ ° ÑÔ ƒ„…E†‡ˆ£‰DŠ‹Œ£]t(XÐTABLE A(f3BÀ$©©Ý ƒ¹!ÝÔ€X(XõôÔÔ€X(XXX(ÔÓ  ÓÝ  ÝÔƒLevel 1Level 2Level 3Level 4Level 5„Level 1Level 2Level 3Level 4Level 5…Level 1Level 2Level 3Level 4Level 53#37=CIQYag­­1.a.i.(1)(a)(i)1)a)TABLE D89:;›&OLE 2.0 Box <=8ÿÿÿÿÿÿÿÿÿÿCÿÿ HKKKK€Level 1Level 2Level 3Level 4Level 5 ÿÿÿd 'ÿÿdxd46Times New Roman RegularHª;+á$ÿÿ359=AEIMQ1(ÈhH  Z ‹6Times New Roman Regular ˜Panasonic DP-3000ˆˆ¬¬¬¬ˆˆ0(;3£$´´Ô2#ÔÚ  Ú0Ú  Ú.Ô3  Ôà0  àÿU‹ÿÀÀÀ PGaCosts PEC DCI ICI DAC IAC MlbsductworkEngelhardNooterEriksen HRSGwashcoatFrameasourcedCamet VOCsbackpressureMMBtu Mwh ABB SCRSCONOxXONONSCONOxTM LLC HAPs ppmCatalytica DLN€CombustorscombustorsÔTABLE DÔTABLE DÔTABLE A&ÿÿ0 d d$ÿÿ359=AEIMQ389:A -<< CÿÿLevel 1Level 2Level 3Level 4Level 5(f3BÀ$££Ý ƒ¹!ÝÔ€X(XõôÔÔ€X(XXX(ÔÓ  ÓÝ  Ý( ±þ$’’ò òFigure€Ú  Ú1Ú  Úó ó'ÈÈÈÈdxdöÿ  d>…¦$"Small Circleð"ðà0  àõÿÿÿÿdÝ ƒ¹!ÝÔ€XW5XõôÔÔ€XW5XXXW5ÔÓ  ÓÝ  ÝÔ_ÔÓ  ÓÔ  ÔÑ  ÑÔ€ XW5XXXW5ÔÑ8€ W5 XXdìdÈ8ÑÌÌÌÌÔ‡XW5XX XW5ÔÓ  ÓSeptember€27,€2001Ô#† XW5XXXW5ô#Ôà@@ìì*ìàÐ `° ÐÓÓà  àÌÌMEMORANDUMÌÌFROM:€à0 ` àSims€RoyÐü L ` (#` (# Ðà  à€€à0 ` àEmission€Standards€DivisionÐè 8 ` (#` (# Ðà  à€€à0 ` àCombustion€Groupà0h` (#` (#àÐÔ$ h(#h(# ÐÌTO:€à0  àà0` (#(#àDocket€A„95„51Ьü ` (#` (# ÐÌSUBJECT:à ` àOxidation€Catalyst€Costs€for€New€Stationary€Combustion€TurbinesÐ „Ô  ÐÌThe€purpose€of€this€memorandum€is€to€summarize€information€on€the€cost€of€oxidation€catalystÏcontrol€for€new€stationary€combustion€turbines.€€Catalyst€vendors€provided€information€to€EPAÏon€the€costs€of€acquiring,€installing,€and€operating€oxidation€catalysts€for€HAP€reduction€forÏvarious€turbines;€these€costs€were€applied€to€seven€model€turbines€ranging€in€size€from€1.13Ïmegawatts€(MW)€to€170€MW.€€Costs€were€provided€for€both€90€and€95€percent€reduction€of€CO.€ÏThe€total€capital€and€annual€costs€were€then€estimated€using€methodologies€from€the€Ô_ÔOAQPSÔ_ÔÏControl€Cost€Manual.€€A€detailed€description€of€the€cost€methodologies€is€given€in€Attachments€AÏand€B.ÌÌThe€total€capital€and€annual€costs€for€each€model€turbine€are€presented€in€the€tables€below.€€TheÏannual€costs€were€estimated€for€both€the€guaranteed€life€of€the€catalyst€(3€years)€and€the€ð ðtypicalððÏlife€of€the€catalyst€(6€years).€€The€costs€for€90€ñ‚ñand€95€ñ‚ñpercent€reduction€of€CO€are€presented€inÏTableñƒñsñƒñ€1ñ…ññ„ñañ„ññ…ññ†ñ€and€2,€respectively.ñ†ññ„ñññ,€andñññ„ñ€€ÌÌÔ‡XW5XX XW5ÔÓ  ÓTable€1.€€CO€Oxidation€Catalyst€Costs€for€90%€CO€ReductionÔ#† XW5XXXW5#ÔÐ D!” ÐÓ¼ÓÌÔ*‹ƒ ddd Xdd Xdd X°(#°(#‹ÔÔ,m dd ÔÔ,Tdd ÔÔ,Tdd ÔÔ,Tdd ÔÔ+  ÔÐ ( #l! €€„„……(Ðò òModel€Turbineó óÐ ;1#€#Ð""3ÀÀ „„‹‹;Ðò òTotal€CapitalÐ €#Ð# ÐCost€($)ó óòòaóóÐ =3!l$¼$" „„……‹‹=ÐTotal€Annual€Cost€($)Ð >4)€#Ð%"   €€……>ÐÐ ! ˆ%Ø % „„!ÐÐ * ì%#Ôñ‡ñÐ \À ÐñˆñÓgÓñˆñÔ‡XW5XX XW5ÔÌÔ*žƒ/ 0d dm dd m Tdd TTdd TTdd T °(#°(#žÔÔ,m dd ÔÔ,Tdd ÔÔ,Tdd ÔÔ,Tdd ÔÔ+  ÔÐ ( 4˜ €€„„……(Ðò òModel€Turbineó óÐ ;1#˜ü"3ÀÀ „„‹‹;Ðò òTotal€CapitalÐ ˜ü ÐCost€($)ó óòòaóóÐ =3!„è " „„……‹‹=ÐTotal€Annual€Cost€($)Ð >4)˜ü"   €€……>ÐÐ !    „„!ÐÐ * h " „„‹‹*Ð3„Year€CostsÐ 6,!h " „„6Ð6„Year€CostsÐ #h "  #ÐGE€PG€7121EA,€85.4€MWÐ C9 „è  €!û@A2225731„„‰€!û@A‰CÐÔ#† XW5XXXW5j#ÔÔ‡XW5XX XW5Ô2,225,731Ð pf7„è " €!û@A2225731 €!û@A J”(A805413„„‰J”(A‰pÐ805,413Ð oe6„è " J”(A805413 J”(A i$A668809„„‰i$A‰oÐ668,809Ô#† XW5XXXW5#ÔÐ B86„è " i$A668809 i$A BÐGE€PG€7231FA,€170€MWÐ C9 h €(ÖHA3255377„„‰€(ÖHA‰CÐÔ‡XW5XX XW5Ô3,255,377Ð qg7h" €(ÖHA3255377 €(ÖHA —×1A1169303„„‰—×1A‰qÐ1,169,303Ð pf7h" —×1A1169303 —×1A 6–-A969499„„‰6–-A‰pÐ969,499Ô#† XW5XXXW5ã#ÔÐ B86h " 6–-A969499 6–-A BÐGE€PG€6561B,€39.6€MWÐ C9 „è! 9“1A1151801„„‰9“1A‰CÐÔ‡XW5XX XW5Ô1,151,801Ð pf7„è"" 9“1A1151801 9“1A ´„A434477„„‰´„A‰pÐ434,477Ð oe6„è#" ´„A434477 ´„A (4A363786„„‰(4A‰oÐ363,786Ô#† XW5XXXW5¸!#ÔÐ B86„è$" (4A363786 (4A BÐGE€LM25000,€27€MWÐ B8 h% „§%A709570„„‰„§%A‰BÐÔ‡XW5XX XW5Ô709,570Ð oe6h&" „§%A709570 „§%A ØEA282998„„‰ØEA‰oÐ282,998Ð oe6h'" ØEA282998 ØEA ¸: A239447„„‰¸: A‰oÐ239,447Ô#† XW5XXXW5…##ÔÐ B86h(" ¸: A239447 ¸: A BÐSolar€Centaur€40,€3.5€MWÐ B8 „è) ¬åA276843„„‰¬åA‰BÐÔ‡XW5XX XW5Ô276,843Ð oe6„è*" ¬åA276843 ¬åA  -A132516„„‰ -A‰oÐ132,516Ð oe6„è+"  -A132516  -A P4ü@115525„„‰P4ü@‰oÐ115,525Ô#† XW5XXXW5V%#ÔÐ B86„è," P4ü@115525 P4ü@ BÐSolar€Mars€T12000,€9€MWÐ B8 h- ¨A411434„„‰¨A‰BÐÔ‡XW5XX XW5Ô411,434Ð oe6h." ¨A411434 ¨A ØA178947„„‰ØA‰oÐ178,947Ð oe6h/" ØA178947 ØA ÃA153697„„‰ÃA‰oÐ153,697Ô#† XW5XXXW5&'#ÔÐ B86h0" ÃA153697 ÃA BÐSolar€Saturn€T1500,€1.13€MWÐ B8 „è1 ðtA192158„„‰ðtA‰BÐÔ‡XW5XX XW5Ô192,158Ð oe6„è2" ðtA192158 ðtA  Fù@103522„„‰ Fù@‰oÐ103,522Ð nd6„è3"  Fù@103522  Fù@ àdö@91726„„‰àdö@‰nÐ91,726Ô#† XW5XXXW5ú(#ÔÐE;9„è4" àdö@91726  àdö@ EÐòòÌaóóÔ‡ ô(¡õX XW5ÔCostsÔ#† XW5Xõ ô(¡z*#ÔÔ‡ ô(¡õX XW5Ô€reflect€2001€figures.Ô#† XW5Xõ ô(¡Á*#ÔÐ , 5 Ðò òòòÔ‡XW5XX XW5ÔÐ  ô X6 Ðó óóóÓ  ÓÌÌÌÌÌAttachment€AòòÐ L œ ÐÓn+ÓÌóóÐ  $ t ÐÑ€OaÑÌÌÌÌÌÌÌMEMORANDUMÌÌDATE:à0  àò òà ` àó óMay€14,€1999Ðü L (#(# ÐÌSUBJECT:ò òà0 ` àó óStationary€Combustion€Turbines€Control€Options€Cost€Information€SummaryÐÔ$ ` (#` (# Ðò òÌó óThe€purpose€of€this€memorandum€is€to€summarize€the€cost€information€that€has€been€received€forÐ ¬ü  Ðcontrol€options€to€date.€€This€information€will€be€used€with€model€turbines€developed€for€theÏStationary€Combustion€Turbines€source€category€as€part€of€estimating€the€national€impacts€ofÏviable€regulatory€options.€ÌÌò òBackgroundòòÐ H˜ Ðó óóóÌIn€support€of€Ô_ÔMACTÔ_Ô€determinations€for€new€and€existing€combustion€turbines,€€a€set€of€modelÏturbines€has€been€developed€that€can€be€used€to€evaluate€the€national€impact€of€control€optionsÏbeing€considered.€The€following€approach€will€be€used€to€determine€national€impacts:ÌÌà  àà0 ` à1)à0¸ ` (#` (#àDevelop€model€turbinesÐÐ ¸ (#¸ (# Ðà  àà0 ` à2)à0¸ ` (#` (#àEstimate€control€costs€for€each€control€option€for€each€model€turbineм ¸ (#¸ (# Ðà  àà0 ` à3)à0¸ ` (#` (#àEstimate€emission€reduction€for€each€control€option€for€each€model€turbineШø¸ (#¸ (# Ðà  àà0 ` à4)à0¸ ` (#` (#àRelate€model€turbines€to€turbines€in€the€EPA€Inventory€Database€forÐ ”ä ÐStationary€Combustion€Turbines€Ð ¸ (#¸ (# Ðà  àà0 ` à5)à0¸ ` (#` (#àExtrapolate€from€the€inventory€database€population€to€the€nationalÐ l¼ ÐpopulationÐ ¸ (#¸ (# Ðà  àà ` à6)à ¸ àDetermine€regulatory€optionsÐ D!” Ðà  àà0 ` à7)à0¸ ` (#` (#àEstimate€economic€impacts€for€each€regulatory€optionÐ0"€ ¸ (#¸ (# ÐÌCost€information€has€been€received€that€will€be€used€to€estimate€the€control€costs€for€each€optionÏbeing€considered€on€a€model€turbine€basis.€€This€memorandum€reflects€the€cost€information€thatÏhas€been€received€to€date.€€Any€additional€cost€data€received€from€vendors€will€be€incorporated,Ïas€necessary,€at€a€later€time.ÌÌò òÔ& Ä ÔCost€InformationòòÐ ¤(ô#' Ðó óóóÌThe€methodology€in€the€Ô_ÔOAQPSÔ_Ô€Control€Cost€Manual€will€be€used€to€determine€the€annual€costÔ'Ĥ(|4ÔÏof€control€technologies.€€The€Ô_ÔOAQPSÔ_Ô€methodology€provides€generic€cost€categories€and€defaultÐ h+¸&* ÐÑOaÑâ âѰ°Ñâ âÑ  Ñassumptions€to€estimate€the€installed€costs€of€control€devices.€€Direct€cost€inputs€are€required€forÏcertain€key€elements,€such€as€the€capital€costs€of€the€control€device.€€Other€costs,€such€asÏinstallation,€are€then€estimated€based€on€percentages€of€the€direct€cost€inputs.€ÌÌIn€the€Ô_ÔOAQPSÔ_Ô€methodology,€five€cost€categories€are€used€to€describe€the€annual€cost€of€a€controlÏdevice.€€These€are€as€follows:ÌÌà0  à1)à0` (#(#àPurchased€Equipment€Costs€(PEC),€which€include€the€capital€cost€of€the€controlÐ $ t Ðdevice€and€auxiliary€equipment,€instrumentation,€sales€tax,€and€freight;€Ð ` (#` (# Ðà0  à2)à0` (#(#àDirect€Costs€for€Installation€(DCI),€which€are€the€construction„related€costsÐ ü L  Ðassociated€with€installing€the€catalyst;€Ð ` (#` (# Ðà0  à3)à0` (#(#àIndirect€Costs€for€Installation€(ICI),€which€include€expenses€related€to€engineeringÐ Ô$  Ðand€start„up;€Ð ` (#` (# Ðà0  à4)€à0` (#(#àDirect€Annual€Costs€(DAC),€which€include€annual€increases€in€operating€andÐ ¬ü  Ðmaintenance€costs€due€to€the€addition€of€the€control€device;€andÐ ` (#` (# Ðà0  à5)à0` (#(#àIndirect€Annual€Costs€(IAC),€which€are€the€annualized€cost€of€the€control€deviceÐ „Ô  Ðsystem€and€the€costs€due€to€tax,€overhead,€insurance,€and€administrative€burdens.Ð ` (#` (# ÐÌThe€cost€that€will€be€used€in€model€turbine€analyses€is€the€total€annual€cost,€which€is€the€sum€ofÏthe€Direct€Annual€Costs€(DAC)€and€the€Indirect€Annual€Costs€(IAC).€€The€following€informationÏreflects€the€capital€and€operating€costs€that€have€thus€far€been€obtained€from€vendors€on€theÏcontrol€technologies€under€consideration.€€Cost€estimates€are€in€1998€dollars€unless€otherwiseÏindicated.ÌÌòòò òCatalytic€Systemsó óóóÐ Ð  ÐÌÝ‚J…¦ÿÝð"ðà0  àÝ  Ýò òCO€Oxidation€Catalyst€Systemsó óÝ‚J…¦ÿ°=ƒÝÝ  ÝШø(#(# ÐÌSeveral€vendors€were€contacted€for€capital€and€operating„related€costs€for€CO€oxidation€catalysts.ÏThe€following€general€information€was€requested:ÌÌà0  à1)à0` (#(#àWhat€is€the€cost€range€of€the€catalyst€material?ÐH!˜` (#` (# Ðà0  à2)à0` (#(#àWould€this€number€change€in€considering€three€flow€ranges,€i.e.,€small,€medium,Ð 4"„  Ðand€large,€starting€with€a€minimum€flow€of€100€Mlbs/hour€and€ending€with€~3000ÏMlbs/hour?Ð ` (#` (# Ðà0  à3)à0` (#(#àWhat€operating€temperature€ranges€with€respect€to€high€CO€removal/oxidation€areÐ ø$H # Ðrecommended?Ð ` (#` (# Ðà0  à4)€€à0` (#(#àWhat€happens€during€start„up€and€low€load€operation?€€What€would€be€the€resultÐ Ð& "% Ðof€a€prolonged€operation€with€gas€turbine€exhaust€temperatures€of€~500òòoóóF?м' #&` (#` (# Ðà0  à5)à0` (#(#àWhat€are€recommended€space€requirements€and€would€flow€straighteningÐ ¨(ø#' Ðequipment€be€necessary?Ð ` (#` (# Ðà0  à6)à0` (#(#àWhat€is€the€cost€of€reactor€housing,€required€steel€support,€foundation€needs€andÐ €*Ð%) Ðductwork?Ðl+¼&*` (#` (# ЇCost€information€for€CO€oxidation€catalysts€was€received€from€Engelhard,€a€catalyst€vendor,€andÏNooter/Eriksen,€a€heat€recovery€steam€generator€(HRSG)€vendor.€€Generalized€estimates€wereÏalso€received€for€costs€associated€with€increased€pressure€drops€and€retrofit€applications.€€TheÏinformation€received€is€summarized€belowÔ#† XW5XXXW54+#ÔÔ‡#XW5XX XW5Ô.Ô#† XW5XX#XW5D#ÔÔ‡XW5XX XW5ԀРtÄ ÐÌòòEngelhardóóÐ L œ ÐEngelhard€CO€catalysts€are€manufactured€with€a€special€stainless€steel€foil€substrate€which€isÏcorrugated€and€coated€with€an€alumina€washcoat.€€The€washcoat€is€impregnated€with€platinumÏgroup€metals.€€The€catalyzed€foil€is€folded€and€encased€in€welded€steel€frames,€approximately€2€ft.Ïsquare,€to€form€individual€modules.€€The€individual€modules€are€installed€within€the€supportÏframe.€€The€modules€typically€weigh€approximately€50€lb.€each.€€The€number€of€modules€requiredÏincreases€with€gas€flow.€€Substrate€depth€and€corrugation€patterns€can€vary€depending€on€projectÏrequirements.€€Typically,€performance€is€warranted€for€2€to€3€years€with€an€expected€life€of€5€to€7Ïyears.€€Typical€guarantees€are€based€on€a€ðð15%€gas€velocity€profile€distribution.€The€catalyst€isÏnot€a€hazardous€material€and€in€most€cases€can€be€recycled€to€reclaim€the€precious€metals.€ÏEngelhard€can€also€provide€catalysts€on€a€ceramic€substrate.€€Ìà  àÌEngelhard€provided€costs€for€a€simple€cycle€turbine€installation€(catalyst€at€turbine€dischargeÏtemperature)€for€six€turbine€exhaust€flows€ranging€from€28.4€lb/sec€to€984.0€lb/sec.€€These€costsÏwere€based€on€an€oxidation€catalyst€that€would€achieve€90%€CO€conversion€efficiency€and€1"Ïpressure€drop€across€the€catalyst€panels€(not€total€system€pressure€drop).€€The€costs€providedÏinclude€the€cost€of€an€internal€support€frame€and€catalyst€modules€only.€€These€costs€are€shown€inÏTable€1.€€ÌÌÓ  ÓTable€1.€€CO€Oxidation€Catalyst€Costs€Provided€by€EngelhardÌÌÓÑJÓÔ*žƒ d dm dd m Tdd TTdd TTdd T/ 0°(#°(#žÔÔ,ždd ÔÔ,ždd ÔÔ,ždd ÔÔ,ždd ÔÔ+  ÔÐ +€1 ¨ø €€„„+ÐTurbine€ExhaustÏFlow€(lb/sec)Ð =€1,!øH"1 „„=ÐTurbine€ExhaustÏTemperature€(F)Ð =€1,!øH"1 „„=ÐRequired€Inside€LinerÏCross€Section€(sq.€ft.)Ð =€1,!øH "1 „„=ÐEstimated€CostÌCatalyst€+€FrameòòaóóÐ ]S&øH""  1 ffffff<@28.4„„‰ffffff<@‰]Ð28.4Ð ka4xÈ#" ffffff<@28.4 ffffff<@ h@1050„„‰h@‰kÐ1050Ð i_4xÈ$" h@1050 h@  ÀP@67„„‰ÀP@‰iÐ67Ð G=2xÈ%"  ÀP@67 ÀP@ „„GÐ$140,000Ð I?xÈ&" €D@41.0„„‰€D@‰IÐ41.0Ð j`4ø H'" €D@41.0 €D@ ˜‰@819„„‰˜‰@‰jÐ819Ð h^3ø H(" ˜‰@819 ˜‰@  €V@90„„‰€V@‰hÐ90Ð G=2ø H)"  €V@90 €V@ „„GÐ$155,000Ð J@ø H*" às@318.0„„‰às@‰JÐ318.0Ð ka5x"È+" às@318.0 às@ ðŽ@990„„‰ðŽ@‰kÐ990Ð i_3x"È," ðŽ@990 ðŽ@ `†@716„„‰`†@‰iÐ716Ð H>3x"È-" `†@716 `†@ „„HÐ$600,000Ð J@x"È." „@658.0„„‰„@‰JÐ658.0Ð ka5ø#H/" „@658.0 „@ 0@998„„‰0@‰kÐ998Ð j`3ø#H0" 0@998 0@ È—@1522„„‰È—@‰jÐ1522Ð I?4ø#H1" È—@1522 È—@ „„IÐ$1,100,000Ð J@ø#H2" `‰@812.0„„‰`‰@‰JÐ812.0Ð ka5x%È 3" `‰@812.0 `‰@ xŽ@975„„‰xŽ@‰kÐ975Ð j`3x%È 4" xŽ@975 xŽ@ d@1881„„‰d@‰jÐ1881Ð I?4x%È 5" d@1881 d@ „„IÐ$1,450,000Ð J@x%È 6" ÀŽ@984.0„„‰ÀŽ@‰JÐ984.0Ð lb5ø&H"7" ÀŽ@984.0 ÀŽ@ p‘@1116„„‰p‘@‰lÐ1116Ð ka4ø&H"8" p‘@1116 p‘@ ¨¢@2388„„‰¨¢@‰kÐ2388Ð I?4ø&H"9" ¨¢@2388 ¨¢@ „„IÐ$1,550,000Ð"ø&H":"  "ÐòòÌaóóÔ‡ô(¡õXXW5ÔCostsÔ#†XW5Xõô(¡ÌV#Ô€Ô‡ô(¡õXXW5Ôreflect€mid„1998€figures.Ô#†XW5Xõô(¡W#ÔÐ  (ð#; ÐÌRegression€analysis€on€the€cost€data€in€Table€1€suggest€there€is€a€nearly€linear€relationshipÏbetween€catalyst€cost€and€exhaust€flow€rate€(ròò2óó€=€0.993,€when€Catalyst€cost€=€1541.8*(lb/sec)€+Ð d+´&> Ð102370).€€Therefore,€in€estimating€catalyst€costs€for€the€model€turbines,€the€capital€cost€of€a€COÏcatalyst€and€frame€for€a€given€exhaust€flow€rate€can€be€calculated€using€this€relationship.ÌÌInformation€was€also€provided€by€Engelhard€in€response€to€the€questions€posed€concerningÏoperating€issues€associated€with€operating€CO€oxidation€catalysts.€€A€graph€showing€that€lowerÏperformance/conversion€accompanies€lower€temperatures€was€supplied.€€Typically,€the€catalystsÏEngelhard€provides€for€gas€turbine€installations€are€supplied€to€a€Heat€Recovery€Steam€GeneratorÏ(HRSG)€supplier.€€The€CO€catalyst€is€generally€installed€within€a€HRSG.€€Supplemental€firingÏusually€is€performed€to€increase€steam€production€and€thus€gas€temperatures€at€the€catalyst€andÏconversion€requirements€can€be€impacted€by€supplemental€firing.€€Engelhard€typically€meets€givenÏHRSG€cross€section€and€maximum€specified€pressure€drop€allowed.ÌÌEngelhard€indicated€that€reasonable€retrofit€estimates€could€not€be€provided€due€to€many€site„¼specific€requirements.€€Their€scope€includes€an€internal€support€frame€and€catalyst€modules€whichÏare€installed€inside€the€HRSG€housing€and€as€such,€issues€including€flow€straightening,€housing,Ïfoundations,€etc.,€are€handled€by€other€vendors.ÌÌòòNooter/EriksenóóÐ \¬ ÐNooter/Eriksen€has€become€virtually€sole€sourced€to€Engelhardððs€Camet€catalyst€for€theirÏoxidation€catalysts€and€provided€an€estimate€of€$650,000€for€a€60%€CO€oxidation€catalyst€(noÏsupport€frame€or€casing)€in€a€GE€Frame€7F€installation€(3,500,000€lb/hr€with€a€catalystÏtemperature€of€approximately€900òòoóóF).€€They€indicated€that€the€price€variation€is€approximatelyÐ  \ Ðlinear€with€mass€flow€and€would€approximately€double€to€achieve€90%€conversion.€€They€were€Ïunable€to€comment€on€HAP€destruction.€€The€CO€catalyst€is€occasionally€required€to€also€oxidizeÏvolatile€organic€compounds€(VOCs),€in€which€cases€the€catalyst€is€generally€effective€withÏunsaturated€VOCs€only€and€the€catalyst€must€be€located€in€a€higher€temperature€window.€ÌÌFor€high€CO€oxidation€(90%),€a€temperature€range€of€approximately€700òòoóóF€to€760òòoóóF€is€preferred.€Ð ”ä ÐIf€Ô_ÔVOCÔ_Ô€oxidation€is€also€required,€the€temperature€window€generally€increases€to€950òòoóóF€toÐ €Ð Ð1,100òòoóóF.€€It€was€indicated€that€prolonged€operation€at€500òòoóóF€will€not€generally€harm€an€oxidationÐ l¼ Ðcatalyst€unless€the€combustion€turbine€is€operating€with€a€high€soot€concentration€in€the€exhaust,Ïalthough€there€is€little€oxidation€activity€at€500òòoóóF.Ð D!” ÐÌConcerning€retrofit€issues,€it€was€indicated€that€new€ductwork€to€redirect€flow€outside€of€theÏoriginal€flow€path€would€probably€have€the€effect€of€obsoleting€the€greater€portion€of€the€HRSG.€ÏMost€catalyst€system€guarantees€are€based€on€even€flow€distribution€(typically€ðð15%€RMS€of€theÏmean)€entering€the€catalyst.€€If€flow€distribution€devices€were€not€originally€included€with€theÏHRSG,€this€could€increase€the€overall€HRSG€pressure€loss€by€0.5"€to€1.0"€W.C.€€€Ìâ âÐ ¸'#& ÐòòÔ& 8 Ôâ âGeneralized€Pressure€Drop€CostsóóÐ ° ÐInstallation€of€a€catalyst€system€will€increase€the€pressure€drop€experienced€by€the€turbine€exhaustÏflow.€€The€additional€pressure€drop€results€in€a€decrease€in€turbine€power€output.€€If€the€turbine€isÏnot€operating€at€full€load,€additional€fuel€can€be€burned€to€make€up€for€the€lost€power€(fuelÏpenalty).€€The€fuel€penalty€is€assessed€as€the€cost€of€increased€fuel,€which€is€calculated€byÏassuming€a€percentage€heat€rate€increase€per€inch€of€pressure€drop€due€to€the€increased€exhaustÏbackpressure€on€the€turbine€that€results€from€installing€an€oxidation€catalyst.€€An€equation€for€theÏfuel€penalty€was€provided€by€the€Gas€Research€Institute,€which€is€based€on€an€anticipated€heatÏrate€increase€of€0.105%€per€inch€pressure€drop,€$2/MMBtu€for€natural€gas,€and€a€9,000€Btu/hp„hrÏbaseline.Ô'8 °«dÔ€ÌÌIf€the€unit€is€operating€at€full€load,€the€loss€in€power€cannot€be€regained€by€burning€additional€fuelÏand€will€result€in€a€loss€in€electricity€sales.€€The€costs€associated€with€the€power€loss€depend€onÏsite„specific€factors,€such€as€value€of€lost€product€or€capital€and€annual€costs€for€equipmentÏrequired€to€make€up€for€the€power€loss.€€Information€on€the€loss€in€annual€sales€at€different€sellingÏprices€for€electrical€power€was€provided€to€EPA€by€Dow€Chemical€Company.€€For€a€GE€Frame€7Ïturbine,€the€annual€cost€(lost€sales)€per€inch€of€water€pressure€drop€may€be€estimated€using€theÏfollowing€relationship:€Annual€Cost€($/inch)€=€1,160*Power€Value€($/Mwh)€+€100.ÌÌòòGeneralized€Retrofit€CostsóóÐ 4„ ÐEstimates€for€retrofit€costs€were€provided€to€EPA€by€Dow€Chemical€Company.€€Site„specificÏfactors€can€have€a€major€impact€on€the€cost€of€retrofitting€a€catalyst€control€system€to€an€existingÏturbine€installation.€€In€general,€the€heat€recovery€unit€(if€one€exists)€must€be€altered,€ductworkÏand€piling€supports€must€be€added,€and€piping,€electrical€conduits,€and€wiring€must€be€lengthened.€ÏSome€turbine€installations€have€enough€space€between€the€turbine€exhaust€and€the€heat€recoveryÏunit€to€add€the€catalyst€system.€€In€cases€where€space€is€very€limited,€the€heat€recovery€unit€mightÏhave€to€be€removed€and€replaced€with€a€new€vertical€style€unit.€€Estimates€were€provided€forÏretrofit€costs€for€adding€a€catalyst€system€to€an€ABB€Type€11€turbine€(gas€flow€rate€=€580€lb/sec).€ÏThe€retrofit€costs€totaled€about€$800,000,€which€included€$100,000€for€ductwork.€€The€cost€ofÏdown€time€must€also€be€estimated.€€It€is€difficult€to€extrapolate€from€the€costs€provided€for€thisÏunit€since€the€complexity€and€cost€associated€with€retrofit€installations€varies€so€much€by€site.€ÌÌÝ‚J…¦ÿÝð"ðà0  àÝ  Ýò òOther€Catalytic€SystemsÝ‚J…¦ÿ&ot€MaÝÝ  ÝÐ0"€ (#(# Ðó óÌCost€information€in€the€form€of€comparisons€to€SCR€systems€for€NOX€control€were€received€forÏSCONOx€and€XONON.€€More€detailed€cost€information€is€needed€from€each€vendor€before€anÏaccurate€assessment€can€be€made€concerning€the€cost€of€using€these€systems€in€conjunction€withÏthe€model€turbines.€€The€information€provided€on€these€two€systems€is€summarized€below.ÌÌòòSCONOxòòóóTMóóÐ ¨(ø#' ÐCost€information€for€SCONOx€was€submitted€by€Goal€Line€Environmental€Technologies€LLC.€ÏThe€information€consisted€of€a€cost€comparison€model€between€SCONOx€and€SCR€(selectiveÏcatalytic€reduction).€€The€comparison€is€difficult€to€use€for€HAPs€since€it€was€based€on€NOXÐ l+¼&* Ðcontrol€and€therefore€takes€into€account€cost€issues€concerning€ammonia€use€in€the€SCR€system.€ÏThe€lifetime€cost€(10€years)€for€the€reduction€of€NOX€from€20€ppm€to€2.5€ppm€for€a€typical€270ÏMW€plant€was€estimated€as€$12,970,970€for€the€SCONOx€system€and€$17,882,560€for€an€SCRÏsystem.€€This€analysis€would€need€to€be€significantly€adapted€to€be€used€constructively€in€modelÏturbine€cost€analyses.ÌÌòòXONONóóÐ 8 ˆ ÐA€cost€comparison€of€the€XONON€system€was€provided€by€Catalytica€Combustion€Systems.€€TheÏcomparison€consisted€of€estimates€for€DLN€(dry€low€NOX),€DLN€+€SCR€(selective€catalyticÏreduction),€and€XONON€for€controlling€NOX€from€two€different€turbine€models.€€As€with€theÏSCONOx€information,€the€use€of€ammonia€is€a€cost€consideration€that€needs€to€be€excluded€whenÏconsidering€the€cost€of€the€XONON€system.ÌÌòòò òLean€pre„mix€(LPM)€CombustorsÐ ¬ü  ÐÌó óóóCost€information€for€lean€pre„mix€combustors€was€taken€from€the€ð ðAlternative€ControlÐ „Ô  ÐTechniques€Document€„„€NOX€Emissions€from€Stationary€Gas€Turbinesðð€(ACT).òòò ò€€ó óóóTheÐ pÀ Ðincremental€capital€costs€for€LPM€units€relative€to€diffusion€flame€units€are€provided€for€eightÏturbines€in€the€ACT.€€A€regression€formula€was€developed€where€the€incremental€capital€cost€is€aÏfunction€of€turbine€rating€(MW).€€This€relationship€is€as€follows:Ì€€Ìà0  àIncremental€capital€cost€(1990$)€=€21454.3*MW€+€408431;€ròò2€óó=€0.981Ð`(#(# ÐÌIt€is€not€expected€that€the€maintenance€requirements€for€an€LPM€unit€will€be€different€than€for€aÏstandard€design;€therefore,€the€incremental€capital€cost€is€the€only€cost€to€be€considered€inÏcalculating€annual€costs.€€According€to€the€ACT,€retrofit€costs€are€40€to€60€percent€greater€thanÏnew€installation€costs.€ÌÐ  ˜è ÐÌÌÌÌÌÓ  ÓAttachment€BÔ#† XW5XXXW5àD#ÔÔ‡XW5XX XW5ÔÐ  L œ ÐÓ™yÓÌÌÌÌÌÌÌÌMEMORANDUMÌÌDATE:à0  àò òà ` àó óSeptember€27,€2001Ðè 8 (#(# ÐÌSUBJECT:ò òà0 ` àó óNew€Stationary€Combustion€Turbines€Oxidation€Catalyst€Cost€InformationÐÀ ` (#` (# Ðò òÌó óThe€purpose€of€this€memorandum€is€to€summarize€new€cost€information€that€has€been€received€forÐ ˜è  Ðoxidation€catalysts.€€In€August€2001,€EPA€received€revised€costs€from€Engelhard€that€are€moreÏcurrent€than€the€costs€provided€by€Engelhard€in€1998.€€The€revised€costs€are€presented€in€Table€1Ïbelow.€€These€costs€were€for€90€percent€reduction€of€CO.€€In€September€2001,€similar€costÏinformation€was€received€for€95€percent€reduction€of€CO.€€These€costs€are€presented€in€Table€2.€€Ô#† XW5XXXW5Ôy#ÔÔ‡XW5XX XW5ÔÐ H˜ ÐÌÓ  ÓTable€1.€€CO€Oxidation€Catalyst€Costs€Provided€by€Engelhard,€August€2001,€90%€CO€ReductionÌÓM}ÓÌÔ*žƒ+ ,ddždd žždd žždd žždd ž °(#°(#žÔÔ,ždd ÔÔ,ždd ÔÔ,ždd ÔÔ,ždd ÔÔ+  ÔÐ +€1 øH €€„„+ÐTurbine€ExhaustÏFlow€(lb/sec)Ð =€1,!H˜"1 „„=ÐTurbine€ExhaustÏTemperature€(F)Ð =€1,!H˜"1 „„=ÐRequired€Inside€LinerÏCross€Section€(sq.€ft.)Ð =€1,!H˜"1 „„=ÐEstimated€CostÌCatalyst€+€FrameòòaóóÐ ]S&H˜"  1 ffffff<@28.4„„‰ffffff<@‰]Ð28.4Ð ka4È" ffffff<@28.4 ffffff<@ h@1050„„‰h@‰kÐ1050Ð i_4È " h@1050 h@  ÀP@67„„‰ÀP@‰iÐ67Ð G=2È!"  ÀP@67 ÀP@ „„GÐ$68,000Ð I?È"" €D@41.0„„‰€D@‰IÐ41.0Ð j`4H˜#" €D@41.0 €D@ ˜‰@819„„‰˜‰@‰jÐ819Ð h^3H˜$" ˜‰@819 ˜‰@  €V@90„„‰€V@‰hÐ90Ð G=2H˜%"  €V@90 €V@ „„GÐ$80,000Ð J@H˜&" às@318.0„„‰às@‰JÐ318.0Ð ka5È'" às@318.0 às@ ðŽ@990„„‰ðŽ@‰kÐ990Ð i_3È(" ðŽ@990 ðŽ@ `†@716„„‰`†@‰iÐ716Ð H>3È)" `†@716 `†@ „„HÐ$325,000Ð J@È*" „@658.0„„‰„@‰JÐ658.0Ð ka5H ˜+" „@658.0 „@ 0@998„„‰0@‰kÐ998Ð j`3H ˜," 0@998 0@ Œ—@1507„„‰Œ—@‰jÐ1507Ð I?4H ˜-" Œ—@1507 Œ—@ „„IÐ$609,000Ð J@H ˜." `‰@812.0„„‰`‰@‰JÐ812.0Ð ka5È!/" `‰@812.0 `‰@ xŽ@975„„‰xŽ@‰kÐ975Ð j`3È!0" xŽ@975 xŽ@ Ìœ@1843„„‰Ìœ@‰jÐ1843Ð I?4È!1" Ìœ@1843 Ìœ@ „„IÐ$734,000Ð J@È!2" ÀŽ@984.0„„‰ÀŽ@‰JÐ984.0Ð lb5H#˜3" ÀŽ@984.0 ÀŽ@ p‘@1116„„‰p‘@‰lÐ1116Ð ka4H#˜4" p‘@1116 p‘@ Š¢@2373„„‰Š¢@‰kÐÔ_Ô2373Ô_ÔÐ I?4H#˜5" Š¢@2373 Š¢@ „„IÐ$891,000Ð"H#˜6"  "ÐòòÌaóóÔ‡ô(¡õXXW5ÔCostsÔ#†XW5Xõô(¡‰#Ô€Ô‡ô(¡õXXW5Ôreflect€August€2001€figures.Ô#†XW5Xõô(¡Ç‰#ÔÐ ð$@ 7 ÐÌâ âÐ È&"9 ÐÔ& ” Ôâ âñŒñÓ  ÓñŒñTable€2.€€CO€Oxidation€Catalyst€Costs€Provided€by€Engelhard,€Sept.€2001,€95%€CO€ReductionÌñŒñÓuŠÓñŒñÌÔ*žƒ- .ddždd žždd žždd žždd ž+ ,°(#°(#žÔÔ,ždd ÔÔ,ždd ÔÔ,ždd ÔÔ,ždd ÔÔ+  ÔÐ +€1 ˆØ €€„„+ÐTurbine€ExhaustÏFlow€(lb/sec)Ð =€1,!Ø("1 „„=ÐTurbine€ExhaustÏTemperature€(F)Ð =€1,!Ø("1 „„=ÐRequired€Inside€LinerÏCross€Section€(sq.€ft.)Ð =€1,!Ø("1 „„=ÐEstimated€CostÌCatalyst€+€FrameòòaóóÐ ]S&Ø( "  1 ffffff<@28.4„„‰ffffff<@‰]Ð28.4Ð ka4X ¨ " ffffff<@28.4 ffffff<@ h@1050„„‰h@‰kÐÔ_Ô1050Ô_ÔÔ'”°jŠÔÐ i_4X ¨ " h@1050 h@  @T@81„„‰@T@‰iÐÔ_Ô81Ô_ÔÐ G=2X ¨ "  @T@81 @T@ „„GÐ$77,000Ð I?X ¨" €D@41.0„„‰€D@‰IÐÔ_Ô41.0Ð j`4Ø (" €D@41.0 €D@ ˜‰@819„„‰˜‰@‰jÐ819Ð i_3Ø (" ˜‰@819 ˜‰@ Z@104„„‰Z@‰iÐ104Ð H>3Ø (" Z@104 Z@ „„HÐ$91,000Ð J@Ø (" às@318.0„„‰às@‰JÐ318.0Ð ka5X ¨" às@318.0 às@ ðŽ@990„„‰ðŽ@‰kÐ990Ð i_3X ¨" ðŽ@990 ðŽ@ ˜Š@851„„‰˜Š@‰iÐ851Ð H>3X ¨" ˜Š@851 ˜Š@ „„HÐ$403,000Ð J@X ¨" „@658.0„„‰„@‰JÐ658.0Ð ka5Ø ( " „@658.0 „@ 0@998„„‰0@‰kÐ998Ð j`3Ø ( " 0@998 0@ tœ@1821„„‰tœ@‰jÐ1821Ð I?4Ø ( " tœ@1821 tœ@ „„IÐ$773,000Ð J@Ø ( " `‰@812.0„„‰`‰@‰JÐ812.0Ð ka5X¨ " `‰@812.0 `‰@ xŽ@975„„‰xŽ@‰kÐ975Ð j`3X¨ " xŽ@975 xŽ@ Ê @2149„„‰Ê @‰jÐ2149Ð I?4X¨ " Ê @2149 Ê @ „„IÐ$903,000Ð J@X¨ " ÀŽ@984.0„„‰ÀŽ@‰JÐ984.0Ð lb5Ø( " ÀŽ@984.0 ÀŽ@ p‘@1116„„‰p‘@‰lÐ1116Ð ka4Ø( " p‘@1116 p‘@ °¥@2776„„‰°¥@‰kÐ2776Ð I?4Ø( !" °¥@2776 °¥@ „„IÐ$1,118,000Ð"Ø( ""  "ÐòòÌaóóÔ‡ô(¡õXXW5ÔCostsÔ#†XW5Xõô(¡—#Ô€Ô‡ô(¡õXXW5Ôreflect€September€2001€figures.Ô#†XW5Xõô(¡e—#ÔÔ#† XW5XXXW5}#ÔÔ‡XW5XX XW5ÔÐ €Ð # ÐÌRegression€analysis€on€the€cost€data€in€Tables€1€and€2€suggest€there€is€a€nearly€linear€relationshipÏbetween€catalyst€cost€and€exhaust€flow€rate€(ròò2óó€=€0.998,€when€Catalyst€cost€=€855.25*(lb/sec)€+Ð D”& Ð46151€for€90€percent€CO€reduction;€ròò2óó€=€0.991,€when€Catalyst€cost€=€1078.1*(lb/sec)€+€50288€forÐ 0€' Ð95€percent€CO€reductionÔ#† XW5XXXW5é—#ÔÔ‡XW5XX XW5Ô).€€Therefore,€in€estimating€catalyst€costs€for€the€model€turbines,€theÐ l( Ðcapital€cost€of€a€CO€catalyst€and€frame€for€a€given€exhaust€flow€rate€can€be€calculated€using€thisÏrelationship.Ô#† XW5XXXW5±™#Ô