Agenda
UNECE Convention on Long-range Transboundary Air Pollution
General cost methodology
Calculation of boiler outlet emission loads
Economic assessment of DeNOx technologies
Economic assessment of dedusting technologies
Economic assessment of DeSOx technologies
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
IED ELVs and Dust emission issues in coal power plant
Existing plants New plants
Power (MW) ELV (mg/Nm3) Power (MW) ELV (mg/Nm3)
50-100 3050-300 20
100-300 25
>300 20 >300 10
0,0
2,0
4,0
6,0
8,0
10,0
12,0
14,0
16,0
0,0E+00
5,0E+04
1,0E+05
1,5E+05
2,0E+05
2,5E+05
Ash
mas
s fra
ction
(%)
Dus
t loa
d (t
/yea
r)
Carbon ash content and Dust load emissions
Dust load (t/h)
Ash mass fraction (%)
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
Specific cost methodology for DedusterAdapted methodogy from US EPA Air pollution cost control manual
Variable operating cost
Fabric Filter Electrostatic Precipitator
Cequip
1.Baghouse compartments2.Bags3.Cages
General equipment
0.74 0.67
0.45 0.57
Cop,var
1.Bag replacement2.Compressed air consumption
3. Fan consumption
1.ESP power requirement2.Fan consumption
3. SO3 consumption
finstdirect
finstindirect
Investment cost
Cinvሾ€ሿ= Cequip ሾ€ሿ+ finstdirect ∙Cequip ሾ€ሿ+ finstindirect ∙Cequip ሾ€ሿ Cop,var €year൨= Cunit €year൨
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
Pulse Jet Fabric Filter
General approach for Pulse Jet Fabric Filter equipment cost
UNECE Convention on Long-range Transboundary Air Pollution
Logic Tree
Economic assessment of Dedusting technologies
Total filtration area calculation and industrial example
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
Atot (m2)
fN-G
AGC (m2)
ANC (m2)
Acomp (m2) Extra-compartment ?
Compartment division
Industrial example from Termokimik1
• Power 660 MWe => 1,650 MWth• Volumetric flow gas = 1,750,000 Nm3/h• A/C = 1.11 cm/s• ANC = 45,900 m2
• AGC = 47,736 m2
• 16 compartments => Acomp = 2,984 m2 1Available online : http://www.termokimik.it/pdf/torrevaldaliga_eng.pdf
Cost comparison for Pulse Jet Fabric Filter units Variable input parameters and comparison with literature data
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
Parameter Value
A/C (m/s) 1.8e-2
Number of compartments
Division made in order to get Acomp = 2,500 m2
Number of extra-compartments
Bettween 0 and 2
Compartement baghouse
Stainless steelInsulated
Filtering media
RT
Reference price for PE media (€)
9
Bag dimension
Lenght : 8mDiameter : 150 mm
Cage price (€/m2)
20250 500 750 1,000 1,250 1,500 1,750 2,000
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
EGTEI Model
RAINS
AEP
Nalbandian [Smith]
Naldandian [Orfanoudakis]
Nalbandian
World bank
IEA
Balcke Durr
PM BART determination [American Electric Power]
Sergent et Lundy
IEA
Wu
Power (MWth)
Inve
stm
ent c
ost (
2010
k€)
Air to Cloth ratio influence and industrial values
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
0
5 000
10 000
15 000
20 000
25 000
30 000
35 000
40 000
20 000
22 500
25 000
27 500
30 000
32 500
35 000
37 500
40 000
42 500
45 000
47 500
8,00E-03 1,00E-02 1,20E-02 1,40E-02 1,60E-02 1,80E-02 2,00E-02 2,20E-02 2,40E-02
Tota
l Air fi
ltrati
on ar
ea (m
2)
Inves
tmen
t cos
t (201
0 k€)
Air to Cloth ratio (m/s)
Evolution of Investment Cost and Total Filtration Area depending on Air to Cloth ratio
Investment cost
Atot (m2)
Industrial example
Air to cloth ratio (m/s)
Termokimik 0.011
Balcke Dürr 0.014
GE Energy 0.014 – 0.017
Lurgi 0.014 – 0.0167
Otter Tail Power Company
0.0172
For a 1000 MWth combustion plant
Operating Cost for Pulse Jet Fabric Filter and Efficiency
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
Operating cost(€2010)
Pressure drop (mbar)
Cleaningfrequency
Total filtration area (m2)
Fan power requirement (MW)
Air compressor power requirement (MW)
Dust load(g/Nm3)
Dust accumulation on bags (g/m2)
Bag lifetime (h)
Efficiency(%)
A/C (m/s)
vሶλ,dry ,secflue gas ሺNm3/sሻ
Operating Cost for Pulse Jet Fabric Filter
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
-10
10
30
50
70
90
110
130
150
0
100
200
300
400
500
600
700
800
0 20 40 60 80 100
Spec
ific
dust
red
ucti
on c
ost
(€/t
/yea
r)
Elec
tric
ity
and
Bag
Repl
acem
ent
cost
(k€
/yea
r)
Capacity factor (%)
utility electricity cost
Bag replacement costspec. Dust reduction costs
Specific dust reduction cost = total cost per year / dust emission saved per yearUtility electricity cost : Fan consumption and comrpessed air consumptionBag replacement : assuming 20,000 hours of bag lifetime
Electrostatic Precipitator
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
General approach for ESP equipment cost
UNECE Convention on Long-range Transboundary Air Pollution
Logic Tree
Economic assessment of Dedusting technologies
fSN
MMDin (µm)
fRR
Efficiency (%)
Specific CollectingPlate (s/m)
Effective CollectingPlate Area (m²)
Equipment costs(€2010)
T (K)
MMDp (µm)
MMDr (µm)
fL
Ε0 (F/m)
pe (%)
Ebd (V/m)
υG (kg/m/s)
Eavg (V/m)
n pes
pec MMDrp (µm)
SCAk (s/m) MMDk (µm)
Ref.Box ESP1
Ref.Box ESP2-3
vሶλ,dry ,secflue gas ሺNm3/sሻ Equations or correlations
Cost equations
Operator data
Calculated values
Cost results
Literature data
Effective collecting plate area determination from method 2
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
SCA1
AECP,1
SCAn
AECP,n
k = 1 k = n
MMD1=MMDin MMDn
𝑀𝑀𝐷𝑘+1,𝑖𝑛ሾµ𝑚ሿ= ቂ𝑀𝑀𝐷𝑘,𝑖𝑛ሾµ𝑚ሿ∗𝑓𝑆𝑁+ 𝑝𝑒𝑐 ∗ቀሺ1− 𝑝𝑒𝑐ሻ𝑀𝑀𝐷𝑝ሾµ𝑚ሿ+ 𝑝𝑒𝑐 ∗𝑀𝑀𝐷𝑘,𝑖𝑛ሾµ𝑚ሿቁቃ𝑝𝑒𝑠 + 𝑀𝑀𝐷𝑟𝑝ሾµ𝑚ሿ
𝑆𝐶𝐴𝑘ቂ𝑠𝑚ቃ= −𝜈𝐺 𝑘𝑔𝑚.𝑠൨𝜀0ቂ 𝐶𝑉.𝑚ቃ∗ሺ1− 𝑓𝑆𝑁ሻ∗ ln ሺ𝑝𝑒𝑐ሻ
ቀ𝐸𝑎𝑣𝑔 ቂ𝑉𝑚ቃቁ2 𝑀𝑀𝐷𝑘,𝑖𝑛ሾµ𝑚ሿ∗10−6
𝐴𝐸𝐶𝑃ሾ𝑚2ሿ= 𝑆𝐶𝐴𝑘ቂ𝑠𝑚ቃ
𝑛𝑘=1 ∗𝑣ሶ𝜆,𝑑𝑟𝑦,𝑠𝑒𝑐𝑓𝑙𝑢𝑒 𝑔𝑎𝑠 ቈ𝑁𝑚3𝑠
1 10 1000
0.2
0.4
0.6
0.8
1
Particle Size Distribution
Particle Diameter (µm)Cum
ulat
ive
Mas
s F
ract
ion
(%)
n = number of ESP fields
Evolution of SCA as a function of MMDin and T
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
0 10 20 30 40 50 60 70 80 90 1000
500
1,000
1,500
2,000
2,500
3,000
3,500SCA = f ( MMDin and T)
400450500550600650
Mass Mean Diameter [MMDin] (µm)
Spec
ific c
olle
cting
Are
a [S
CA] (
s/m
)
T (K)
CUECost workbook : 50 s/m < SCA <190 s/mSchwarze Pumpe: SCA =117.4 s/m [Balcke Dürr]Waigaoqiao : SCA = 85.6 s/m [Balcke Dürr]Baclke Dürr : SCA = 226 s/m
𝑆𝐶𝐴ቂ𝑠𝑚ቃ= 𝐴𝐸𝐶𝑃ሾ𝑚2ሿ𝑣ሶ𝜆,𝑑𝑟𝑦,𝑠𝑒𝑐𝑓𝑙𝑢𝑒 𝑔𝑎𝑠 𝑚3𝑠 ൨
Cost comparison for ESP units Variable input parameters and comparison with literature data
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
Parameter Range choice
Efficiency [η] (%)
99.89
Temperature [T] (K)
400
Mass Mean diameter [MMDin] (µm)
12
ESP specific equipment
Yes
ESP material Stainless steel 304
SO3 injection precaution
Yes
250 500 750 1,000 1,250 1,500 1,750 2,0000
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
EGTEI Model
RAINS
AEP
Nalbandian
Naldandian [Or-fanoudakis]
World bank
IEA
Balcke Durr
Questionnary Plant D
Zevenhoven & Kilpinen
Rubin
Sankey
IEA
Power (MWth)
Inve
stm
ent c
ost (
2010
k€)
Operating Cost for ESP units
UNECE Convention on Long-range Transboundary Air Pollution
Economic assessment of Dedusting technologies
0
25
50
75
100
125
150
0
100
200
300
400
500
600
0 20 40 60 80 100
Spec
ific d
ust r
educ
tion
cost
(€/t
/yea
r)
Elec
tric
ity a
nd S
O3
cost
(k €
/yea
r)
Capacity factor (%)
utility electricity cost
SO3 consumption costspec. Dust reduction costs
Specific dust reduction cost = total cost per year / dust emission saved per yearUtility electricity cost : Fan consumption and ESP power requirementSO3 consumption : assuming precaution injection at 35 kg/h