PROCESS ECONOMICS PROGRAM

Transcription

1 PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Abstract Mod0 Park, California Process Economics Program Report No. 136 PLANT UTILITIES COSTS (September 1980) The report is concerned with the current technology and economics for providing plant water, steam, electricity, cogenerated steam and electricity, and Inert gas. Also shown are the projected costs for these utilities (except for cogeneration) on a yearly basis to 1985 and thereafter on a S-year basis to Estimated water costs are for clarified water, process water, cooling water, potable water, and makeup water for boilers operating at 150, 600, and 1500 psig. Estimated steam costs are for producing steam at 150 psig/ saturated, 600 psig/750of, and 1500 psig/gsoof, in four different types of boilers: package oil-fired, field-erected oil-fired, stoker coalfired, and pulverized coal-fired. Electricity costs are the purchase prices to large users of four representative public utilities in the United States: Commonwealth Edison, Houston Lighting and Power, Public Service Electric and Gas, and Union Electric. Three cases of cogeneration have been evaluated for the extraction of low pressure steam and production of electricity in turbogenerators. At present, the economics of the systems are not competitive with that of raising steam separately and buying power from a public utility in the Houston area. Estimated costs for inert gas produced from stoichiometric combustion of natural gas are at two delivery pressures: 10 in Hz0 and 100 psig. PEP'78 JJLM

2 Report No. 136 PLANT UTILITIES COSTS by JAMES J. L. MA I I September 1980 A private report by the PROCESS ECONOMICS PROGRAM Menlo Park, California 94025

3 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe. ii

4 CONTENTS INTRODUCTION , 1 SUMMARY Economic Aspects..., Water and Inert Gas,,.,... Steam and Electricity, Separately and Cogenerated Technical Aspects Water Purification Electricity Steam... Cogeneration Inert Gas...., Generated INDUSTRY STATUS Power and Energy Price Trends in Houston SRI's Projection of Fuel Prices and Plant Utilities Costs.. 15 Power Costs in Different States Fuel Mix and Fuel Cost of Selected Power Companies Status of Cogeneration WATER Water Quality Review of Water Treating Processes Aeration Clarification Filtration Cold Lime/Soda Softening Hot Lime Softening Ion Exchange Electrodialysis and Reverse Osmosis Iron, Manganese, and Silica Removal Production of Clarified Raw Water Review of Treatment Technology and Cost Estimate Bases,.. 38 Cost Estimates Capital Investment Operating Costs Production of Process Water Review of Treatment Technology and Cost Estimate Bases Cost Estimates Capital Investment Operating Costs iii

5 CONTENTS 4 WATER (Continued) Production of Cooling Water.... Quality Criteria... Review of Treatment Technology... Design Considerations and Cost Estimate Bases.... Cost Estimates... Operating Costs.... Production of Boiler Water... Quality Criteria... Review of Treatment Technology and Cost Estimate Bases... Cost Estimates... Operating Costs.... Production of Potable Water.... Quality Criteria... Review of Treating Processes... Cost Estimates.... Operating Cost... 5 ELECTRICITY Definition of Terms.... Electricity Rates.... Houston Lighting and Power Company (HL&P).... Commonwealth Edison Company (CE)... Union Electric Company (UE).... Public Service Electric and Gas Company (PSE&G).... Transformer Substation Costs... 6 STEAM... Review of Technology... Package Boilers Field-Erected Oil/Gas-Fired Boilers.... Stoker Coal-Fired Boilers.... Pulverized-Coal-Fired Boilers.... Other Coal-Fired Boilers... Environmental Controls... Process Description.... Package Oil/Gas-Fired Boilers.... Field-Erected Oil/Gas-Fired Boilers.... Stoker Coal-Fired Boilers.... Pulverized-Coal-Fired Boilers.... Cost Estimates... Package Oil/Gas-Fired Boilers iv

6 CONTENTS 6 STEAM (Continued) Operating Costs.... Field-Erected Oil/Gas-Fired Boilers.... Operating Costs.... Stoker Coal-Fired Boilers.... Operating Costs.... Pulverized-Coal-Fired Boilers.... Operating Cost... Cost Comparison... 7 COGENERATION... Review of Technology... Thermodynamics.... Cogeneration Cycles.... Comparison of Bottoming Cycle and Topping Cycle Power Production... Process Description.... Cost Estimates... Cost/Benefit Analysis for Cogeneration... Comparison by Product Values... Comparison by Discounted Rates of Return... 8 INERT GAS... Chemistry and Product Qualities.... Review of Commercial Systems... Cost Estimates..... Operating Costs.... CITEDREFERENCES...,..., V

7 ILLUSTRATIONS Electricity and Utility Fuel Costs in the Houston Area.... External Water Treatment Processes... Industrial Water Demineralizer Systems... Plant Water Distribution... Water Treatment Distribution Diagram for Design Cases... Clarified Raw Water Investment Cost.... Clarified Raw Water Operating Cost and Value... Process Water Investment Cost.... Process Water Operating Cost and Value... Evaporative Cooling Tower Flow Diagram... Cooling Tower Investment Cost.... Cooling Water Operating Cost and Value... Hydrogen and Sodium Zeolite Water Softening System... Hot Lime Zeolite Boiler Water Softening Process.... Demineralization Water Treatment Flow Diagram.... Boiler Water Treatment Investment Cost... Boiler Water Treatment Operating Cost Excluding Capital Charges.... Potable Water Capital Investment Cost.... Potable Water Operating Cost... Electricity Rate of Houston Lighting and Power Company Schedule LGS (Large General Service)... Electricity - - Rate of Houston Lighting and Power Company Schedule LOS A (Large Overhead Service A) Electricity Rate of Houston Lighting and Power Company Schedule LOS B (Large Overhead Service B) Electricity Rate of Commonwealth Edison Company for Service in Northern Illinois Electricity Rate of Union Electric Company for Services in Missouri Electricity Rate of Public Service Gas and Electric Company for Service in New Jersey Vii

8 ILLUSTRATIONS Basic Power Distribution Systems.... Main Transformer Substation Cost.... Transformer Substation Operating Cost or Value.... Basic Structural Designs of Packaged Water Tube Boilers... Package Steam Boiler Flow Diagram... Approximate Boiler Capacity Ranges of Coal-Fired systems... Equipment Arrangement of a Spreader Stoker Coal-Fired Boiler... Direct-Firing System for Pulverized Coal.... Equipment Arrangement of a Field-Erected Oil/Gas- Fired Boiler.... Stoker Coal-Fired Steam Boiler Flow Diagram... Equipment Arrangement of a Pulverized-Coal-Fired Boiler.. Comparison of Boiler Investment Costs... Comparison of Steam Value by Different Types of Boiler... Conventional Power Generation Cycle... Conventional Process Steam Raising Cycle.... Cogeneration by the Use of a Back Pressure Turbine.... Cogeneration by Topping Cycles... Cogeneration by Bottoming Cycle... Mollier Diagram of Steam... Power from Cogeneration... Condensing-Extraction Cogeneration Flow Diagram.... Comparison of Power Generation by Different Topping Cycles... Cogeneration Case I Flow Diagram.... Cogeneration Case II Flow Diagram... Cogeneration Case III Flow Diagram.... Cogeneration Profit/Loss Analysis Diagram... Discounted Cash Flow of Cogeneration 10 Percent Per Annum Depreciation Viii

9 ILLUSTRATIONS 7.15 Discounted Cash Flow of Cogeneration 5 Percent Per Annum Depreciation Combustion Gas Compositions Types of Inert Gas Package Low Pressure Inert Gas Generator Flow Diagram Package High Pressure Inert Gas Generator Flow Diagram Inert Gas Generation Investment Cost Value of Inert Gas......, ix

10 TABLES Summary of Water and Inert Gas Costs Summary of Steam, Electricity Generation, and Cogeneration Costs Projected Oil and Natural Gas Prices in Current Dollars Projected Plant Utilities Costs on the U.S. Gulf Coast A Comparison of Electricity Rate Increases from 1977 to 1979 by Representative Power Companies Fuel Mix and Sales Revenue Distribution for Selected Power Companies Summary of New Cogeneration Projects in U.S. Chemical Industry Raw Water Qualities from Several U.S. Sources Effects of Water Impurities on Operating Difficulties and Preventive Treating Processes Composition of Water After Various Methods of Treatment Clarified Raw Water Investment Costs Clarified Raw Water Operating Costs Process Water Investment Cost Process Water Operating Costs Quality Guidelines for Cooling Tower Water Cooling Tower Investment Cost Cooling Water Operating Costs Quality Guidelines for Boiler Feedwater and Boiler Water Boiler Water Treatment and Feedwater System Investment Costs Boiler Makeup Water Operating Costs Drinking Water Standards Potable Water Investment Costs Potable Water Operating Costs Xi

11 TABLES Power Charge Schedules to Large Customers of Houston Lighting and Power Average Power Cost in the Houston Area Basic Energy Charge of Union Electric Company Transformer Substation Investment and Operating Costs EPA Emission Performance Standards Steam Boiler Flue Gas Particulate Control Equipment Package Oil/Gas-Fired Boiler Investment and Operating Costs Pressure and Temperature Investment Cost Adjustment Factors for Steam Boilers Field-Erected Gas/Oil-Fired Boiler Investment and Operating Costs Stoker Coal-Fired Boiler Investment and Operating Costs Pulverized Coal-Fired Boiler Investment and Operating Costs Summary of Cogeneration Investment and Operating Costs and Central Plant-Power Generation Costs Public Utility Pulverized Coal-Fired Power Plant Investment and Operating Costs in the Houston Area Cogeneration Cost/Benefit Analysis by Comparison of Product Values Discounted Rates of Return of Cogeneration Inert Gas Generation Investment Costs Inert Gas Generation Operating Costs Inert Gas Generation Utility Consumptions Xii