Abstract Process Economics Program Report 136A PLANT UTILITIES COSTS (January 1995) This report updates the utilities costs previously developed in PEP Report 136, also titled Plant Utilities Costs (September 1980). The previous report evaluated four quality grades of water, steam at three different pressures, electricity prices in several regions of the United States, investment and operating costs for three cases of cogeneration, and inert gas production. We have added in the present report the capital investments and operating costs for refrigeration, high temperature hot oil heating, and compressed plant air. The estimated costs for each utility are tabulated for three or more capacities; these costs are then graphically correlated to permit interpolation/extrapolation. The report also discusses new technologies in providing those plant utilities, energy price trends, air emission control limits for steam boilers and fired-heaters, and cogeneration economics. The utilities costs developed in this report are useful to process engineers, project planners, and utilities engineers, not only in the petrochemical industry sector but in all manufacturing industries where plant utilities are essential parts of all production operations. PEP 93 JJLM
CONTENTS 1 INTRODUCTION 1-1 2 SUMMARY 2-1 GENERAL ASPECTS 2-1 ECONOMIC ASPECTS 2-1 Water Costs 2-2 Electricity Prices 2-2 Steam Costs 2-3 Cogeneration Costs 2-3 Inert Gas Costs 2-3 Refrigeration Costs 2-3 Hot Oil Heating System Costs 2-4 Plant Air Costs 2-4 TECHNICAL ASPECTS 2-4 Water Purification 2-4 Steam 2-5 Electricity 2-5 Cogeneration 2-5 Inert Gas 2-6 Refrigeration 2-6 Hot Oil Heating 2-6 Plant Air 2-7 3 INDUSTRY STATUS 3-1 AIR EMISSION CONTROL LIMITS 3-1 ENERGY PRICE TRENDS 3-3 COGENERATION 3-5 SECTION SUMMARY 3-11 4 WATER 4-1 IMPURITIES IN NATURAL WATER 4-1 - iii -
CONTENTS (Continued) 4 WATER (Continued) WATER TREATMENT TECHNOLOGIES 4-5 Aeration 4-5 Clarification 4-7 Filtration 4-7 Cold Lime/Soda Softening 4-7 Hot Lime/Soda Softening 4-9 Ion Exchange Processes 4-9 Electrodialysis and Reverse Osmosis 4-10 Iron, Manganese, and Silica Removal 4-12 PRODUCTION OF CLARIFIED WATER FROM RAW WATER 4-12 Water Distribution 4-12 Water Qualities after Various Treatments 4-12 Cost Estimates 4-16 Capital Costs 4-16 Operating Costs 4-16 PRODUCTION OF PROCESS WATER 4-22 Treatment Technology and Cost Estimate Bases 4-22 Cost Estimates 4-22 Capital Costs 4-22 Operating Costs 4-23 PRODUCTION OF COOLING WATER 4-28 Review of Treatment Technology 4-30 Design Considerations and Cost Estimate Bases 4-32 Cost Estimates 4-33 Capital Costs 4-33 Operating Costs 4-34 PRODUCTION OF BOILER FEEDWATER 4-39 Boiler Makeup Water Quality Criteria 4-39 Review of Treatment Technologies 4-40 Cost Estimate Bases 4-44 - iv -
CONTENTS (Continued) 4 WATER (Concluded) COST ESTIMATES 4-44 Capital Costs 4-44 Operating Costs 4-45 PRODUCTION OF POTABLE WATER 4-51 Potable Water Quality Criteria 4-51 Review of Treatment Technologies 4-54 Cost Estimates 4-54 Capital Costs 4-54 Operating Costs 4-54 5 ELECTRICITY 5-1 DEFINITION OF TERMS 5-1 ELECTRICITY RATES 5-2 Houston Lighting and Power Company (HL&P) 5-2 Customer Categories 5-2 Electric Bill Components 5-2 Standard Electricity Rate Schedules 5-3 Economic Redevelopment Service (ERS) 5-6 Interruptible Service (IS) Rates 5-7 Gulf States Utilities (GSU) Company 5-8 High Load Factor Service Rate 5-10 Commonwealth Edison Company (C-E) 5-10 Pacific Gas and Electric (PG&E) Company 5-12 Public Service Electric and Gas (PSE&G) Company 5-12 Union Electric Company (UE) 5-13 Comparison of Power Companies Electricity Prices 5-14 AVERAGE ELECTRICITY SALES PRICES IN THE UNITED STATES 5-14 6 STEAM 6-1 REVIEW OF TECHNOLOGY 6-1 Package Boilers 6-1 Boiler Configuration 6-2 Thermal Efficiency 6-2 - v -
CONTENTS (Continued) 6 STEAM (Concluded) REVIEW OF TECHNOLOGY (Concluded) Field-Erected Oil/Gas-Fired Boilers 6-4 Stoker Coal-Fired Boilers 6-4 Pulverized Coal-Fired Boilers 6-5 Cyclonic and Fluidized-Bed Boilers 6-8 Environmental Protection 6-10 NO x Emission Control 6-11 SO x Emission Control 6-12 Particulates Emission Control 6-13 PROCESS DESCRIPTION 6-15 Package Oil/Gas-Fired Boilers 6-15 Field-Erected Oil/Gas-Fired Boilers 6-15 Stoker Coal-Fired Boilers 6-18 Pulverized Coal-Fired Boilers 6-20 COST ESTIMATES 6-22 Package Oil/Gas-Fired Boilers 6-22 Capital Costs 6-22 Operating Costs 6-23 Field-Erected Oil/Gas-Fired Boilers 6-29 Capital Investment 6-29 Operating Costs 6-29 Stoker Coal-Fired Boilers 6-35 Capital Investment 6-35 Operating Costs 6-35 Pulverized Coal-Fired Boilers 6-41 Capital Investment 6-41 Operating Costs 6-41 7 COGENERATION 7-1 COGENERATION CYCLES 7-1 STEAM TURBINE-BASED COGENERATION SYSTEMS 7-1 GAS TURBINE-BASED COGENERATION SYSTEMS 7-3 ENERGY ACCOUNTING IN COGENERATION 7-5 - vi -
CONTENTS (Continued) 7 COGENERATION (Concluded) DESIGN AND COST ESTIMATE BASES 7-9 PROCESS DESCRIPTION 7-14 PROCESS DISCUSSION 7-16 COST ESTIMATES 7-16 Capital Costs 7-17 Operating Costs 7-22 DISCUSSION OF COSTS 7-27 8 INERT GAS 8-1 PRESSURE SWING ADSORPTION (PSA) PROCESS 8-1 PSA Process Principle 8-1 PSA Process Description 8-2 MEMBRANE SEPARATION PROCESS 8-2 Membrane Process Principle 8-2 Membrane Process Description 8-4 COST ESTIMATES FOR PSA AND MEMBRANE 8-6 Capital Costs 8-6 Operating Costs 8-6 DISCUSSION OF COSTS 8-7 9 REFRIGERATION 9-1 REVIEW OF TECHNOLOGIES 9-1 Refrigeration Systems 9-1 Steam Jet Refrigeration 9-1 Absorption Refrigeration 9-2 Vapor Compression Refrigeration 9-2 Refrigerants 9-5 EQUIPMENT SELECTION 9-6 Compressors 9-7 Compressor Drivers 9-7 Heat Exchangers 9-7 DESIGN AND COST ESTIMATE BASES 9-7 - vii -
CONTENTS (Concluded) 9 REFRIGERATION (Concluded) COST ESTIMATES 9-9 Capital Costs 9-9 Operating Costs 9-9 DISCUSSION OF COSTS 9-10 10 HOT OIL HEATING SYSTEM 10-1 FLUID TYPES 10-1 DESIGN FEATURES 10-3 PROCESS DESCRIPTION 10-3 COST ESTIMATES 10-5 Capital Costs 10-5 Operating Costs 10-5 DISCUSSION OF COSTS 10-7 11 PLANT AIR 11-1 EQUIPMENT DESCRIPTION 11-1 EQUIPMENT DISCUSSION 11-3 Compressor Selection 11-3 Air Dryer Selection 11-3 COST ESTIMATES 11-4 Capital Costs 11-4 Operating Costs 11-4 DISCUSSION OF COSTS 11-4 APPENDIX A: DESIGN AND COST BASES A-1 APPENDIX B: CHEMICAL REACTIONS FREQUENTLY REFERRED TO IN THE TREATMENT OF WATER B-1 APPENDIX C: CITED REFERENCES C-1 APPENDIX D: PROCESS FLOW DIAGRAMS D-1 - viii -
ILLUSTRATIONS 3.1 Energy Price Trends 3-4 4.1 External Water Treatment Processes 4-6 4.2 Operating Mechanism of a Mixing and Coagulating Clarifier 4-8 4.3 Industrial Water Demineralizer Systems 4-11 4.4 Typical Water Distribution in Process Plants 4-13 4.5 Water Treatment Processes for Estimate Cases 4-14 4.6 Raw Water Clarifier Investment Costs 4-19 4.7 Raw Water Clarifier Operating Costs 4-21 4.8 Process Water Investment Costs 4-25 4.9 Process Water Operating Costs 4-27 4.10 Evaporative Cooling Tower Flow Diagram 4-31 4.11 Cooling Water Investment Costs 4-36 4.12 Cooling Water Operating Costs 4-38 4.13 Hydrogen and Sodium Zeolite Water Softening System 4-41 4.14 Hot Lime Zeolite Boiler Water Softening Process 4-42 4.15 Demineralization Water Treatment Flow Diagram 4-43 4.16 Boiler Feedwater Treatment Investment Costs 4-47 4.17 Boiler Feedwater Treatment Cash Operating Costs 4-49 4.18 Boiler Feedwater Treatment Operating Costs, Including Capital Charges 4-50 4.19 Potable Water Investment Costs 4-57 4.20 Potable Water Operating Costs 4-59 5.1 Large Overhead Service-A (LOS-A) 5-9 6.1 Basic Structural Designs of Package Water Tube Boilers 6-3 6.2 Approximate Boiler Capacity Ranges of Coal-fired Systems 6-6 6.3 Equipment Arrangement of a Spreader Stoker Coal-fired Boiler 6-7 - ix -
ILLUSTRATIONS (Continued) 6.4 Direct-Firing System for Pulverized Coal 6-9 6.5 Package Steam Boiler 6-16 6.6 Equipment Arrangement of a Field-Erected Oil/Gas-Fired Boiler 6-17 6.7 Stoker Coal-Fired Steam Boler 6-19 6.8 Equipment Arrangement of a Pulverized Coal-Fired Boiler 6-21 6.9 Package Gas/Oil-Fired Steam Boiler Investment Costs 6-25 6.10 Package Gas/Oil-Fired Steam Boiler Cash Operating Costs 6-27 6.11 Package Gas/Oil-Fired Steam Boiler Operating Costs, Including Capital Charges 6-28 6.12 Field-Erected Gas/Oil-Fired Steam Boiler Investment Costs 6-31 6.13 Field-Erected Gas/Oil-Fired Steam Boiler Cash Operating Costs 6-33 6.14 Field-Erected Gas/Oil-Fired Steam Boiler Operating Costs, Including Capital Charges 6-34 6.15 Stoker Coal-Fired Steam Boiler Investment Costs 6-37 6.16 Stoker Coal-Fired Steam Boiler Cash Operating Costs 6-39 6.17 Stoker Coal-Fired Steam Boiler Operating Costs, Including Capital Charges 6-40 6.18 Pulverized Coal-Fired Steam Boiler Investment Costs 6-43 6.19 Pulverized Coal-Fired Steam Boiler Cash Operating Costs 6-45 6.20 Pulverized Coal-Fired Steam Boiler Operating Costs, Including Capital Charges 6-46 7.1 Steam Turbine Cogeneration Configurations 7-2 7.2 Gas Turbine Combined Cycle Cogeneration 7-4 7.3 Net Heat to Process Energy Accounting Method 7-6 7.4 Fuel Chargeable to Power Accounting Method 7-7 7.5 Steam-Power Production Ratios in Cogeneration 7-8 - x -
ILLUSTRATIONS (Continued) 7.6 Process Steam Generation by the Package Boiler Process-Base Case Process Flow Diagram D-3 7.7 Cogeneration of Steam and Electricity by the Combined Cycle Process Process Flow Diagram D-5 8.1 Pressure Swing Adsorption (PSA) Process for Nitrogen Separation 8-3 8.2 Membrane Process Flow Diagram for Nitrogen Separation 8-5 8.3 Effect of Capacity on the Total Fixed Capital of On-Site Nitrogen Generation Systems 8-10 8.4 Effect of Capacity on the Product Value of On-Site Nitrogen Generation Systems 8-11 9.1 Ammonia Absorption Refrigeration Process 9-3 9.2 Vapor Compression Refrigeration Process 9-4 9.3 Package and Modular Refrigeration System Costs Low Capacities 9-11 9.4 Package and Modular Refrigeration System Costs High Capacities 9-12 9.5 Unit Capital Investments of Vapor Compression Refrigeration Systems Investment versus Capacity 9-14 9.6 Unit Capital Investments of Vapor Compression Refrigeration Systems Investment versus Temperature 9-15 9.7 Cash Operating Costs of Vapor Compression Refrigeration Systems Cost versus Capacity 9-16 9.8 Total Operating Costs of Vapor Compression Refrigeration Systems Cost versus Capacity 9-17 9.9 Cash Operating Costs of Vapor Compression Refrigeration Systems Cost versus Temperature 9-18 9.10 Total Operating Costs of Vapor Compression Refrigeration Systems Cost versus Temperature 9-19 10.1 High Temperature Heating Fluids Service Temperature Ranges 10-2 - xi -
ILLUSTRATIONS (Concluded) 10.2 Basic Hot Oil Heating System 10-4 10.3 Total Fixed Capitals of On-Site Hot Oil Heating Systems 10-8 10.4 Operating Costs of On-Site Hot Oil Heating Systems 10-9 11.1 Compressed Air System 11-2 11.2 Total Fixed Capitals of On-Site Compressed Air Systems 11-6 11.3 Operating Costs of On-Site Compressed Air Systems 11-7 - xii -
TABLES 2.1 Summary of Plant Utilities Investment and Operating Costs 2-8 3.1 U.S. EPA Emission Performance Standards for Public Utilities and Industrial-Commercial Steam Boilers 3-2 3.2 U.S. Annual Average Energy Price Trends 3-3 3.3 U.S. Cogeneration Capacities by Industry 3-6 3.4 Cogenerators in Louisiana and Electricity Sold to Public Utilities 3-7 3.5 Electricity Sales by Texas Cogenerators to Louisiana Public Utilities 3-8 3.6 Texas Cogenerators and Electricity Sold to Public Utilities in Texas 3-9 4.1 Raw Water Qualities From Several U.S. Sources 4-3 4.2 Effects of Water Impurities on Operating Difficulties and Preventive Treating Processes 4-4 4.3 Water Qualities After Various Methods of Treatment 4-15 4.4 Raw Water Clarifier Investment Costs 4-18 4.5 Clarified Water Operating Costs 4-20 4.6 Process Water Investment Costs 4-24 4.7 Process Water Operating Costs 4-26 4.8 Quality Guidelines for Cooling Tower Water 4-29 4.9 Cooling Water Investment Costs 4-35 4.10 Cooling Water Operating Costs 4-37 4.11 Quality Guidelines for Boiler Feedwater and Boiler Water 4-39 4.12 Boiler Feedwater Treatment Investment Costs 4-46 4.13 Boiler Feedwater Treatment Operating Costs 4-48 4.14 Comparison of the U.S. Primary Drinking Water Standards with EC and WHO Guidelines 4-52 4.15 Comparison of the U.S. Secondary Drinking Water Standards with EC and WHO Guidelines 4-53 - xiii -
TABLES (Continued) 4.16 Potable Water Investment Costs 4-56 4.17 Potable Water Operating Costs 4-58 5.1 Power Rate Schedules to Large Customers of Houston Lighting & Power Company 5-5 5.2 Comparison of Interruptible Electricity Rates: Houston Lighting & Power Company 5-8 6.1 U.S. Air Emission Performance Standards for Industrial-Commercial-Institutional Units 6-11 6.2 Steam Boiler Flue Gas Particulate Control Equipment 6-14 6.3 Package Gas/Oil-Fired Steam Boiler Investment Costs 6-24 6.4 Package Gas/Oil-Fired Steam Boiler Operating Costs 6-26 6.5 Field-Erected Gas/Oil-Fired Steam Boiler Investment Costs 6-30 6.6 Field-Erected Gas/Oil-Fired Steam Boiler Operating Costs 6-32 6.7 Stoker Coal-Fired Steam Boiler Investment Costs 6-36 6.8 Stoker Coal-Fired Steam Boiler Operating Costs 6-38 6.9 Pulverized Coal-Fired Steam Boiler Investment Costs 6-42 6.10 Pulverized Coal-Fired Steam Boiler Operating Costs 6-44 7.1 Summary of Design Capacities and Process Configurations of Study Cases 7-10 7.2 Estimate Bases and Design Parameters Process Steam from a Package Boiler No Cogeneration Case (Base) 7-11 7.3 Estimate Bases and Design Parameters Combined Cycle 1 Cogeneration Case 7-12 7.4 Package Boiler and Combined Cycles Utilities Summary 7-15 7.5 Process Steam Generation by the Package Boiler Process Base Case-Noncogeneration Total Capital Investment 7-18 - xiv -
TABLES (Continued) 7.6 Process Steam Generation by the Combined Cycle Process Cycle 1-Unfired HRSG Total Capital Investment 7-19 7.7 Process Steam Generation by the Combined Cycle Process Cycle 2-Partially Fired HRSG Total Capital Investment 7-20 7.8 Process Steam Generation by the Combined Cycle Process Cycle 3-Fully Fired HRSG Total Capital Investment 7-21 7.9 Process Steam Generation by the Package Boiler Process Base Case-Noncogeneration Operating Costs 7-23 7.10 Process Steam Generation by the Combined Cycle Process Cycle 1-Unfired HRSG Operating Costs 7-24 7.11 Process Steam Generation by the Combined Cycle Process Cycle 2-Partially Fired HRSG Operating Costs 7-25 7.12 Process Steam Generation by the Combined Cycle Process Cycle 3-Fully Fired HRSG Operating Costs 7-26 8.1 High Purity Nitrogen from Air by the Pressure Swing (PSA) Process Design and Estimate Bases 8-8 8.2 High Purity Nitrogen from Air by the Membrane Separation Process Design and Estimate Bases 8-8 8.3 Cost Estimates for Providing Nitrogen for In-Plant Use by Three Processes 8-9 9.1 Common Refrigerants 9-5 9.2 Vapor Compression Refrigeration System Design and Estimate Bases 9-8 9.3 Refrigeration Operating Costs 9-13 10.1 Hot Oil Heating System Design and Estimate Bases 10-3 - xv -
TABLES (Concluded) 10.2 Capital and Operating Cost Estimates for Hot Oil Heaters 10-6 11.1 General Purpose Utility Air Design and Estimate Bases 11-1 11.2 Capital and Operating Cost Estimates for Plant Air 11-5 - xvi -