Capital Cost Scaling Methodology

DOE/NETL-341/013113
DOE/NETL-2010/????
Capital Cost Scaling Methodology
Quality Guidelines for Energy System Studies January 2013
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.
National Energy Technology Laboratory Office of Program Performance and Benefits
2
Quality Guidelines for Energy System Studies

DOE/NETL-341/013113
Final Report
January 31, 2013
NETL Contact:
James Black
General Engineer
Office of Program Planning & Analysis, Performance Division
National Energy Technology Laboratory

www.netl.doe.gov
3
Prepared by:
Energy Sector Planning and Analysis (ESPA)
Marc J. Turner
Booz Allen Hamilton, Inc.
Lora L. Pinkerton
WorleyParsons Group, Inc.
DOE Contract Number DE-FE0004001
4
Acknowledgments
This report was prepared by Energy Sector Planning and Analysis (ESPA) for the United States
Department of Energy (DOE), National Energy Technology Laboratory (NETL). This work was
completed under DOE NETL Contract Number DE-FE0004001. This work was performed
under ESPA Task 341.03.01.
The authors wish to acknowledge the excellent guidance, contributions, and cooperation of the
NETL staff, particularly:
James Black, NETL Technical Project Monitor
Kristin Gerdes
William Morgan Summers
John Wimer, NETL, Division Director,
Office of Program Performance and Benefits (OPPB)
5
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Table of Contents
1 Introduction .................................................................................................................................11
1.1 Limitations of Scaling Approach .............................................................................................14
1.2 Methodology ............................................................................................................................15
1.3 Scaled Cost Estimate Development Examples ........................................................................16
2 Scaling Exponents and Equations ...............................................................................................22
2.1 PC and CFBC ...........................................................................................................................22
2.2 IGCC ........................................................................................................................................32
2.3 NGCC ......................................................................................................................................43
3 Revision Control .........................................................................................................................49
4 References ...................................................................................................................................50
7
List of Exhibits
Exhibit 1-1 Category matrix ........................................................................................................ 12
Exhibit 1-2 Reference cost estimates ........................................................................................... 13
Exhibit 1-3 Example Account 5: Parameter listing ..................................................................... 18
Exhibit 1-4 Example Account 5: Parameter listing ..................................................................... 21
Exhibit 2-1 Category matrix: PC and CFBC ............................................................................... 23
Exhibit 2-2 Scaling parameters and exponents for categories 1-5: “Fuel and Sorbent Handling” 24
Exhibit 2-3 Scaling parameters and exponents for categories 1-5: “Fuel and Sorbent Prep and
Feed” ..................................................................................................................................... 25
Exhibit 2-4 Scaling parameters and exponents for categories 1-5: “Feedwater and Miscellaneous
BOP Systems” ....................................................................................................................... 26
Exhibit 2-5 Scaling parameters and exponents for categories 1-5: “PC Boiler and Accessories” 26
Exhibit 2-6 Scaling parameters and exponents for categories 1-5: “Flue Gas cleanup” .............. 27
Exhibit 2-7 Scaling parameters and exponents for categories 1-5: “CO2 Removal and
Compression” ........................................................................................................................ 27
Exhibit 2-8 Scaling parameters and exponents for categories 1-5: “HRSG, Ducting, and Stack” 28
Exhibit 2-9 Scaling parameters and exponents for categories 1-5: “Steam Turbine Generator” . 28
Exhibit 2-10 Scaling parameters and exponents for categories 1-5: “Cooling Water System” .... 29
Exhibit 2-11 Scaling parameters and exponents for categories 1-5: “Ash and Spent Sorbent
Handling System” ................................................................................................................. 29
Exhibit 2-12 Scaling parameters and exponents for categories 1-5: “Accessory Electric Plant” . 30
Exhibit 2-13 Scaling parameters and exponents for categories 1-5: “Instrumentation and Control”
............................................................................................................................................... 30
Exhibit 2-14 Scaling parameters and exponents for categories 1-5: “Improvements to Site”...... 31
Exhibit 2-15 Scaling parameters and exponents for categories 1-5: “Buildings and Structures” 31
Exhibit 2-16 Category matrix: IGCC ............................................................................................ 32
Exhibit 2-17 Scaling parameters and exponents for categories 6-9: “Fuel and Sorbent Handling”
............................................................................................................................................... 33
Exhibit 2-18 Scaling parameters and exponents for categories 6-9: “Fuel and Sorbent Prep and
Feed” ..................................................................................................................................... 34
Exhibit 2-19 Scaling parameters and exponents for categories 6-9: “Feedwater and
Miscellaneous BOP Systems”............................................................................................... 35
Exhibit 2-20 Scaling parameters and exponents for categories 6-9: “Gasifier and Accessories” 36
8
Exhibit 2-21 Scaling parameters and exponents for categories 6-9: “Gas Cleanup and Piping” . 37
Exhibit 2-22 Scaling parameters and exponents for categories 6-9: “CO2 Compression” ........... 38
Exhibit 2-23 Scaling parameters and exponents for categories 6-9: “Combustion Turbine and
Accessories” .......................................................................................................................... 38
Exhibit 2-24 Scaling parameters and exponents for categories 6-9: “HRSG, Ducting, and Stack”
............................................................................................................................................... 39
Exhibit 2-25 Scaling parameters and exponents for categories 6-9: “Steam Turbine Generator” 39
Exhibit 2-27 Scaling parameters and exponents for categories 6-9: “Ash and Spent Sorbent
Handling System” ................................................................................................................. 40
............................................................................................................................................... 41
Exhibit 2-32 Category matrix: NGCC .......................................................................................... 43
Exhibit 2-33 Scaling parameters and exponents for categories 6-9: “Feedwater and
Miscellaneous BOP Systems”............................................................................................... 44
Exhibit 2-34 Scaling parameters and exponents for categories 6-9: “Gas Cleanup and Piping” . 44
Exhibit 2-35 Scaling parameters and exponents for categories 6-9: “CO2 Removal and
Compression” ........................................................................................................................ 45
Exhibit 2-36 Scaling parameters and exponents for categories 6-9: “Combustion Turbine and
Accessories” .......................................................................................................................... 45
............................................................................................................................................... 45
Exhibit 2-38 Scaling parameters and exponents for categories 6-9: “Steam Turbine Generator” 46
............................................................................................................................................... 47
Exhibit 3-1 Revision table ............................................................................................................ 49
9
Acronyms and Abbreviations

acfm Actual cubic feet per minute Misc. Miscellaneous
AGR Acid gas removal MMBtu/hr Million British thermal units per
BEC Bare erected cost hour
BFW Boiler feed water MVA Mega volt-amps
BOP Balance of plant MW Megawatt
C Coefficient in equations N/A Not applicable
CFBC Circulating fluidized bed ND North Dakota
combustion NETL National Energy Technology
Circ. Circulating Laboratory
CO2 Carbon dioxide NGCC Natural gas combined cycle
CTG Combustion turbine generator O2 Oxygen
DCF Dry coal feed in equations PC Pulverized coal
DOE Department of Energy PRB Powder River Basin
EGR Exhaust gas recycle RBEC Reference plant bare erected cost
Equip. Equipment in equations
Exp Exponent in equations RC Reference cost in equations
FG Flue gas RCon Reference plant’s contingency in
equations
FGD Flue gas desulfurization
RP Reference parameter in equations
ft3 cubic feet
RTPC Reference total plant cost for
gpm Gallons per minute
subaccount in equations
Hg Mercury
SARU Soot Ash Removal Unit
HGCU Hot-gas-cleanup unit
SC Scaled cost in equations
HP High pressure
SCon Scaled plant’s contingency,
HRSG Heat recovery steam generator percent
IGCC Integrated gasification combined SGC Synthesis gas cooler
cycle
SP Scaled parameter in equations
ISO International Standards
STG Steam turbine generator
Organization
STPC Scaled total plant cost for
kW Kilowatt
subaccount in equations
kWe Kilowatt electric
TG Turbine Generator
kWth Kilowatt thermal
TPC Total plant cost
lb/hr Pounds per hour
TPD tons per day
LHV Lower heating value
TX Texas
LT Low temperature
WGS Water gas shift
MDEA Methyldiethanolamine
min minute
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1 Introduction
Costs are frequently required as part of systems analysis work at the National Energy
Technology Laboratory (NETL). Many of the cost results provided as part of systems analysis
work were created with the use of scaling, since obtaining new vendor-supplied cost quotes for
each category developed by NETL would be prohibitively time consuming and costly.
Additionally, many of the technologies being investigated by NETL have not progressed far
enough to have quotable costs.
The costs are scaled from a quote for a similar plant configuration by use of various equations
that typically employ at least one process parameter (e.g., coal-feed rate, oxidant-feed rate, etc.)
and often an exponent. The primary purpose of the exponent is to account for economies of
scale (i.e. as equipment size gets larger, it gets progressively cheaper to add additional capacity).
The purpose of this section of the Quality Guidelines is to provide a standard basis for scaling
costs, with specific emphasis on scaling exponents. The intention of having a standardized
document is to provide guidelines for proper procedures to reduce the potential of errors and
increase credibility through consistency.
This document contains a listing of frequently used pieces of equipment and their corresponding
scaling exponent for various plant types, along with their ranges of applicability. This document
also details the equations to be used with each exponent.
The scaling exponents used in systems analysis work are logarithmically derived from previously
obtained vendor supplied cost quotes using Equation 1.
Equation 1
( ⁄ )
( ⁄ )
Where:
 Exp – Exponent
 RC – Reference Cost
 RP – Reference Parameter
Exhibit 1-1 provides a listing of the categories used in this document and a description of the
types of technologies to which the associated exponents are applicable. Exhibit 1-2 provides a
listing of reference reports for the various categories.
The listings are divided into three major technologies frequently analyzed at NETL: combustion
[pulverized coal (PC) and circulating fluidized bed combustion (CFBC)]; integrated gasification
combined cycle (IGCC); and natural gas combined cycle (NGCC).
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Exhibit 1-1 Category matrix
Category Technologies
PC/CFBC
Supercritical PC, air-fired, with and without CO2 capture, Illinois No. 6 coal with hybrid poplar
1 Supercritical PC, oxy-fired, with CO2 capture, Illinois No. 6 coal with hybrid poplar
Supercritical and ultra-supercritical1 PC, oxy-fired, with CO2 capture, Illinois No. 6 coal
CFBC, air-fired, with and without CO2 capture, PRB and ND Lignite coals
2
CFBC, oxy-fired, with CO2 capture, PRB and ND Lignite coals
Supercritical PC, air-fired, with and without CO2 capture, ND Lignite and PRB coals
Ultra-supercritical PC1, air-fired, with and without CO2 capture, ND Lignite and PRB coals
3
Supercritical PC, oxy-fired, with CO2 capture, ND Lignite and PRB coals
Ultra-supercritical PC1, oxy-fired, with CO2 capture, ND Lignite and PRB coals
4 Supercritical and ultra-supercritical PC1, air-fired, with and without CO2 capture, Illinois No. 6 coal
5 Subcritical PC, air-fired, with and without CO2 capture, Illinois No. 6 coal
IGCC
Single-stage, dry-feed, oxygen-blown, down-flow gasifier with and without CO2 capture, PRB and
6
ND Lignite coals
Two-stage, slurry-feed, oxygen-blown gasifier with and without CO2 capture, PRB coal
7
Single-stage, slurry-feed, oxygen-blown gasifier with and without CO2 capture, Illinois No. 6 coal
Single-stage, dry-feed, oxygen-blown, up-flow gasifier, with CO2 capture, PRB coal with and
without switchgrass
Single-stage, dry-feed, oxygen-blown, up-flow gasifier with CO2 capture, Illinois No. 6 coal with
8 switchgrass
Single-stage, dry-feed, oxygen-blown, up-flow gasifier, with and without CO2 capture, PRB and ND
Lignite coals
Single-stage, dry-feed, oxygen-blown, up-flow gasifier without CO2 capture, Illinois No. 6 coal
Transport gasifier, air- and oxygen-blown, with and without CO2 capture, PRB and TX Lignite
9 coals
Transport gasifier, oxygen-blown with CO2 capture, TX Lignite coal, with hybrid poplar
NGCC
Natural gas, air-fired, with and without CO2 capture
10
Natural gas, air-fired with CO2 capture and gas recycle
1
Ultra-supercritical PC plants have a 10-percent process contingency applied to line item 4.1 (PC Boiler and
Accessories) and a 15-percent process contingency applied to line item 8.1 (Steam Turbine Generator and
Accessories).
12
Exhibit 1-2 Reference cost estimates
Technologies
Category
Report Hyperlinks
PC/CFBC
Cost and Performance Baseline for Fossil Energy Power Plants, Volume 1: Bituminous Coal
and Natural Gas to Electricity[1]
1 Greenhouse Gas Reductions in the Power Industry Using Domestic Coal and Biomass NETL
– Volume 2: PC Plants[2]
Advanced Oxycombustion Technology for Bituminous Coal Power Plants: An R&D Guide [3]
Cost and Performance Baseline for Fossil Energy Plants – Volume 3: Low Rank Coal and
2 Natural Gas to Electricity[4]
Advanced Oxycombustion Technology for Bituminous Coal Power Plants: An R&D Guide [3]
3
Natural Gas to Electricity[4]
4
5
IGCC
6
7
8
9
NGCC
10
National Energy Technology Laboratory Office of Program Planning and Analysis
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1.1 Limitations of Scaling Approach

It is important to note that when scaling costs, the technologies must be as similar as possible.
For instance, if scaling a plant that fires Illinois No. 6, both the scaling exponents and the
reference cost should be for a plant that fires Illinois No. 6. The same is true for the following
specifications as well:
 Oxidant type (Air or Oxygen)
 Elevation/Location (International Standards Organization [ISO], North Dakota, Montana,
etc.)
 Plant type (Sub-critical, supercritical, ultra-supercritical, etc.)
 Technology type (PC, IGCC, NGCC, etc.)
 Emissions control technologies (with/without CO2 capture, with/without flue gas
desulfurization [FGD], etc.)
For many of the items provided in this report, the approach presented scales on a single
parameter for a given account. In reality, some accounts, particularly some of the major
equipment items, may be impacted by more than one parameter. For example, a line item may
be scaled on one or more flows/outputs but should, in reality, be scaled on multiple flows/outputs
and on both pressure and temperature, or thermal duty and delta temperature. While the single-
parameter approach can be used for high-level scaling, it is recommended that individual
items/systems be scaled from the most similar reference possible, particularly for the cost
drivers.
There are limitations on the ranges that can accurately be addressed by the scaling approach.
There can be step changes in pricing at certain equipment sizes that may not be captured by the
scaling exponents. Care should be taken in applying the scaling factors when there is a large
percentage difference between the scaling parameters. This is particularly true for the major
equipment items. For example, it is known that the combustion turbine is an incremental cost
and is specific to one level of performance.
The configuration also has a significant impact on costs. In addition to the base scaling,
adjustments must be made for considerations such as number of trains for a particular system and
equipment redundancy (i.e. 2 x 100% versus 3 x 50%).
The plant location is another issue that must be kept in mind when scaling costs. Project location
and labor basis can have a significant impact on overall project costs. An additional adjustment
to the labor component may be required to reflect local wage rates, local labor productivity, and
a union versus non-union environment.
It is imperative that the reader understand that even subtle differences in equipment
specifications can result in significant cost impacts. Adjustments, often in the form of additions
or deductions, must be incorporated to address these elements. These could include items such
as unique site considerations (piles, access requirements, salt water environment), or specific
equipment requirements (stack height, re-heat versus non re-heat, single pressure versus multiple
pressure, turbine backpressure).
Finally, the cost basis date must be considered. Equipment, material, and labor costs may need
to be escalated or de-escalated to adjust for the differences between the cost basis date for the
18
scaled estimate and the reference estimate. Additionally, significant elapsed time between the
reference cost date and the desired date for the scaled estimate could potentially encompass
technology or approach changes for a specific item and/or system.
In general, the approach presented in this report is valid for high-level evaluation only. The
accuracy of the factored estimate will be less than or equal to that for a reference estimate.
1.2 Methodology
When developing a cost estimate for a plant that requires scaled costing, determine the category
type from the category matrix in Exhibit 1-1 that exhibits as much commonality as possible
when compared to the plant of interest. Once the category type has been determined, an estimate
for a plant of the same type must be obtained for use as a reference. A listing of reports
containing example reference cost estimates for each category type is provided in Exhibit 1-2.
Reference cost estimates may also be found on the NETL Energy Analysis web1.
If the plant of interest does not match any of the available reference cost estimates, select one
that most suitably matches, taking care to minimize the impact from the limitations of the scaling
approach detailed in Section 2.
For plants of interest that differ significantly from any available reference cost estimates, the
plant of interest may still have many of the same subsystems as one or more of the reference cost
estimates. If so, then the reference cost estimate used may be a combination of various
individual reference cost estimates, matched based on subaccount.
Using the category type obtained from the category matrix, utilize Exhibit 2-2 through
Exhibit 2-43 to obtain the scaling parameters, exponents, and coefficients. The scaling
parameter values associated with the reference cost estimate will be taken from the report from
which the reference cost estimate was obtained.
Determine the scaling parameter values for the plant of interest and compare them to the range of
applicability provided in Exhibit 2-2 through Exhibit 2-43. If the value is outside the
recommended range, significant deviation from realistic results could occur.
Once the scaling parameters, exponents, and coefficients as well as the reference cost and scaling
parameter values are obtained, the scaled cost estimate can be developed by utilizing the
equations provided in Section 2. Specific guidelines are available in subsections, as follows:
Section 2.1 “PC and CFBC”
Section 2.2 “IGCC”
Section 2.3 “NGCC”
The following subsection provides an example for developing cost estimates.
1
http://www.netl.doe.gov/research/energy-analysis
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1.3 Scaled Cost Estimate Development Examples

The plant of interest:
The plant of interest is an oxygen-blown two-stage slurry feed gasifier, firing Powder River
Basin (PRB) coal at ISO elevation. The plant is equipped with CO2 capture and compression
systems and utilizes a wet cooling tower.
Category type:
Category 7 from the category matrix (Exhibit 1-1) most suitably matches the plant of interest as
it shares the following items in common:
1) Two-stage slurry feed gasifier
2) Oxygen-blown
3) CO2 capture
4) PRB coal
Reference plant:
No exact match is available for a ‘reference plant’ as a comparison to the ‘plant of interest’.
Therefore, the ‘reference plant’ will have to be a combination of various ‘reference plants’ based
on subaccount matches. The reference plants selected are Case S4B from the Category 7 report
“Cost and Performance Baseline for Fossil Energy Plants – Volume 3: Low Rank Coal and
Natural Gas to Electricity” [4] (Exhibit 1-2) and Case 4 from the Category 8 report, “Cost and
Performance Baseline for Fossil Energy Power Plants, Volume 1: Bituminous Coal and Natural
Gas to Electricity” [1] (Exhibit 1-2).
Case 4 matches:
1) Cooling type
2) Elevation
3) CO2 capture
4) Gasifier type
Case S4B matches:
1) Coal type
2) CO2 capture
3) Gasifier type
It was decided that all accounts that have direct influence from coal will be scaled using Case
S4B. All other accounts will be scaled using Case 4.
Accounts scaled using Case S4B include:
1) Coal and Sorbent Handling
2) Coal and Sorbent Preparation and Feed
4) Gasifier and Accessories
5A) Gas Cleanup and Piping
6) Combustion Turbine and Accessories
18
The section that will be utilized in the example will be Account 5 “Gas Cleanup and Piping”
Obtain Scaling Parameters
Exhibit 2-21 contains the scaling parameters, exponents, coefficients, and ranges for Account 5
of the selected category 7 plant type.
Exhibit 1-3 provides the account number, item description, scaling parameter, exponent and
coefficient, range of applicability, reference parameter value, reference cost, and scaling
parameter value.
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Exhibit 1-3 Example Account 5: Parameter listing

Reference Cost Scaling
Account Item 1 Exponent 1 Reference
Parameter 1 Range 2 (Equipment/ Parameter
3
Number Description [Coefficient] Parameter 2
TPC)
Selexol Gas flow to
5A.1 0.79 5,000 – 30,000 11,389 $73,047 12,068
(Double) AGR, acfm
Sulfur
Elemental
5A.2 Production, 0.67 200 – 44,000 4,901 $5,613 5,339
Sulfur Plant
lb/hr
Mercury Hg bed carbon 4
5A.3 3 See Note 2,000 – 35,000 N/A $1,328/$3,218 3,916
Removal fill, ft
WGS Catalyst
5A.4 Shift Reactors 3 0.80 1,000 – 11,000 6,257 $8,762 6,692
volume, ft
Blowback Candle filter
5A.5 0.30 2,000 – 96,000 24,282 $2,030 26,838
Gas Systems flow rate, acfm
Fuel Gas Fuel gas flow, 185,000 –
5A.6 0.72 202,347 $0 221,487
Piping lb/hr 2,490,000
Sulfur
HGCU
5A.9 Production, 0.79 200 – 44,000 4,901 $0 5,339
Foundations
lb/hr
1
Information from exhibits in this document
2
Information from the ‘reference’ plant report
3
Scaling parameter from the ‘plant of interest’
4
The exponent 1.57 is used with PRB coal, the exponent 1.64 is used with Illinois No. 6 coal without CO2 capture, and the exponent 1.59 is used with Illinois
No. 6 coal with CO2 capture. The coefficient 0.0141 is used with all instances.
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Calculating scaled cost estimates

Unless otherwise specified, calculating the material cost, labor costs, and equipment cost differs
only in the value used as the reference plants reference cost (RC). When calculating the scaled
plant’s equipment cost, one should use the reference plant’s equipment cost as the reference cost;
likewise, when calculating the scaled plant’s material cost, one should use the reference plant’s
material cost as the reference cost, etc. The sum of these costs is the bare erected cost (BEC).
The process contingency, project contingency, engineering construction management, home
office, and fee are based on a percentage of the BEC. These percentages can be calculated by
using the following equation:
Equation 2
Where:
 SCon – Scaled plant’s contingency, %
 RCon – Reference plant’s contingency, $
 RBEC – Reference plant’s BEC, $
The scaled plant’s contingency percentage is multiplied by the scaled plant’s BEC to get the
scaled plant’s contingency dollar value. The process is repeated for each of the individual
contingencies.
The sum of the BEC and the contingencies is the total plant cost (TPC) for each sub-account.
The example calculations will focus on determining a scaled Equipment Cost for each
subaccount. As such, subaccounts 5A.6 and 5A.9 will not be demonstrated, as their reference
value is $0.
By comparing the scaling parameter to the range of applicability, it is confirmed that it is suitable
to develop a scaled cost estimate for the plant of interest using the scaling parameters, exponents,
and coefficients obtained from within this document.
Based on the general guidelines provided in Section 2 along with the specific guidelines
provided in section 2.2 for IGCC plants, the following equations will be utilized:
For all categories, unless otherwise specified, Equation 3 is used to scale costs.
Equation 3
( )
Where:
 RC– Reference cost
 SC – Scaled cost
 SP – Scaling parameter
19
For IGCC categories, use Equation 4 for items that utilize a coefficient in addition to an
exponent.
Equation 4
Where:
 C – Coefficient
 RTPC – Reference total plant cost for subaccount
Account 5A.1 will use Equation 3 with the parameter “Gas flow to AGR” in actual ft3/min. The
equation is as follows:
Example 1
( )
Based on the Note for Account 5A.3, it contains a coefficient. Therefore, this account will use
Equation 4 with the parameter “Hg bed carbon fill” in ft3. The equation is as follows:
Example 2
All other subaccounts will use Equation 3 as was demonstrated in Example 1. Exhibit 1-4
provides the results of the calculations and compares them to the reference value.
20
Exhibit 1-4 Example Account 5: Parameter listing
Account Item Reference Reference Cost Scaling Scaled Cost

Parameter (Equipment)
Number Description Parameter (Equipment/) Parameter
Selexol Gas flow to
5A.1 11,389 $73,047 12,068 $76,466
(Double) AGR, acfm
Elemental Sulfur
5A.2 4,901 $5,613 5,339 $5,944
Sulfur Plant Production, lb/hr
Mercury Hg bed carbon
5A.3 3 N/A $1,328 3,916 $2,544
Removal fill, ft
WGS Catalyst
5A.4 Shift Reactors 3 6,257 $8,762 6,692 $9,246
volume, ft
Blowback Candle filter flow
5A.5 24,282 $2,030 26,838 $2,092
Gas Systems rate, acfm
21
2 Scaling Exponents and Equations

In all instances, the range is intended to present the reader with the ranges at which the exponents
have already been utilized. It is expected that the ranges, in reality, would be capable of being
applied to the median range ± 25 percent.
For all categories, unless otherwise specified, Equation 3 is used to scale costs.
Equation 3
( )
Where:
2.1 PC and CFBC

For PC and CFBC categories, use Equation 5 for items that utilize a coefficient in addition to an
exponent. In the “Scaling parameters and exponents” tables below, the values presented within
brackets [] are coefficients.
Equation 5
( )
Where:
 C – Coefficient
 RTPC – Reference Total Plant Cost of subaccount
Exhibit 2-1 provides the category matrix for the PC and CFBC categories.
22
Exhibit 2-1 Category matrix: PC and CFBC
Supercritical PC, air-fired, with and without CO2 capture, Illinois No. 6 coal with hybrid poplar
1 Supercritical PC, oxy-fired, with CO2 capture, Illinois No. 6 coal with hybrid poplar
1
Supercritical and ultra-supercritical PC, oxy-fired, with CO2 capture, Illinois No. 6 coal
CFBC, air-fired, with and without CO2 capture, PRB and ND Lignite coals
2
CFBC, oxy-fired, with CO2 capture, PRB and ND Lignite coals
Supercritical PC, air-fired, with and without CO2 capture, ND Lignite and PRB coals
1
Ultra-supercritical PC , air-fired, with and without CO2 capture, ND Lignite and PRB coals
3
Supercritical PC, oxy-fired, with CO2 capture, ND Lignite and PRB coals
1
Ultra-supercritical PC , oxy-fired, with CO2 capture, ND Lignite and PRB coals
1
Supercritical and ultra-supercritical PC, air-fired, with and without CO2 capture, Illinois No. 6
4
coal
5 Subcritical PC, air-fired, with and without CO2 capture, Illinois No. 6 coal
Exhibit 2-2 through Exhibit 2-15 contains the scaling parameters and exponents that are suitable
for PC and CFBC plants at the given ranges.
1
Ultra-supercritical PC plants have a 10 percent process contingency applied to line item 4.1 (PC Boiler and
Accessories) and a 15 percent process contingency applied to line item 8.1 (Steam Turbine Generator and
Accessories).
23
Account Item Description Parameter Exponent Range

Number
Category 1-5 1 2 3 4 5 1-5
1 FUEL & SORBENT HANDLING
1.1 Coal Receive & Unload Coal Feed Rate, lb/hr 0.62 275,000 – 1,110,000
1.2 Coal Stackout & Reclaim Coal Feed Rate, lb/hr 0.62 275,000 – 1,110,000
1.3 Coal Conveyors & Yard Crushing Coal Feed Rate, lb/hr 0.62 275,000 – 1,110,000
1.4 Other Coal Handling Coal Feed Rate, lb/hr 0.62 275,000 – 1,110,000
1
1.5 Biomass Receiving & Processing Biomass Feed Rate, lb/hr See Note 412,000 – 616,000
1.6 Sorbent Receive & Unload Limestone Feed Rate, lb/hr 0.64 9,000 – 63,000
1.7 Sorbent Stackout & Reclaim Limestone Feed Rate, lb/hr 0.64 9,000 – 63,000
1.8 Sorbent Conveyors Limestone Feed Rate, lb/hr 0.64 9,000 – 63,000
1.9 Other Sorbent Handling Limestone Feed Rate, lb/hr 0.64 9,000 – 63,000
Coal & Sorbent Handling
1.10 Coal and Limestone Feed Rate, lb/hr 0.62 302,000 – 1,150,000
Foundations
Equation 7
Equation 6
( )
( )
1
Only applicable to plants co-firing hybrid poplar. Use Equation 6 with exponent 0.37 for equipment and Equation 7 with exponent 0.45 for direct labor. Values
provided in $1,000 (2007$).
24
Exhibit 2-3 Scaling parameters and exponents for categories 1-5: “Fuel and Sorbent Prep and Feed”

Number
Category 1-5 1 2 3 4 5 1-5
2 FUEL & SORBENT PREP & FEED
2.1 Coal Crushing & Drying Coal Feed Rate, lb/hr 0.66 275,000 – 1,110,000
2.2 Prepared Coal Storage & Feed Coal Feed Rate, lb/hr 0.66 275,000 – 1,110,000
1
2.5 Biomass Drying Biomass Feed Rate, lb/hr 0.66 412,000 – 616,000
2
2.6 Biomass Pelletization Biomass Feed Rate, lb/hr 0.66 412,000 – 616,000
2.7 Prepared Biomass Storage & Feed Biomass Feed Rate, lb/hr 0.66 412,000 – 616,000
2.8 Sorbent Prep Equipment Limestone Feed Rate, lb/hr 0.65 10,000 – 57,000
2.9 Sorbent Storage & Feed Limestone Feed Rate, lb/hr 0.65 10,000 – 57,000
2.12 Coal & Sorbent Feed Foundation Coal and Limestone Feed Rate, lb/hr 0.64 303,000 – 1,150,000
Equation 9
Equation 8
( )
( )
1
Only applicable to plants co-firing hybrid poplar. Use Equation 8 with a coefficient of 7.0428 for equipment and 1.3724 for direct labor. Values provided in
$1,000 (2007$).
2
Only applicable to plants co-firing hybrid poplar. Use Equation 9 for equipment.
25
Exhibit 2-4 Scaling parameters and exponents for categories 1-5: “Feedwater and Miscellaneous BOP Systems”

Number
Category 1-5 1 2 3 4 5 1-5
3 FEEDWATER & MISC. BOP SYSTEMS
3.1 Feedwater System HP BFW Flow Rate, lb/hr 0.68 1,960,000 – 5,600,000
3.2 Water Makeup & Pretreating Raw Water Makeup, gpm 0.71 2,000 – 11,000
3.3 Other Feedwater Subsystems HP BFW Flow Rate, lb/hr 0.68 1,960,000 – 5,600,000
3.4 Service Water Systems Raw Water Makeup, gpm 0.71 2,000 – 11,000
3.5 Other Boiler Plant Systems HP BFW Flow Rate, lb/hr 0.75 1,960,000 – 5,600,000
3.6 FO Supply Sys & Nat Gas Total Fuel Feed, lb/hr 0.25 410,000 – 1,110,000
3.7 Waste Treatment Equipment Water to Treatment, lb/hr 0.71 100 – 1,210,000
3.8 Misc. Power Plant Equipment Total Fuel Feed, lb/hr 0.25 410,000 – 1,110,000
Exhibit 2-5 Scaling parameters and exponents for categories 1-5: “PC Boiler and Accessories”

Number
Category 1-5 1 2 3 4 5 1-5
4 PC BOILER & ACCESSORIES
1 1
4.1 PC Boiler & Accessories See Note 0.69 See Note
4.2 ASU/Oxidant Compression O2 Flow Rate, TPD 0.60 13,200 – 15,100
1
CFBC plants use the sum of limestone and coal feed rates (lb/hr) with the total ranging from 303,000 – 1,150,000; Oxy-fired PC with no biomass use coal-feed
rates (lb/hr) ranging from 275,000 – 1,112,000; PC air-fired and PC with biomass use high pressure (HP) boiler feed water (BFW) flow rates (lb/hr) ranging
from 1,958,000 – 5,603,000.
26
Exhibit 2-6 Scaling parameters and exponents for categories 1-5: “Flue Gas cleanup”
Account Item Description Parameter Exponent [Coefficient] Range

Number
Category 1-5 1 2 3 4 5 1-5
5 FLUE GAS CLEANUP
FGD Exit Flow, acfm 0.73 0.59 1,020,000 – 2,560,000
5.1 Absorber Vessels & Accessories N/A 1 {0.73} 0.73
{Limestone Feed Rate, lb/hr} [3.08] [23.75] 9,000 – 63,400
FGD Exit Flow, acfm 0.73 2 1,020,000 – 2,560,000
5.2 Other FGD N/A 0.49 {0.73} 0.73
{Limestone Feed Rate, lb/hr} [0.28] 9,000 – 63,400
0.78
5.3 Bag House & Accessories Baghouse Flow, acfm N/A N/A 0.79 0.79 1,390,000 – 2,560,000
[0.47]
0.40
5.4 Other Particulate Removal Materials Baghouse Flow, acfm 0.77 N/A 3 0.79 0.79 1,390,000 – 2,560,000
[112.22]
5.5 Gypsum Dewatering System Gypsum Flow, lb/hr 0.62 N/A N/A 0.58 0.60 42,900 – 96,600
Exhibit 2-7 Scaling parameters and exponents for categories 1-5: “CO2 Removal and Compression”

Number
Category 1-5 1 2 3 4 5 1-5
5B CO2 REMOVAL & COMPRESSION
CO2 Condensing Heat Exchanger Heat Duty, MMBtu/hr 0.80 0.80 0.80 200 – 600
5B.1 CO2 Flowrate (lb/hr)/ 4 4 4 445,000 – 689,000/
CO2 Removal System 0.60 N/A 0.60 0.60 5
Inlet to Absorber, acfm N/A
5B.2 CO2 Compression & Drying CO2 Captured, lb/hr 0.61 850,000 – 2,290,000
1
Ultra-supercritical plants use a coefficient of 25.9090 and an exponent of 0.5810.
2
Ultra-supercritical plants use an exponent of 0.46.
3
Ultra-supercritical plants use a coefficient of 92.44 and an exponent of 0.4152.
4
40% of cost is applied to gas flow and the remainder applied to CO2 capture.
5
Range has not yet been developed as parameter has not been implemented to date.
27

Number
Category 1-5 1 2 3 4 5 1-5
7 HRSG, DUCTING & STACK
7.1 Flue Gas Recycle Heat Exchanger Heat Duty, MMBtu/hr 0.80 20 – 1,000
0.38 0.38 0.38
7.3 Ductwork Total Fuel Feed, lb/hr 0.29 0.29 410,000 – 1,110,000
[126.25] [126.25] [126.25]
0.48 0.48 0.48
7.4 Stack Stack Flow, acfm 0.06 0.06 378,000 – 1,840,000
[19.52] [19.52] [19.52]
0.14 0.14 0.14
7.9 HRSG, Duct & Stack Foundations Total Fuel Feed, lb/hr 0.06 0.06 410,000 – 1,110,000
[471.71] [471.71] [471.71]
Exhibit 2-9 Scaling parameters and exponents for categories 1-5: “Steam Turbine Generator”

Number
Category 1-5 1 2 3 4 5 1-5
8 STEAM TURBINE GENERATOR
8.1 Steam TG & Accessories Turbine Capacity, MW 0.70 600 – 800
8.2 Turbine Plant Auxiliaries Turbine Capacity, MW 0.70 600 – 800
8.3a Condenser & Auxiliaries Condenser Duty, MMBtu/hr 0.67 0.67 0.67 0.67 0.40 1,000 – 3,000
8.3b Air Cooled Condenser Condenser Duty, MMBtu/hr N/A N/A N/A 0.70 N/A 1,000 – 3,000
8.4 Steam Piping HP BFW Flow Rate, lb/hr 0.70 1,960,000 – 5,600,000
8.9 TG Foundations Turbine Capacity, MW 0.71 600 – 800
28
Exhibit 2-10 Scaling parameters and exponents for categories 1-5: “Cooling Water System”

Number
Category 1-5 1 2 3 4 5 1-5
9 COOLING WATER SYSTEM
9.1 Cooling Towers Cooling Tower Duty, MMBtu/hr 0.74 1000 – 6,000
9.2 Circulating Water Pumps Circulating Water Flow Rate, gpm 0.86 0.73 0.73 0.86 0.73 115,000 – 550,000
9.3 Circ. Water System Auxiliaries Circulating Water Flow Rate, gpm 0.63 115,000 – 550,000
9.4 Circ. Water Piping Circulating Water Flow Rate, gpm 0.63 115,000 – 550,000
1
9.5 Make-up Water System Raw Water Makeup, gpm 0.64 0.64 0.64 0.64 0.64 2,000 – 11,200
9.6 Component Cooling Water System Circulating Water Flow Rate, gpm 0.63 115,000 – 550,000
9.9 Circ. Water System Foundations Circulating Water Flow Rate, gpm 0.58 115,000 – 550,000
Exhibit 2-11 Scaling parameters and exponents for categories 1-5: “Ash and Spent Sorbent Handling System”

Number
Category 1-5 1 2 3 4 5 1-5
10 ASH/SPENT SORBENT HANDLING SYSTEM
10.6 Ash Storage Silos Total Ash Flow, lb/hr 0.56 10 – 100
10.7 Ash Transport & Feed Equipment Total Ash Flow, lb/hr 0.56 10 – 100
10.9 Ash/Spent Sorbent Foundation Total Ash Flow, lb/hr 0.56 10 – 100
1
The exponent 0.82 should be used with ultra-supercritical plants.
29
Exhibit 2-12 Scaling parameters and exponents for categories 1-5: “Accessory Electric Plant”

Number
Category 1-5 1 2 3 4 5 1-5
11 ACCESSORY ELECTRIC PLANT
11.1 Generator Equipment Turbine Capacity, MW 0.57 600 – 800
11.2 Station Service Equipment Auxiliary Load, kW 0.43 28,300 – 272,000
11.3 Switchgear & Motor Control Auxiliary Load, kW 0.43 28,300 – 272,000
11.4 Conduit & Cable Tray Auxiliary Load, kW 0.43 28,300 – 272,000
11.5 Wire & Cable Auxiliary Load, kW 0.43 28,300 – 272,000
11.6 Protective Equipment Auxiliary Load, kW 0.00 28,300 – 272,000
11.7 Standby Equipment Turbine Capacity, MW 0.46 588 – 835
0.46 0.46 0.46
11.8 Main Power Transformers STG Rating, MVA 0.48 2.11 10 – 1000
[418.03] [418.03] [418.03]
11.9 Electrical Foundations Turbine Capacity, MW 0.69 600 – 800

Number
Category 1-5 1 2 3 4 5 1-5
12 INSTRUMENTATION & CONTROL
12.6 Control Boards, Panels & Racks Auxiliary Load, kW 0.13 28,300 – 272,000
12.7 Computer Accessories Auxiliary Load, kW 0.13 28,300 – 272,000
12.8 Instrument Wiring & Tubing Auxiliary Load, kW 0.13 28,300 – 272,000
12.9 Other I & C Equipment Auxiliary Load, kW 0.13 28,300 – 272,000
30
Exhibit 2-14 Scaling parameters and exponents for categories 1-5: “Improvements to Site”

Number
Category 1-5 1 2 3 4 5 1-5
13 IMPROVEMENTS TO SITE
13.1 Site Preparation BEC (Minus Acts. 13 and 14) 0.20 735,000 – 1,630,000
13.2 Site Improvements BEC (Minus Acts. 13 and 14) 0.20 735,000 – 1,630,000
13.3 Site Facilities BEC (Minus Acts. 13 and 14) 0.20 735,000 – 1,630,000
Exhibit 2-15 Scaling parameters and exponents for categories 1-5: “Buildings and Structures”

Number
Category 1-5 1 2 3 4 5 1-5
14 BUILDINGS & STRUCTURES
14.1 Boiler Building BEC (Minus Acts. 13 and 14) 0.09 735,000 – 1,630,000
14.2 Turbine Building BEC (Minus Acts. 13 and 14) 0.12 735,000 – 1,630,000
14.3 Administration Building BEC (Minus Acts. 13 and 14) 0.10 735,000 – 1,630,000
14.4 Circulation Water Pumphouse Circulating Water Flow Rate, gpm 0.60 115,000 – 550,000
14.5 Water Treatment Buildings Raw Water Makeup, gpm 0.65 2,000 – 11,200
14.6 Machine Shop BEC (Minus Acts. 13 and 14) 0.10 735,000 – 1,630,000
14.7 Warehouse BEC (Minus Acts. 13 and 14) 0.10 735,000 – 1,630,000
14.8 Other Buildings & Structures BEC (Minus Acts. 13 and 14) 0.10 735,000 – 1,630,000
14.9 Waste Treating Building & Structures Raw Water Makeup, gpm 0.07 2,000 – 11,200
31
Quality Guidelines for Energy Systems Studies January 2013
2.2 IGCC
Exhibit 2-16 provides the category matrix for IGCC categories.
Exhibit 2-16 Category matrix: IGCC
Single-stage, dry-feed, oxygen-blown, down-flow gasifier with and without CO2 capture, PRB and
6
ND Lignite coals
Two-stage, slurry-feed, oxygen-blown gasifier with and without CO2 capture, PRB coal
7
Single-stage, slurry-feed, oxygen-blown gasifier with and without CO2 capture, Illinois No. 6 coal
Single-stage, dry-feed, oxygen-blown, up-flow gasifier, with CO2 capture, PRB coal with and
without switchgrass
Single-stage, dry-feed, oxygen-blown, up-flow gasifier with CO2 capture, Illinois No. 6 coal with
8 switchgrass
Single-stage, dry-feed, oxygen-blown, up-flow gasifier, with and without CO2 capture, PRB and ND
Lignite coals
Single-stage, dry-feed, oxygen-blown, up-flow gasifier without CO2 capture, Illinois No. 6 coal
Transport gasifier, air- and oxygen-blown, with and without CO2 capture, PRB and TX Lignite
9 coals
Transport gasifier, oxygen-blown with CO2 capture, TX Lignite coal, with hybrid poplar
For IGCC categories, use Equation 4 for items that utilize a coefficient in addition to an
exponent. In the “scaling parameters and exponents” tables below, the values presented within
brackets [] are coefficients.
Equation 4
Exhibit 2-17 through Exhibit 2-31 contain the scaling parameters and exponents that are suitable
for IGCC plants at the given ranges.
32
Account
Item Description Parameter Exponent Range
Number
Category 6-9 6 7 8 9 6-9
1 FUEL & SORBENT HANDLING
1.1 Coal Receive & Unload Coal feed rate, lb/hr 0.62 18,400 – 1,750,000
1.2 Coal Stackout & Reclaim Coal feed rate, lb/hr 0.62 18,400 – 1,750,000
1.3 Coal Conveyors & Yard Crush Coal feed rate, lb/hr 0.62 18,400 – 1,750,000
1.4 Other Coal Handling Coal feed rate, lb/hr 0.62 18,400 – 1,750,000
See
1.5 Biomass Receive & Unload Biomass Feed, lb/hr 0.62 0.62 0.62 1 6,000 – 934,000
Note
1.6 Biomass Handling Biomass Feed, lb/hr 0.62 6,000 – 934,000
1.7 Biomass Conveyors Biomass Feed, lb/hr 0.62 6,000 – 934,000
1.8 Biomass Handling Foundations Biomass Feed, lb/hr 0.62 6,000 – 934,000
1.9 Coal & Sorbent Handling Foundations Coal feed rate, lb/hr 0.62 18,400 – 1,750,000
1
Use Equation 6 with exponent 0.37 for equipment and Equation 7 with exponent 0.45 for direct labor. Values provided in $1,000 (2007$).
33
Exhibit 2-18 Scaling parameters and exponents for categories 6-9: “Fuel and Sorbent Prep and Feed”
Account
Item Description Parameter Exponent [Coefficient] Range
Number
Category 6-9 6 7 8 9 6-9
2 FUEL & SORBENT PREP & FEED
2.1 Coal Crushing & Drying Coal feed rate, lb/hr 0.66 18,400 – 1,750,000
2.2 Prepared Coal Storage & Feed Coal feed rate, lb/hr 0.66 18,400 – 1,750,000
Dry Coal Injection System/
2.3 Coal feed rate, lb/hr 0.66 18,400 – 1,750,000
Slurry Prep and Feed
2.4 Misc. Coal Prep & Feed Coal feed rate, lb/hr 0.66 0.66 0.66 0.90 18,400 – 1,750,000
1
2.5 Biomass Shredding & Drying Biomass Feed, lb/hr 0.66 6,000 – 934,000
Biomass Pelletization/
2.6 Biomass Feed, lb/hr 0.66 6,000 – 934,000
Dry Biomass Injection System
2.7 Prepared Biomass Storage & Feed Biomass Feed, lb/hr 0.66 6,000 – 934,000
2.9 Coal & Sorbent Feed Foundation Total Feed Flow Rate, lb/hr 0.66 467,100 – 1,750,000
Equation 8
( )
1
For oxygen-blown transportation gasification with CO2 capture firing TX Lignite coal with hybrid poplar co-fire, use Equation 8 with a coefficient of 7.0428 to
calculate equipment costs and a coefficient of 1.3724 to calculate direct labor costs. Values are provided in $1,000 (2007$).
34
Account
Number
Category 6-9 6 7 8 9 6-9
3.1 Feedwater System BFW (HP only), lb/hr 0.71 1,000 – 4,000
3.2 Water Makeup & Pretreating Raw water makeup, gpm 0.71 300 – 9,000
3.3 Other Feedwater Subsystems BFW (HP only), lb/hr 0.71 1,000 – 4,000
3.4 Service Water Systems Raw water makeup, gpm 0.71 300 – 9,000
3.5 Other Boiler Plant Systems Raw water makeup, gpm 0.73 0.73 0.73 0.25 300 – 9,000
3.6 FO Supply Sys & Nat Gas Total Feed Flow Rate, lb/hr 0.00 0.24 0.24 0.00 467,000 – 1,750,000
3.7 Waste Treatment Equipment Raw water makeup, gpm 0.71 300 – 9,000
3.8 Misc. Power Plant Equipment Total Feed Flow Rate, lb/hr 0.66 0.24 0.24 0.06 467,000 – 1,750,000
35
Exhibit 2-20 Scaling parameters and exponents for categories 6-9: “Gasifier and Accessories”
Account
Number
Category 6-9 6 7 8 9 6-9
4 GASIFIER & ACCESSORIES
SGC Duty, MMBtu/hr / 0.77/1.19 0.53 0.31/0.64 200 – 1,000
4.1 Gasifier, Syngas Cooler & Auxiliaries 0.00 1 2 1
Total Feed Flow Rate, lb/hr [0.29/0.71] [214.0] [0.51/0.49] 467,000 – 1,750,000
4
O2 Production, lb/hr / MAC 2.39/0.89 0.70/0.70 0.70/0.54 0.36/0.36 285,000 – 1,750,000
4.3 ASU/Oxidant Compression 1 1 3 1
Power, kW [0.09/0.91] [0.50/0.50] [0.80/0.20] [0.50/0.50] 5,000 – 316,000
LT Heat Recovery & FG Saturation/ 5 6 6
4.4 Total Feed Flow Rate, lb/hr See Note See Note See Note 0.40 467,000 – 1,750,000
Scrubber & Low Temperature Cooling
Flare Stack System/
7
4.6 Soot Recovery & SARU/ Total Feed Flow Rate, lb/hr See Note 0.50 0.50 0.40 467,000 – 1,750,000
Other Gasification Equipment
4.9 Gasification Foundations Total Feed Flow Rate, lb/hr 0.50 0.50 0.50 0.40 467,000 – 1,750,000
Equation 10 Equation 11
( ) ( ) ( ) Where:
 STPC – Scaled total plant cost
Equation 12
( ) ( )
Equation 13  DCF – Dry coal feed, lb/hr
[ ]
( )
1
Use Equation 10.
2
Non-biomass plants with PRB or ND Lignite coal use Equation 11. Non-biomass plants with Illinois No. 6 coal use exponent 0.66 with Equation 3.
3
Biomass plants use Equation 13, values provided in $1,000 (2007$). Non-biomass plants use Equation 10 with Exponents of 0.70/0.70 and Coefficients of
0.50/0.50.
4
TRIG air-fired plants scale on combustion turbine extraction air flow rate, lb/hr, rather than O 2 production rate.
5
For capture plants, the TPC is 22.0 percent of the TPC of the “Gasifier, Syngas Cooler &Auxiliaries.” For non-capture plants, the TPC is 23.0 percent.
6
For capture plants, the TPC is 20.6 percent of the TPC of the “Gasifier, Syngas Cooler &Auxiliaries.” For non-capture plants with PRB or ND Lignite coals,
the TPC is 10.7 percent. For non-capture plants with Illinois No. 6 coal, use exponent of 0.23 with Equation 3.
7
Use Equation 12.
36
Exhibit 2-21 Scaling parameters and exponents for categories 6-9: “Gas Cleanup and Piping”
Account
Number
Category 6-9 6 7 8 9 6-9
5 GAS CLEANUP & PIPING
5A.1 Sulfinol/Selexol (Single and Double)/MDEA-LT Gas flow to AGR, acfm 0.85 0.79 0.79 0.95 6,000 – 30,500
0.58
5A.2 Elemental Sulfur Plant Sulfur Production, lb/hr 0.67 0.67 1 0.67 300 – 43,900
[131.42]
3 0.69 2 0.034
5A.3 Mercury Removal Hg bed carbon fill, ft See Note 3 0.70 2,000 – 35,100
[11.05] [1.461]
WGS Catalyst volume, ft /
3
2,000 – 10,600
5A.4 Shift Reactors/ COS Hydrolysis 3 0.12 0.80 0.59/0.78 0.75
COS Catalyst volume, ft 9,000 – 25,500
4
5A.5 Blowback Gas Systems Candle filter flow rate, acfm N/A 0.30 0.75 0.41 2,000 – 96,000
0.7224 0.78
5A.6 Fuel Gas Piping Fuel gas flow, lb/hr 0.72 5 0.58 185,000 – 2,490,000
[2.282] [1.87]
6
5A.9 HGCU Foundations Sulfur Production, lb/hr 0.79 0.79 0.52 0.79 300 – 43,900
1
Non-biomass plants use the exponent 0.67 and coefficient 61.981.
2
Use exponent 1.57 with PRB coal, use exponent 1.64 with Illinois No. 6 coal without CO2 capture, and use exponent 1.59 with Illinois No. 6 coal with CO2
capture. The coefficient 0.0141 is used with all plants.
3
Non-biomass plants with Illinois No. 6 coal, use Equation 3 with an exponent of 0.60. All other non-biomass plants use the coefficient of 0.0141 and exponent
of 1.5742.
4
Non-biomass plants use the exponent of 0.30.
5
Non-biomass plants use the coefficient 2.282 and exponent 0.7224.
6
Non-biomass plants use the exponent of 0.79.
37
Exhibit 2-22 Scaling parameters and exponents for categories 6-9: “CO2 Compression”
Account
Number
Category 6-9 6 7 8 9 6-9
5B CO2 COMPRESSION
1 28,300 – 43,500
5B.2 CO2 Compression & Drying Compressor Power, kW 0.63 0.88 {0.88} 0.67
1,000,000 – 2,200,000
Exhibit 2-23 Scaling parameters and exponents for categories 6-9: “Combustion Turbine and Accessories”
Account
Number
Category 6-9 6 7 8 9 6-9
6 COMBUSTION TURBINE/ACCESSORIES
6.1 Combustion Turbine Generator Fuel gas flow, lb/hr 0.00 185,000 – 2,490,000
6.9 Combustion Turbine Foundations Fuel gas flow, lb/hr 0.00 185,000 – 2,490,000
1
Biomass plants use the exponent 0.79 with the scaling parameter “CO2 Captured, lb/hr.”
38
Account
Number
Category 6-9 6 7 8 9 6-9
7.1 Heat Recovery Steam Generator HRSG duty, MMBtu/hr 0.70 600 – 5,000
7.3 Ductwork volumetric flow to stack, acfm 0.70 0.70 0.70 0.57 1,010,000 – 2,810,000
7.4 Stack volumetric flow to stack, acfm 0.70 1,010,000 – 2,810,000
7.9 HRSG, Duct & Stack Foundations volumetric flow to stack, acfm 0.70 0.70 0.70 0.67 1,010,000 – 2,810,000
Account
Number
Category 6-9 6 7 8 9 6-9
8.1 Steam TG & Accessories Turbine capacity, kW 0.70 195,000 – 371,000
8.2 Turbine Plant Auxiliaries Turbine capacity, kW 0.72 195,000 – 371,000
0.70
8.3a Condenser & Auxiliaries Condenser duty, MMBtu/hr 0.71 0.71 1 0.71 500 – 2,000
[52.90]
BFW (HP only), lb/hr 1,000 – 4,000
8.3b Air Cooled Condenser 0.36 0.73 {0.70} 1.14
{Condenser Duty, MMBtu/hr} 500 – 2,000
0.63
8.4 Steam Piping BFW (HP only), lb/hr 0.72 0.72 2 0.72 1,000 – 4,000
[122.80]
8.9 TG Foundations Turbine capacity, kW 0.72 195,000 – 371,000
1
Non-biomass plants use a coefficient of 45.921 and exponent of 0.7.
2
Non-biomass plants with PRB or ND Lignite coal use the exponent 0.7018 and coefficient 71.1. Non-biomass plants with Illinois No. 6 coal use the exponent
0.70 with Equation 3.
39
Account
Number
Category 6-9 6 7 8 9 6-9
9.1 Cooling Towers Cooling tower duty, MMBtu/hr 0.90 0.72 0.72 0.72 1,000 – 4,000
1
9.2 Circulating Water Pumps Circ. water flow rate, gpm 0.72 0.72 0.69 [0.54] 0.72 92,600 – 330,000
9.3 Circ. Water System Auxiliaries Circ. water flow rate, gpm 0.64 92,600 – 330,000
2
9.4 Circ. Water Piping Circ. water flow rate, gpm 0.606 [6.185] 92,600 – 330,000
9.5 Make-up Water System Raw water makeup, gpm 0.60 300 – 9,000
9.6 Component Cooling Water System Circ. water flow rate, gpm 0.64 92,600 – 330,000
9.9 Circ. Water System Foundations Circ. water flow rate, gpm 0.59 92,600 – 330,000
Exhibit 2-27 Scaling parameters and exponents for categories 6-9: “Ash and Spent Sorbent Handling System”
Account Exponent
Item Description Parameter Range
Number [Coefficient]
Category 6-9 6 7 8 9 6-9
10 ASH/SPENT SORBENT HANDLING SYSTEM
10.1 Slag Dewatering & Cooling Slag production, lb/hr 0.64 7,000 – 351,000
10.6 Ash Storage Silos Slag production, lb/hr 0.55 7,000 – 351,000
10.7 Ash Transport & Feed Equipment Slag production, lb/hr 0.55 7,000 – 351,000
10.8 Misc. Ash Handling Equipment Slag production, lb/hr 0.55 7,000 – 351,000
10.9 Ash/Spent Sorbent Foundation Slag production, lb/hr 0.55 7,000 – 351,000
1
Non-biomass plants use the coefficient 0.6273 and exponent 0.6714.
2
Non-biomass plants use the exponent 0.6085 and coefficient 6.0862.
40
Account
Number
Category 6-9 6 7 8 9 6-9
11.1 Generator Equipment Turbine capacity, kW 0.54 195,000 – 371,000
11.2 Station Service Equipment Auxiliary load, kW 0.45 107,000 – 423,000
11.3 Switchgear & Motor Control Auxiliary load, kW 0.45 107,000 – 423,000
11.4 Conduit & Cable Tray Auxiliary load, kW 0.45 107,000 – 423,000
11.5 Wire & Cable Auxiliary load, kW 0.45 107,000 – 423,000
11.6 Protective Equipment Auxiliary load, kW 0.00 0.00 0.00 0.65 107,000 – 423,000
11.7 Standby Equipment Total Gross Output, kW 0.48 0.48 0.48 0.00 621,000 – 835,000
11.8 Main Power Transformers Total Gross Output, kW 0.71 0.71 0.71 0.00 621,000 – 835,000
11.9 Electrical Foundations Total Gross Output, kW 0.70 0.70 0.70 0.00 621,000 – 835,000
Account
Number
Category 6-9 6 7 8 9 6-9
12.4 Other Major Component Control Auxiliary load, kW 0.24 0.13 0.13 0.24 107,000 – 423,000
12.6 Control Boards, Panels & Racks Auxiliary load, kW 0.24 0.13 0.13 0.24 107,000 – 423,000
12.7 Computer & Accessories Auxiliary load, kW 0.24 0.13 0.13 0.24 107,000 – 423,000
12.8 Instrument Wiring & Tubing Auxiliary load, kW 0.24 0.13 0.13 0.24 107,000 – 423,000
12.9 Other I & C Equipment Auxiliary load, kW 0.24 0.13 0.13 0.24 107,000 – 423,000
41
Account
Number
Category 6-9 6 7 8 9 6-9
13.1 Site Preparation BEC Accts 1-12 0.34 0.08 0.08 0.34 1,040,000 – 1,680,000
13.2 Site Improvements BEC Accts 1-12 0.33 0.08 0.08 0.33 1,040,000 – 1,680,000
13.3 Site Facilities BEC Accts 1-12 0.34 0.08 0.08 0.34 1,040,000 – 1,680,000
Account
Number
Category 6-9 6 7 8 9 6-9
14.1 Combustion Turbine Area Gas Turbine Power, kWe 0.00 51,200 – 471,000
14.2 Steam Turbine Building BEC Accts 1-12 0.17 0.17 0.17 0.45 1,040,000 – 1,680,000
14.3 Administration Building BEC Accts 1-12 0.00 0.10 0.10 0.00 1,040,000 – 1,680,000
14.4 Circulation Water Pumphouse Circ. water flow rate, gpm 0.01 0.46 0.46 0.46 92,600 – 330,000
14.5 Water Treatment Buildings Raw water makeup, gpm 0.71 300 – 9,000
14.6 Machine Shop BEC Accts 1-12 0.32 0.10 0.02 0.00 1,040,000 – 1,680,000
14.7 Warehouse BEC Accts 1-12 0.32 0.10 0.02 0.00 1,040,000 – 1,680,000
14.8 Other Buildings & Structures BEC Accts 1-12 0.35 0.10 0.02 0.21 1,040,000 – 1,680,000
14.9 Waste Treating Building & Str. Raw water makeup, gpm 0.08 0.08 0.08 0.08 300 – 9,000
42
2.3 NGCC
Exhibit 2-32 provides the category matrix for NGCC categories.
Exhibit 2-32 Category matrix: NGCC
Natural gas, air-fired, with and without CO2 capture
10
Natural gas, air-fired with CO2 capture and gas recycle
Exhibit 2-33 through Exhibit 2-43 contain the scaling parameters and exponents that are suitable
for NGCC plants at the given ranges.
43
Account
Number
Category 10 10 10
3.1 Feedwater System Feedwater flow (HP only), lb/hr 0.72 886,000 – 1,350,000
3.2 Water Makeup & Pretreating Raw Water Withdrawal (gpm) 0.71 3,000 – 5,000
3.3 Other Feedwater Subsystems Feedwater flow (HP only), lb/hr 0.72 886,000 – 1,350,000
3.4 Service Water Systems Raw Water Withdrawal (gpm) 0.71 3,000 – 5,000
3.5 Other Boiler Plant Systems Raw Water Withdrawal (gpm) 0.71 3,000 – 5,000
1
3.6 Natural Gas, incl. pipeline Fuel gas flow, acfm average 0.07 2,000 – 4,000
3.7 Waste Treatment Equipment Raw Water Withdrawal (gpm) 0.71 3,000 – 5,000
3.8 Misc. Equip. (cranes, Air Compressor, etc.) Fuel gas flow, acfm average 0.76 2,000 – 4,000
Exhibit 2-34 Scaling parameters and exponents for categories 6-9: “Gas Cleanup and Piping”
Account
Number
Category 10 10 10
5A GAS CLEANUP & PIPING
5A.6 Exhaust Gas Recycle System EGR Flowrate (lb/hr) 1.47 3,150,000 – 3,280,000
1
As noted in the item description, this line item also includes the natural gas pipeline. The natural gas pipeline is an additive cost and would not be scaled. The
pipeline cost is specific to the plant location and needs. Scaling over larger ranges will result in unrealistic costs since this has the effect of essentially increasing
and decreasing the pipe length.
44
Exhibit 2-35 Scaling parameters and exponents for categories 6-9: “CO2 Removal and Compression”
Account
Number
Category 10 10 10
5B CO2 REMOVAL & COMPRESSION
CO2 Flowrate (lb/hr)/ 1 2
5B.1 CO2 Removal System 0.61 445,000 – 689,000/ N/A
Inlet to Absorber, acfm
5B.2 CO2 Compression & Drying CO2 Flowrate (lb/hr) 0.77 445,000 – 689,000
Exhibit 2-36 Scaling parameters and exponents for categories 6-9: “Combustion Turbine and Accessories”
Account
Number
Category 10 10 10
6 COMBUSTION TURBINE/ACCESSORIES
6.1 Combustion Turbine Generator Fuel Gas Flow, acfm 0.00 N/A
6.9 Combustion Turbine Foundations Gas Turbine Power (kWe) 0.00 421,000 – 811,000
Account
Number
Category 10 10 10
7.1 Heat Recovery Steam Generator HRSG Duty (MMBtu/hr) 0.70 2,000 – 3,000
7.2 HRSG Accessories HRSG Duty (MMBtu/hr) 1.40 2,000 – 3,000
3
7.9 HRSG, Duct & Stack Foundations Stack flow rate, acfm 0.70 2,390,000 – 2,860,000
1
40% of cost is applied to gas flow and the remainder is applied to CO2 capture.
2
Range has not yet been developed as parameter has not been implemented to date.
3
Natural gas, air-fired with CO2 capture and gas recycle uses an exponent of 0.47.
45
Account
Number
Category 10 10 10
8.1 Steam TG & Accessories Steam Turbine Power (kWe) 0.80 230,000 – 321,000
8.2 Turbine Plant Auxiliaries Steam Turbine Power (kWe) 0.73 230,000 – 321,000
1
8.3 Condenser & Auxiliaries Thermal Input (LHV) (kWth) See Note 1,100,000 – 1,710,000
8.4 Steam Piping HRSG Duty (MMBtu/hr) 0.83 2,000 – 3,000
8.9 TG Foundations Steam Turbine Power (kWe) 0.73 230,000 – 321,000
Account
Number
Category 10 10 10
9.1 Cooling Towers Cooling Tower Duty (MMBtu/hr) 0.71 1,000 – 3,000
9.2 Circulating Water Pumps Circulating water flow rate, gpm 0.72 125,000 – 294,000
9.3 Circ. Water System Auxiliaries Circulating water flow rate, gpm 0.60 125,000 – 294,000
9.4 Circ. Water Piping Circulating water flow rate, gpm 0.60 125,000 – 294,000
9.5 Make-up Water System Raw water makeup, gpm 0.60 2,000 – 4,000
9.6 Component Cooling Water Sys. Circulating water flow rate, gpm 0.60 125,000 – 294,000
9.9 Circ. Water System Foundations Circulating water flow rate, gpm 0.60 125,000 – 294,000
1
Natural gas, air-fired without CO2 capture uses the exponent 0.43. Natural gas, air-fired with CO2 capture uses the exponent 0.12. Natural gas, air-fired with
CO2 capture and gas recycle uses the exponent 0.29.
46
Account
Number
Category 10 10 10
11.1 Generator Equipment Gross Total (kWe) 0.59 650,000 – 1,130,000
11.2 Station Service Equipment Net Auxiliary Load (kWe) 0.64 50,700 – 73,500
11.3 Switchgear & Motor Control Net Auxiliary Load (kWe) 0.64 50,700 – 73,500
11.4 Conduit & Cable Tray Net Auxiliary Load (kWe) 0.64 50,700 – 73,500
11.5 Wire & Cable Net Auxiliary Load (kWe) 0.64 50,700 – 73,500
11.6 Protective Equipment Net Auxiliary Load (kWe) 1.10 50,700 – 73,500
11.7 Standby Equipment Gross Total (kWe) 0.48 650,000 – 1,130,000
11.8 Main Power Transformers STG output, MVA PLUS CTG output, MVA 0.70 750 – 820
11.9 Electrical Foundations Gross Total (kWe) 0.70 650,000 – 1,130,000
Account
Number
Category 10 10 10
12.4 Other Major Component Control Net Auxiliary Load (kWe) 0.60 50,700 – 73,500
12.6 Control Boards, Panels & Racks Net Auxiliary Load (kWe) 0.60 50,700 – 73,500
12.7 Computer & Accessories Net Auxiliary Load (kWe) 0.60 50,700 – 73,500
12.8 Instrument Wiring & Tubing Net Auxiliary Load (kWe) 0.60 50,700 – 73,500
12.9 Other I & C Equipment Net Auxiliary Load (kWe) 0.60 50,700 – 73,500
47
Account
Number
Category 10 10 10
13.1 Site Preparation Gross Total (kWe) 0.47 650,000 – 1,130,000
13.2 Site Improvements Gross Total (kWe) 0.47 650,000 – 1,130,000
13.3 Site Facilities Gross Total (kWe) 0.47 650,000 – 1,130,000
Account
Number
Category 10 10 10
14.1 Combustion Turbine Area Gas Turbine Power, kWe 0.53 421,000 – 811,000
14.2 Steam Turbine Building Steam Turbine Power, kWe 0.60 230,000 – 321,000
14.3 Administration Building Gross Total (kWe) 0.34 650,000 – 1,130,000
1
14.4 Circulation Water Pumphouse Circulating water flow rate, gpm 0.60 125,000 – 294,000
14.5 Water Treatment Buildings Circulating water flow rate, gpm 0.66 125,000 – 294,000
14.6 Machine Shop Gross Total (kWe) 0.34 650,000 – 1,130,000
14.7 Warehouse Gross Total (kWe) 0.34 650,000 – 1,130,000
14.8 Other Buildings & Structures Gross Total (kWe) 0.34 650,000 – 1,130,000
14.9 Waste Treating Building & Str. Gross Total (kWe) 0.34 650,000 – 1,130,000
1
Natural gas, air-fired without CO2 capture uses an exponent of 0.82.
48
3 Revision Control
Exhibit 3-1 Revision table
Revision
Revision Date Description of Change Comments
Number
Document formatted and

1 February 5, 2014
edited
49
4 References
1 National Energy Technology Laboratory (NETL). (September 2013). “Cost and

Performance Baseline for Fossil Energy Plants, Volume 1: Bituminous Coal and Natural
Gas to Electricity,”. DOE/NETL-2007/1281, Final Report (Original Issue Date, May
2007); Revision 2a Issue Date, September 2013. Available at
http://www.netl.doe.gov/research/energy-analysis/energy-baseline-studies.
2 National Energy Technology Laboratory (NETL). (February 2013). “Greenhouse Gas
Reductions in the Power Industry Using Domestic Coal and Biomass - Volume 2: PC
Plants,”. DOE/NETL-2012/1547,. Available at http://netl.doe.gov/research/energy-
analysis/publications/details?pub=14d167f7-4020-4d88-a511-1df8506a894d.
3 National Energy Technology Laboratory (NETL). (April 2010). “Advancing
Oxycombustion Technology for Bituminous Coal Power Plants: An R&D Guide”.
NETL/DOE-2010/1405. Available at http://www.netl.doe.gov/research/energy-
analysis/publications/details?pub=58bf5a99-6e78-4258-be7c-9787f505011a.
4 National Energy Technology Laboratory (NETL). (September 2011). “Cost and
Performance Baseline for Fossil Energy Plants - Volume 3: Low Rank Coal and Natural
Gas to Electricity,” Multiple files, DOE/NETL-2010/1399. Available at
http://www.netl.doe.gov/research/energy-analysis/energy-baseline-studies.
50

Capital Cost Scaling Methodology

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DOE/NETL-341/013113

National Energy Technology Laboratory Office of Program Performance and Benefits

Quality Guidelines for Energy System Studies

January 31, 2013

National Energy Technology Laboratory

National Energy Technology Laboratory Office of Program Performance and Benefits

DOE Contract Number DE-FE0004001

National Energy Technology Laboratory Office of Program Performance and Benefits

National Energy Technology Laboratory Office of Program Performance and Benefits

This page intentionally left blank.

National Energy Technology Laboratory Office of Program Performance and Benefits

National Energy Technology Laboratory Office of Program Performance and Benefits

National Energy Technology Laboratory Office of Program Performance and Benefits

National Energy Technology Laboratory Office of Program Performance and Benefits

Acronyms and Abbreviations

National Energy Technology Laboratory Office of Program Performance and Benefits

National Energy Technology Laboratory Office of Program Performance and Benefits

Exhibit 1-1 Category matrix

National Energy Technology Laboratory Office of Program Performance and Benefits

Exhibit 1-2 Reference cost estimates

National Energy Technology Laboratory Office of Program Planning and Analysis

1.1 Limitations of Scaling Approach

National Energy Technology Laboratory Office of Program Planning and Analysis

1.3 Scaled Cost Estimate Development Examples

National Energy Technology Laboratory Office of Program Planning and Analysis

National Energy Technology Laboratory Office of Program Planning and Analysis

Exhibit 1-3 Example Account 5: Parameter listing

Calculating scaled cost estimates

National Energy Technology Laboratory Office of Program Performance and Benefits

National Energy Technology Laboratory Office of Program Performance and Benefits

Exhibit 1-4 Example Account 5: Parameter listing

Account Item Reference Reference Cost Scaling Scaled Cost

National Energy Technology Laboratory Office of Program Performance and Benefits

2 Scaling Exponents and Equations

2.1 PC and CFBC

National Energy Technology Laboratory Office of Program Performance and Benefits

Exhibit 2-1 Category matrix: PC and CFBC

National Energy Technology Laboratory Office of Program Performance and Benefits

Account Item Description Parameter Exponent Range

Account Item Description Parameter Exponent Range

Account Item Description Parameter Exponent Range

Account Item Description Parameter Exponent Range

Account Item Description Parameter Exponent [Coefficient] Range

Account Item Description Parameter Exponent [Coefficient] Range

Account Item Description Parameter Exponent [Coefficient] Range

Account Item Description Parameter Exponent Range

National Energy Technology Laboratory Office of Program Performance and Benefits

Account Item Description Parameter Exponent Range

Account Item Description Parameter Exponent Range

Account Item Description Parameter Exponent [Coefficient] Range

Account Item Description Parameter Exponent [Coefficient] Range

National Energy Technology Laboratory Office of Program Performance and Benefits

Account Item Description Parameter Exponent Range

Account Item Description Parameter Exponent Range

National Energy Technology Laboratory Office of Program Performance and Benefits

Exhibit 2-16 Category matrix: IGCC

National Energy Technology Laboratory Office of Program Performance and Benefits

National Energy Technology Laboratory Office of Program Performance and Benefits

National Energy Technology Laboratory Office of Program Performance and Benefits